SERIAL NO. SPECIFICATION NO. VHP 5108/5790/7042 G/GSI/GL ENGINES REPAIR & OVERHAUL MANUAL First EditionCONTENTS Warranty List Of illustrations List Of Tables How To Use This Manual CHAPTER 1 —-SAFETY AND GENERAL Section 1.00 - Warning Tags & Decal Locations Warning Tags And Decal Locations Section 1.05 - Safety Salety Introduction Salety Tags And Decals Equipment Repair And Service dias Batteries Body Protection Chemicals General Cleaning Solvents Liquid Nirogen/Dry Ice Components Heated Or Frozen Interference Fit Coating System Etectical General Ignition Exhaust Fite Protection Fuels General Gaseous guid tntoxicants And Narcotics Pressurized Fluids/Gas/Ait.. Protective Guards ‘Sodium Cooled Vawve Springs Tools electrical Hydraulic Pneumatic 1.00-1 105-1 105-1 1.05 ~ 1 1.05 -2 1.05 ~ 2 105-2 1.05 -2 1.05 ~2 1.05 -2 105-2 105-2 1.05 ~2 1.05 ~2 105-2 405-3 105-3 1.05 -3 1.05 -3 105-3 105-3 105-3 1.05 -3 105-3 105-4 1.05 ~4 105-4 1.05 = 4 = 105-4 105-4 1.05 -4 105-4 105-4 Weiding General On Engine Weight Section 1.10 - Rigging And Lifting Engines Engine Rigging And Litng Location OF The Liting Eyes Correct Method OF Rigging And Ling Engine a Section 1.15 — General Information Seation Main Points: OvernauRepair Process Preventing Engine Damage Handling And Shipping Engine Removal Serial Number And Engine Nameplate Engine Identiication Views Right Side View Lett Side View Rear View Basi Engine Description Service Tools List Engine Stangards Component Weights Clearances Torque Specifications Genera Torquing Sequence Procedure Thread Lubrication For Torque Fasteners Critical Engine Torque Values Cylinder Head Torquing Procedure Connecting Rod Capscrew Torquing Procedure (PIN Series 205407 And 205507) Main Bearing Cap Torquing Procedure General Torque Recommendations. EnglistvMetric Conversions Index Of Sealants, Adhesives And Lubricants ‘Spit Ring Washer Usabilty Criteria 105-5 108-5 405-5 105-5 110-1 1.10-1 140-4 115-1 115-1 ANS -1 415-1 118-2 115-3 1415-4 115-4 115-5 115-6 415-7 115-8 115-10 118—10 118-11 115-12 115-12 118=12 115-13 118-14 118 ~ 14 1.15 =15 138-16 118-17 115-18 118-19 Form 6248 First GattonCONTENTS Section 1.20 - Specifications Specifications 120-1 Gear Tooth Wear -General . 120-1 Timing Gears 420-1 Engine Timing Data 1.20~28 CHAPTER 2 - ENGINE TEARDOWN Section 2,00 — Cylinder Head Removal Cylinder Head Removal 200-1 Section 2.05 — Crankcase Removal Piston/Connecting Rod Removal 205-1 Cylinder Sieeve Removal 205-4 Vibration Damper Removal 205-5 Front Gear Cover Removal 205-7 Magneto Drive Gear Removal 2.05 -9 Idler Gear Removal 2.05 -10 Camshaft Gear Removal 205-10 Front Gear Housing Removal 205-11 Rocker Arm Oil Header Removal 2.05 ~ 12 Valve Litter Housing Removal 205-13, ‘Camshaft Removal 205-15 Barring Device Removal 205-16 Flyuheel Removal 205-16 il Pickup Screen Removal 2.05 - 18 il Pan Removal 208-19 Crankshaft Removal 2.05 -20, Crankcase . 