SECTION 4.

00
CRANKCASE ASSEMBLY

CRANKCASE ASSEMBLY IDLER GEAR SPINDLE INSTALLATION

NOTE: Install idler gears prior to installation of the
crankshaft.
The bare engine crankcase may weigh as much as 1. Install two idler gear spindles, if removed (see
4965 lb. (2252 kg). Use a suitable lifting device and Figure 4.00-1). Using a rubber mallet, drive shafts into
exercise caution during removal or installation to spindle bores until their collars are seated solidly against
avoid severe personal injury or death. front face of engine block. For best results, install
spindles at hot tank area while case is still hot. Spindles
are more difficult to install after block has cooled.

2. Slide washer onto threaded end of each idler gear

Always lift the engine using the approved lifting
spindle.
eyes. The 12 cylinder VHP Series Four engine is
equipped with two pairs of lifting eyes, one pair at 3. Apply a small amount of Loctiteâ 271 Adhesive
the front, the other pair at the rear. Lifting eyes are Sealant (High Strength) onto threads of spindle.
meant for lifting the engine only. They must not be
used to lift driven or auxiliary equipment that may be 4. Install idler gear spindle nut (see Figure 4.00-1).
attached to the engine. Follow approved rigging Turn reverse threaded nut counterclockwise to tighten.
procedures. Always use the proper spreader bar to
ensure that no undue strain is placed on the lifting
eyes and hoisting chains. Disregarding this in- FRONT MAIN
BEARING SADDLE
formation could result in severe personal injury or
death.

Never raise the crankcase more than an inch or two

off the floor (except to remove it from the hot tank,
install it in the rollover stand or position it on the oil
pan). While the block is suspended, do not put
hands, arms, feet or any other body parts beneath it. IDLER GEAR
Stand back as far as possible and exercise extreme SPINDLE NUTS
caution. Disregarding this information could result
in severe personal injury or death. Figure 4.00-1. Crankcase -- Inside Front

5. Tighten idler gear spindle nut to 775 -- 780 ft-lb

(1051 -- 1058 N×m).
The engine crankcase depicted in the accompany-
ing photographs is mounted in a rollover stand. A
rollover stand is necessary to ensure maximum
safety and ease of assembly. Tipping or flipping the
engine block using dual chains and lifting devices is
a tricky and extremely dangerous maneuver that is
not recommended. Disregarding this information
could result in severe personal injury or death.

FORM 6296 First Edition 4.00 -- 1

CRANKCASE ASSEMBLY

OIL TUBE INSTALLATION MAIN BEARING STUD INSTALLATION

1. Check 28 main bearing cap studs for nicks, cracks,
If the slot in the oil
burrs, galled or stretched threads and other obvious
spray tube is not posi-
damage. Replace as necessary.
tioned correctly, or if the internal oil passage is
obstructed, insufficient lubrication of the gear train 2. Apply Loctiteâ 271 Adhesive Sealant (High
will result in premature wear and gear failure. Strength) into the two stud holes on each side of the
seven main bearing saddles (see Figure 4.00-4).
1. Verify oil passages in spray tubes are free of dirt, grit
or other obstructions (see Figure 4.00-2). Replace
tubes if bent or damaged.

INTERNAL OIL PASSAGE

MAIN BEARING
STUDS

SLOT

Figure 4.00-2. Gear Train Oil Spray Tube

Figure 4.00-4. Main Bearing Cap Studs

Do not use Loctiteâ on
the threads of the oil
spray nozzles. Loctiteâ or any similar substance Do not install main
may obstruct the oil passage and deprive the gear bearing studs with a pipe
train of proper lubrication. Disregarding this in- wrench or similar device, since these devices may
formation could result in product damage and/or scratch or gouge the studs, causing weak points.
personal injury. Use a collet type stud driver that grips the OD of the
threads without causing damage to properly install
2. Install two oil tubes on each side of camshaft idler the main bearing studs. Disregarding this
gear spindle (see Figure 4.00-3). Thread tubes into information could result in product damage and/or
block until tight. Position each tube so center of slot personal injury.
points toward center of crankshaft bore.
3. Using a collet type stud driver, turn each main
bearing cap stud until lead bottoms out in bore. Tighten
OIL TUBES studs to 50 ft-lb (68 N×m).

DOWEL INSTALLATION
1. Inspect 24 dowel pins on cylinder head deck.
Replace if damaged or missing.