205-24 Crankshaft No. 1 Main Bearing Removal In Field Conditions 205-24 Crankshaft No, 1 Main Beaving Installation in Field Conditions 208-27 Crankshatt Main Bearings Removal In Field Conditions 2.05 -20 CCrankshatt Main Bearings installation In Field Conditions 2.05 ~90 Camshalt Bearing Removal In Field Conditions 205-31 Camshaft Bearing Installation In Field Conditions 2.05 32 CHAPTER 3 ~ ENGINE INSPECTION AND OVERHAUL Section 3.00 - Cylinder Head Disassembly Cylinder Head Disassembly 300-1 Rocker Arms 300-1 Intake And Exhaust Valves 300-8 Valve Seat insert And Vaive Guide Removal 300-9 Cylinder Head Cleaning And Inspection ... 3.0010 Oylinder Head Casting Pressure Testing ... 3.00 ~12 Cylinder Head Casting Magnatiux® 3.00-13 Cylinder Head Lower Deck Recondition... 3.00-14 Valve Failure Analysis - 300-14 Cylinder Head Assembly 300-19 Valve Guide Installation 3.00~19 Gylinder Head Casting Plug Installation... 3.00~20 \Valve Seat insert Installation 3.00 -20 Valve Seat Grinding 3.00-21 Valve Seat Lapping 300-22 Intake And Exhaust Valve Installation ..... 3.00 -23, Section 3.05 — Crankcase Disassembly Crankoase 305-1 ‘Crankcase Cleaning And Inspection 3.05 - Lower Sleeve Bore And Sleeve Projection Inspection 308-3 Grankcase Lower Bore Restoration 308-3 Main Bearing Bore Cleaning And Inspection 305-5 Main Bearing Running Clearance 308-6 Camshaft Bearing Bore inspection 3.05 -9 Crankshatt 3.05-9 Crankshaft Cleaning And Inspection 305-9 Crankshaft Journal Repair 308-11 Crankshaft Polishing... 3.05 - 11 Crankshaft Repair 305-11 Crankshaft Counterweight Retorque 05-12 Camshatt 305-14 Camshaft Cleaning And Inspection 3.05 - 14 Form 6248 Frat EatonCONTENTS Valve Litters 3.05 ~ 15, Roller Type Litters 305-15 Hydraulic Liters 805-16 Piston 305-17 Piston Disassembly 305-17 Piston Cleaning And Inspection 305-18 Piston Ring Inspection 3.05 -23 Piston Ring Assembly ........- 3.05 -27 6:17 Inch Bore GIGSUGL (4 Ring Piston) . 308 -27 9-4/8 Inch Bore G/GSI (4 Ring Piston) .... 3.05 ~29, Previous Production 9-3/8 Inch Bore GL. (4 Fing Piston) «oe... 3.05 -90 Current Production 9-9/8 Inch Bore GL. (Ring Piston) 3.05 -31 Piston Pin Cleaning And inspection 3.05 -92 Connecting Rod 3105-33 Connecting Rod Disassembly see, 805-33 Connecting Rod Cleaning And Inspection . 3.05 ~ 35, Connecting Rod Assembly 3.05 38 Connecting Rod Bestng Rurring Clearance 3.05 ~ 40 Connecting Rod Bearing Running Clearance Measurement With Piastigage® ...... 3.05 - 42 Cylinder Sleeve 105 - 42 Cylinder Sleeve Disassembly ... 805 ~ 42, Cylinder Sieve Cleaning And Inspection .. 8.05 ~ 43, Cylinder Sleeve Daglazing 3.08 -47, Flywheel : 3.05 ~ 48 Ring Gear Removal 3.05 - 48 Ring Gear installation 3.05 ~48 CHAPTER 4-ENGINE ASSEMBLY Section 4.00 - Crankcase Assembly Crankcase Assembly severe 400-1 Idler Gear Spindle instalation 400-1 Tube Installation 400-1 Main Bearing Stud Installation 400-2 Dowel installation 400-3 Water Header Plug Installation 400-3 Lube Oil Strainer Adapter Installation 400-5 Lower Valve Litter Housing Cover Installation Valve Liter Housing Gasket Installation ‘Camshaft And Bearing Installation Gear Housing Installation ‘Camshaft End Play Measurement Cam Gear Installation Valve Lifter Housing Installation Rocker Arm Oil Header instalation Rear Oil Seal