2. Inspect 14 dowel pins on each side of camshaft

bearing saddle. Replace, if damaged or missing.

3. Inspect 7 dowel pins on inside deck of main bearing

saddle. Replace if damaged or missing.

WATER HEADER PLUG INSTALLATION

CENTER OF 1. Apply Loctiteâ 271 Adhesive Sealant (High
CRANKSHAFT BORE
Strength) to threads of two 1-1/2 in. NPT square head
pipe plugs. Install plugs where right and left side water
Figure 4.00-3. Oil Tubes headers open at rear of the block (see Figure 4.00-5).
Tighten plugs to 50 ft-lb (68 N×m).

4.00 -- 2 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

The oil header plugs

WATER HEADER must be installed so that
(COUNTERSUNK HEADLESS)
they are recessed 0.015 -- 0.062 in. (0.38 -- 1.58 mm)
below the machined surface of the crankcase to
prevent interference with the flywheel. Failure to
properly install these plugs may cause damage to
equipment.

3. Verify that oil header plugs are 0.015 in. -- 0.062 in.
(0.38 -- 1.58 mm) below machined surface of block.
WATER HEADER
(COUNTERSUNK The rear face of the
HEADLESS) crankcase is machined
OIL OUTLET PORT WATER HEADER to mate with the front flywheel housing. Traces of
(SQUARE HEAD) (SQUARE HEAD) Loctiteâ left on the machined surface may result in a
rear flywheel housing face runout that exceeds
Figure 4.00-5. Rear Left Pipe Plugs specification. Traces of Loctiteâ left on the ma-
chined surface at the front of the crankcase may
2. Apply Loctiteâ 271 Adhesive Sealant (High result in oil leakage from beneath the rear gear
Strength) to threads of twelve 1-1/2 in. NPT countersunk housing. Disregarding this information could result
headless pipe plugs. Install plugs in right and left side in product damage and/or personal injury.
water headers (see Figure 4.00-5). Tighten plugs to
50 ft-lb (68 N×m). 4. Remove all traces of Loctiteâ from machined sur-
faces at front and rear of block.
3. Apply pipe thread sealant to threads of four 3/4 in.
NPT countersunk headless pipe plugs. Install plugs in 5. Install five 3/4 in. NPT square head pipe plugs in right
drain holes just below water header on both right and left side main oil header (from front to rear, ports #2, #3, #6,
sides (front and rear) (see Figure 4.00-5). Tighten plugs #7 and #8) (see Figure 4.00-7). These plugs will be
to 50 ft-lb (68 N×m). removed for connection of external oil supply lines.
Oil Header -- Right Side 6. Apply Loctiteâ 271 Adhesive Sealant (High
1. Apply Loctiteâ 271 Adhesive Sealant (High Strength) to threads of three 3/4 in. NPT square head
Strength) to threads of two 1-1/4 in. NPT countersunk pipe plugs. Install plugs in remaining ports of right main
headless pipe plugs. oil header (ports 1, 4 and 5). Tighten plugs to 50 ft-lb
(68 N×m).
2. Install plugs where right side main oil header opens
at front and rear of block (see Figure 4.00-6). Tighten 7. Apply Loctiteâ 242 Removable Threadlocker to
plugs to 233 ft-lb (316 N×m). threads of a single 1/4 in. NPT hex head pipe plug. Install
plug adjacent to farthest rearward square head in right
main oil header (see Figure 4.00-7). Tighten plug to
Install oil outlet
plugs 0.015 -- 0.062 in.
50 ft-lb (68 N×m).
(0.38 to 1.58 mm) below machined surface
of crankcase. Oil Outlet Ports -- Left Side
1. Apply Loctiteâ 271 Adhesive Sealant (High
Strength) to threads of a 3/4 in. NPT square head pipe
plug. Install plug in rear oil outlet port on left side of
engine (at level of right main oil header) (see
Figure 4.00-5). Tighten plug to 50 ft-lb (68 N×m).

2. Install a 3/4 in. NPT square head pipe plug in front oil
outlet port. This plug will be removed for connection of
an external oil supply line.