Retainer installation Main Bearing Installation Crankshaft Installation Rear Oil Seal Retainer (Lower Halt) instalation Main Bearing Caps Installation Crankshatt End Piay Measurement Outside Crankshaft Thrust Ring Installation Crankshatt Gear Installation (011 Pump loler Gear Camshatt Idler Gear Installation Accessory Idler Gear Installation Gear Backlash Measurement Magneto Drive Assembly Installation Magneto Drive Gear Installation Cylinder Sleeve Installation Piston And Connecting Rod Installation Ol Pan Crankcase Installation Front Fiywhee! Housing Installation Timing Tape Installation Flywheel Installation Magnetic Pickup Sensor Installation Roar Flywheel Housing Installation Flywheel Fiywhee! Housing Bore And Face Runout Measure Batting Device Installation (Oil Filler Bracket installation ‘Gear Train Lubrication i Stinger/Front Oil Seal/Gear Cover Installation Front Gear Cover Plates installation 400-5 400-6 400-6 4.00 - 10 400-11 -12 400-13 4.00-18 400-18 4.00 -20 4.00 -22 4.00 -25 - 4.0026 4.00 26 - 400-28 4.00 -30 400-31 400-32 4.00 ~35, 4.00 -36 400-37 4.00 -39 400-44 4.00 - 42 4.00 - 46 4.00 -49 4.00 - 50 400-51 400-52 4.00 ~53 4.00 ~ 400-55 4.00 ~58 4.00 ~ 58 4.00 ~59 400-60 4.00 -64 Form 6248 First EanCONTENTS Rear Gear Housing Cover Plate Installation 4.00 -64 Vibration Damper/Crankshatt Pulley Installation 4.00 - 65 Section 4.05 — Cylinder Head Assembly Cylinder Head Installation 4.05 Cylinder Head Torquing Procedure 405-3 Exhaust Manifolds 405-5 Section 4.10 - Valve Adjustment And Web Deflection Valve Adjustment Procedure 440-1 Crankshaft Web Deflection Measurement 410-4 CHAPTER 5 —- ENGINE SYSTEMS Section 5.00 - Speed Governing System ‘Spoed Governing System Components 500-1 ‘Speed Governing System Description 500-1 Woodward UG-BL Governor 500-1 Woodward UG-8 Dial Governor 500-1 Woodward EG-3P Electronic Governing ‘Systern 500-1 Governor Linkages 5.00 -2 Magnetic Pickup 500-2 Control Pane! 5.00 -2 Overspeed Governor soe 500-2 Governor Drive Gear/CEC Timing Dise ....,.. §.00-3 Governor Drive Gear/CEC Timing Disc (Current Production) Removal 500-3 Governor Drive GearlCEC Timing Disc (Current Production) Cleaning And Ingpection sees 600-4 Governor Drive GearlCEC Timing Disc (Current Production} installation 500-4 ‘Governor Drive Gear/OEC Disc (Previous Production) Removal 500-6 ‘Governor Drive Gear/CEC Disc (Previous Production) Disassembly 500-7 Governor Drive GearlCEC Dise (Previous Production) Cleaning And Inspection 7 500-7 Governor Drive GeariCEC Dise (Previous Production) Assembly 500-7 Governor Drive Gear/CEC Disc {Previous Production) Installation 500-8 Governor Drive Shatt 5,00 ~10 Governar Drive Shaft Removal 5,00 - 10 Governor Drive Shaft Disassembly 5.00 ~10 Governor Drive Shaft Cleaning And inspection 500-11 Govemor Drive Shaft Assembly 500-11 Governor Drive Shaft Installation 5.00~12 Governor Drive Housing - 5.00~13 Governor Drive Housing Removal 5.00 ~13 Governor Drive Housing Disassembly ..... 