OIL OUTLET PLUG

Figure 4.00-6. Oil Outlet Plugs -- Rear Right View

FORM 6296 First Edition 4.00 -- 3

CRANKCASE ASSEMBLY

7
LOCTITEâ 1/4² NPT
HEX HEAD
6
5

PORTS: 1 4 5 ONLY
4
LOCTITEâ 3/4² NPT SQUARE HEADS

PORTS: 2 3 6 7 8
3
FINGER TIGHTEN 3/4² NPT SQUARE HEADS 2
1

Figure 4.00-7. 3/4² NPT Oil Header Pipe Plugs

OIL STRAINER ADAPTER INSTALLATION 2. Install new gasket. Secure oil strainer adapter to
crankcase with four 5/16 in.--18 x 1-1/2 in. capscrews
Deposits left on gasket with lock washers (see Figure 4.00-9).
surfaces will cause
leaks. Verify that the gasket and gasket mating 3. Tighten capscrews to 17 ft-lb (23 N×m). Strainer
surfaces are clean and completely free of grease adapter should point upward (see Figure 4.00-9).
and oil. Disregarding this information could result
in product damage. STRAINER ADAPTER

1. Locate 2 in. diameter hole in right rear side of main oil

header (see Figure 4.00-8).

Figure 4.00-9. Oil Strainer Adapter

2 IN. DIAMETER HOLE

4. Place masking tape over adapter opening to keep

Figure 4.00-8. Crankcase -- Main Oil Header --
out dust and dirt while engine is being assembled.
Rear Right

4.00 -- 4 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

LOWER VALVE LIFTER HOUSING COVER

INSTALLATION CAMSHAFT RECESS

Deposits left on gasket

surfaces will cause
leaks. Verify that all gaskets and gasket mating
surfaces are clean and completely free of grease
and oil. Disregarding this information could result
in product damage.

1. Apply 3M Scotch Gripâ 847 Rubber and Gasket

Adhesive to rear portion of block that mates with VALVE LIFTER HOUSING
GASKET ADHESIVE MATING FLANGE
camshaft cover plate (see Figure 4.00-10).
Figure 4.00-11. Crankcase -- Top Rear

3. Carefully place gasket strips on adhesive. Gasket is

made up of five separate pieces (two sets of side
gaskets and one rear). Fit dovetailed sections together
to interlock gasket strips.

4. Remove excess gasket material that overlaps block

at front of engine (see Figure 4.00-12).

GASKET

LOWER COVER

Figure 4.00-10. Lifter Housing Lower Cover

2. Place a new gasket on contact cement. Gently push

down on gasket to verify that it is properly seated.

3. Install camshaft cover plate and secure with four

3/8 in.--16 x 3/4 in. capscrews and lock washers.
Tighten to 31 ft-lb (42 N×m). GASKET

VALVE LIFTER HOUSING GASKET INSTALLATION

Figure 4.00-12. Valve Lifter Housing Gasket -- Front

Deposits left on gasket 5. Apply Permatexâ Aviation Form-A-Gasketâ Sealant

surfaces will cause to exposed side of rear valve lifter housing gasket (see
leaks. Disregarding this information could result in Figure 4.00-13). Apply Aviation Form-A-Gasketâ
product damage. Sealant to those areas where four dovetails interlock.
1. Verify gaskets and gasket mating surfaces are clean
and completely free of grease and oil.

2. Apply 3M Scotch Gripâ 847 Rubber and Gasket

Adhesive to area of crankcase around camshaft recess
(mates with bottom flange of valve lifter housing) (see
Figure 4.00-11).

FORM 6296 First Edition 4.00 -- 5

CRANKCASE ASSEMBLY

FORM-A-GASKET
SEALANT

CAMSHAFT
BEARING SADDLE

Figure 4.00-14. Camshaft Bearing Saddles

If installed incorrectly,
Figure 4.00-13. Valve Lifter Housing Gasket -- Rear internal stress may
distort or damage the roll pins, resulting in
CAMSHAFT AND BEARING INSTALLATION dislocation of the thrust ring. Disregarding this
information could result in product damage.
5. Verify pin holes in front and rear face of front
camshaft bearing cap are completely free of dirt and grit.
Compressed air can pierce the skin and cause
severe personal injury. Never use your hand to 6. Install new roll pins with split opposite bearing seat
check for leaks or to determine air flow rates. Wear (see Figure 4.00-15). Measure length of each pin to
safety glasses to shield your eyes from flying dirt verify it protrudes 0.125 in. (±0.015 in.) from face of
and debris. camshaft cap.