5.00~13 Governor Drive Housing Cleaning And inspection 5.00~13 Governor Drive Housing Assembly 5.00~14 Governor Drive Housing Installation 500-14 Govemors 5.00 ~ 16 Woodard UG-8L. Governor Linkage Removal pee 5.00~16 Woodward UG-BL Governor Removal .... 5.00~17 Woodward UG-BL Governor Disassembly . 5.00 ~17 Woodward UG-BL Governor Assembly ... 5.00~17 Woodward UG-8L Governor Installation ... 5.00~ 18 UG-AL. Governor Linkage Installation And ‘Adjustment Woodward UG-8L. Governor ‘Compensation Adjustment 5.00~18 5.00~22 Woodward UG-8L Governor High’Low ‘Speed Limit Adjustment 500-26 Woodward UG-8L Governor Droop ‘Adjustment Woodward UG-8 (Dial) Governor Removal 5.00~28 Linkage 500-25 Woodward UG-8 (Dial) Governor Removal 5.00-26 Woodward UG-8 (Dial) Governor Disassembly 5.00-27 Woodward UG-8 (Dial) Governor ‘Assembly. 500-27 Woodward UG-8 (Dial) Governor Installation 500-27 Woodward UG-8 (Dial) Governor Linkage Installation And Adjustment 8.00 -27 Woodward UG-8 Dial Governor ‘Compensation Adjustment 5,00 -29 Woodward UG-8 Dial Governor HighvLow ‘Speed Adjustment 5.00 -30 wi Form 6248 Fst EatonCONTENTS Woodward UG-8 (Dial) Governor Droop ‘Adjustment Woodward EG-P Electric Governor Linkage Removal Wooaward EG-SP Governor Removal Woodward EG-3P Governor Disassembly Wooaward EG-3P Governor Cleaning And Inspection Woodward EG-3P Governor Assembly EG-3P Governor Drive Removal £G-AP Governor Drive Disassembly £6-9P Govemor Ove Cleaning And Inspection, E6-3P Governor Dive Assembiy EG-GP Governor Drive Instaliation Woodward EG-aP Governor Installation EG-3P Governor Linkage Cleaning And Inspection 6-9P Governor Linkage nsalation Ard ‘Adjustment Manual Shutdown Lever - GL. Manual Shutdown Lever Adjustment GL Gigs! Manual Shutdown Lever Installation ~ GIGS! Manual Shutdown Lever Adjustment GIGS ‘Overspeed Governor .. Manual Shutdown Lever Removal ~ Overspeed Governor Removal (Overspeed Governor Adjustment (Overspeed Governor Installation Hour Meter Hour Meter Removal Hour Meter installation Tachometer Drive “Tachometer Drive Flemoval Tachometer Drive instalation Section 5.05 — Fuel System Ful System Components Main Fuel Gas Pressure Regulators Operation Of The Fisher 99 Main Fuel Gas Pressure Regulator Carburetors Pilot Operated Prochamber Gas Valve - GL 500-31 500-31 500-32 5,00 - 92 5.00 -39 5.00 -33 500-33 5,00 -34 5.00 ~ 35 5,00 - 35 8.00 - 35 5.00 -36 5.00 -37 5.00 -38 5.00 -40 5.00 - 40 5.00 -42 5,00 - 42 5,00 - 42 5,00 - 42 8.00 - 42 500-43 5,00 - 43 5,00 -44 8.00 - 44 5.00 - 44 5.00 - 45 5.00 ~ 45 5,00 - 45 505-1 5.05 - 505-4 505-5 5.08 -5 Prechamber Gas Safety Shutdown Valve ~ Gu Prechamber Regulator ~ GL Prechamber Manifolds ~ GL. Buttery Cross Shat - G/GSI utterly Cross Shaft Removal - G/GSt Butterfly Cross Shaft Installation ~ GIGS! Carburetor Gross Shaft - GL Carburetor Cross Shaft Removal - GL. Carburetor Gross Shalt Installation ~ GL Prechamber Manifold Cross Pipe - GL Prechamber Manifold Cross Pipe Removal ~ Gl. Prechamber Manifold Cross Pipe Installation - GL Carburetors Carburetor Removal - G/GS! Carburetor Disassembly - G/GS! Career Gearing And inspection - GiGs!. Carburetor Assembly ~ G/GSI Carburetor Installation ~ G/GSI Carburetor Removal - GL. Carburetor Disassembly - GL. Carburetor Cleaning And inspection ~ GL Carburetor Assembly ~ GL Carburetor Installation ~ GL Buttery Valves) utterly Valve Removal - GIGS! Buttenly Valve Disassembly - G/GSI utterly Valve Assembly - GIGS! utterly Vaive Installation - G/GSI ‘Admission Valve - GL ‘Admission Valve Removal - GL. ‘Admission Valve Disassembly - GL. ‘Admigsion Valve Cleaning And Ingpection - GL : ‘Admission Valve Assembly ‘Admission Valve Installation ~ GL Prechamber Cup ~ Gl. Prechamber Cup Removal - GL 505-5 505-5 505-6 505-6 505-6 505-7 505-8 505-8 505-8 505-9 505-9 5.05~10 505-11 505-11 5.05 -12 5.05 ~ 5.05 -13 505-13 505-15 5.05~15 5.05 - 16 5.08 -17 5.08 - 17 5.05 ~18 505-18 505-18 505-19 505-19 5.05 19 505-19 5.05 -19 5.05 ~20 505-20 5.0521 505-21 Form 6248 Fist EatonCONTENTS. Prechamber Cup Cleaning And Inspection - GL Prechamber Cup Installation ~ GL. Prechamber Manifold ~ GL Prechamber Manifold Removal ~ GL Prechamber Manifold Installation - GL. Main Fuel Gas Pressure Regulator (Fisher 99) 5 Main Fuel Gas Pressure Reguiator (Fisher 99) Removal Right Bank Installation Loft Bank Installation Prechamber Regulator (Fisher 951) ~ GL Prechamber Regulator (Fisher 961) Removal ~ GL. Prechamber Regulator Fisher 951) Installation GL... : Fuel Systm Maintenance Fisher 99 Regulator Fiter Cleaning And Inspection Section 5.10 ~ Ignition System Ignition System Components CEC Ignion Module Magneto Wing Harness Ignition Cots Spork Plugs Spark Pugs Spark Plug Carer Removal ~ GL. Spark Plug Carter instalation = GL. Spark Plug Carrier Removal ~CSA Spark Pug Carter Instalaion = CSA Spark Plug Removal Spark Plug inspection Spark Plug Instaiation Spark Plug Extension Repair Ignition Cols Wiring Harness Wing Harness Removal Wing Hamess Inspection Wiring Harness Insalaton CEC Ignition Module 5.05 -22 5.05 -22 5.05 23 505-23, 5.05 -24 5.08 - 25 5.05 -25 5.05 ~25 5.05 -28 5.05 29 5.05 -28 5.05 -30 5.05 93 5.05 ~33 810-1 510-1 5.0 510-1 510-1 510-1 B10-1 510-1 510-3 510-3 510-4 510-5 510-7 510-8 510-10 510-11 510-13 510-13, 510-14 510-15 5.10 -19 CEC Ignition Module Removal CEC Ignition Module Installation. . Governor Drive GearlCEC Timing Dise (Current Production) Governor Drive Gear/CEC Timing Disc emaval (Current Production) Governor Drive Gear/CEC Timing Disc Cleaning And Inspection (Current Production) Governor Drive GeariCEC Timing Dise {nstalation (Current Production) CEC Ignition Module Static Timing SET (Cutrent Production) Setting The Air Gap Specification (Current And Previous Production) CEC Ignition Modute Tining Set (Current Production) ‘Steps Required To Adjust CEC lgntion Module Timing (Current Production) Governor Drive Gear!CEC Timing Dise (Previous Production) Governor Drive GeariCEC Timing Dise (Previous Production) Removal Governor Drive GeariCEC Timing Disc (Previous Production) Cleaning And inspection Govemor Drive geariCEC Timing Dise (Previous Production) installation CEC Ignition Module Ignition Timing (Previous Production) Set Steps Required To Adjust CEC ignition ‘Module Timing (Previous Production) Magneto Drive Dise Coupling Replacement Magneto - Static Timing Set Magneto — Ignition Timing Set Magneto Adapter Magneto Adapter Disassembly . Magneto Adapter Cleaning And Inspection ‘Magneto Adapter Assembly Magneto Orive Magneto Drive Disassembiy Magneto Drive Assembly 610-18 510-19 5.10 -20 510-20 510-20 510-21 510-22 510-24 510-24 610-25 510-26 5.10 -26 5.10 -26 510-27 5.10 ~28 5.10 ~90 510-20 5.1030 510-32 610-37 5.10 ~39 5.10 ~39 5.10 ~ 40 5.10 ~ 40 5.10 ~42 510-42 5.10-43 vi Form 6248 Fret EdoCONTENTS, Section 5.15 — Air Induction System Air Induction System Ar Cleaners Turbochargers Interooolers é Carburetor And intake Manifold Ar induction System Specifications Air Cleaners Precleaner Pad Removal Precleaner Pad Cleaning And Inspection Precleaner Pad Installation Main Air Filter Element Removal Main Air Filter Element Cleaning And Inspection, ‘Main Air Filter Element Installation .... Air Restriction Indicator Air Cleaner Ducts 7 Air Cleaner Duct Removal - G Air Cleaner Duct Installation - G Air Cleaner Duct Removal - GSVGL Ar Cleaner Duct Installation - GSUGL Air Tubing Air Tubing Removal ~ G Ai Tubing Installation - G Air Tubing Removal - GS} Air Tubing instalation - GSI Air Tubing Removal ~ GL Air Tubing Installation ~ GL. Intake Manifolés Intake Manifold Removal - G/GS! Intake Manifold Installation - G/GSI Intake Manifold Flange Attachments Intake Manifold Flange Attachments ~ Gest Lett Bank Right Bank : Intake Manifold Removal ~ GL. Intake Manifold Instaliation ~ GL Intake Manifold Flange Attachments ~ GL Left Bank ight Bank 815-1 515-1 515-1 515-1 515-1 515-1 515-2 515-2 518-3 518-3 518-3 515-3 515-4 515-4 515-5 515-5 515-7 515-8 515-10 515-10 515-10 515-11 8.15-11 5.18 ~12 815-12 5.15 -14 515-14 515-14 515-15 515-16 6.15 -16 5.18 - 16 515-17 515-18 515-19 6.15 -20 5.18 -20 5.1520 Section 5.20 - Turbochargers Tubochargers ‘Turbocharger(s) Removal ‘Turbocharger Cleaning Ang inspection “Turbocharger Installation Prelube Pressure MaintonancelCheck Valve Inspection : Section 5.25 ~ Cooling System Cooling System Components Jacket Water Header/Jacket Water Exhaust Maniold Water Manifold Jacket Water Pump Cluster Thermostat Housing Remote Heat Transter Device ‘Auxiliary Water Pump Intercooler 0 Cooler ‘Auxitary Water Temperature Control Valve ‘Auxillary Water Remote Heat Transfer Device Cooling System Problems ‘Scale Build-up, Cavitation Erosion And Corrosion Scale Build-up Cavitation Erosion Corrosion Water Treatment Ethylene Giyco! Cooling System Specifications And Recommendations Cooling System Specifications Cooling System Recommendations Jacket Water Circuit ~ Initial Fil. ‘Auxiary Cooling Water Circuit Cooling Water System Air Bleod Jacket Water And Auxilary Cooling Water Circuits ~ Drain And Flush Grease Fittings rit Fil Idler Pulley Bearing Lubrication Auxiliary Water Pump Bearings Lubrication Grease Recommendations 5.20 820-1 520-3 520-8 620-12 525-1 525-1 525-1 525-1 525-2 525-7 525-7 525-7 528-8 525-8 525-8 525-9 525-9 525-9 525-9 525-9 525-10 525-10 5.25~10 525-11 525-11 525-11 525-12 5.25~13 525-14 525 ~14 825-17 525-17 525-17 525-47 Form 6208 Frei Eaton