1. Verify internal oil passages leading from main oil ROLL PIN SPLIT
header to camshaft bearing saddles are completely free
of dirt, grit and other accumulations. Check oil passage
in camshaft bearing caps for cleanliness. Visually
inspect passageways wherever possible or insert a
piece of drill welding rod to feel for obstructions. Use
compressed air to blow out all dirt and debris.

The camshaft bearing

saddles and caps must
be completely free of oil, dirt or other foreign
material. Any dirt or debris caught between the
bearing and camshaft bore can result in bearing
distortion and reduced service life.

2. Thoroughly clean camshaft bearing saddles (see .125² ± .015² BOTH SIDES
Figure 4.00-14) and caps. Inspect bearing running
surfaces for burrs, nicks, minor scuff marks or Figure 4.00-15. Front Camshaft Bearing Cap Roll Pin
scratches. Use compressed air to blow away all dust
and debris. Do not touch the cam-
3. Verify roll pins in front and rear face of front camshaft shaft bearing running
bearing cap are clean and straight. surface. Acidic skin secretions can promote the
start of surface corrosion and wear.
4. Remove and discard pins if bent or damaged.
7. Wipe camshaft bearing clean. Inspect bearing sur-
faces for burrs, nicks, minor scuff marks or scratches.
Use compressed air to blow away all dust and debris
(use new bearings).

4.00 -- 6 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

8. Locate two front camshaft bearings. An oil groove 14. Verify oil hole in each bearing matches up with hole
distinguishes front camshaft bearing from others (see in center of camshaft bearing bore.
Figure 4.00-16). Twelve intermediate, center and rear
camshaft bearings are ungrooved and about 1/2 in. 15. Apply oil to running surface of lower camshaft
thinner. bearing. Use a quality high viscosity oil. Evenly spread
oil up over entire bearing surface.

2-5/16² 1-3/4²
(58.72 MM) (44.45 MM)
OIL The camshaft weighs approximately 115 lb. (52 kg).
GROOVE
Use a suitable lifting device and exercise caution
during removal or installation to avoid severe per-
sonal injury or death.
OIL
HOLE
16. While camshaft is suspended, slide a new thrust
ring over camshaft end. Move ring down shaft until flat
side (with oil grooves) is flush against circular plate
attached to rear face of front camshaft bearing journal
(see Figure 4.00-17). Rotate ring so notch on outside
edge faces upward.

PLATE

LOCATING TANG
INTERMEDIATE
FRONT REAR
(UPPER & LOWER) (UPPER & LOWER)

Figure 4.00-16. Camshaft Bearings

9. Position fully grooved bearing above bearing seat of

front camshaft saddle. Both halves of front camshaft
bearing are interchangeable.
FRONT CAMSHAFT
10. Position narrow, ungrooved bearing above six JOURNAL
remaining camshaft bearing saddles. All intermediate,
center and rear camshaft bearings (both upper and Figure 4.00-17. Inside Camshaft Thrust Ring
lower) are interchangeable.
17. Install camshaft into bore. Front of camshaft is
11. Verify locating tang of each bearing is directly above easily identified by gear mount and wider front bearing
notch machined on bearing saddle. journal.
12. Install bearing. Apply even pressure to each NOTE: Install the wider fully grooved bearing in the
bearing. front camshaft bearing cap (stamped with the #1). Install
the narrow ungrooved bearings in the intermediate,
While loose fitting bear- center and rear camshaft bearing caps (stamped with #2
ings are noisy, they also through #7).
can have an adverse affect on the bearing’s ability
to transfer heat. Excessive temperatures shorten 18. Install second half of bearing into cap. Locating tang
bearing service life and may lead to camshaft on parting edge of each bearing must fit squarely in
damage. notch machined on inside edge of cap.

19. Verify bearing fit tightly into bearing caps.

13. Verify bearings fit tightly in camshaft bore.

Oil starvation results in

rapid bearing failure and
possible damage to the camshaft journal.

FORM 6296 First Edition 4.00 -- 7

CRANKCASE ASSEMBLY

Oil starvation results in

rapid failure of the af- BEARING CAP
fected valve lifter and possible damage to the
camshaft lobe.
20. Verify oil hole in each bearing aligns with hole in
center of bearing cap.

21. Apply a quality high viscosity oil to upper bearing.

Evenly spread oil over entire bearing surface.

22. Verify dowels and pin holes in bearing caps are free
of dirt and grit.

Do not mix or cross -- Figure 4.00-18. Front Bearing Cap

mate camshaft bearing
caps. The camshaft bearing saddles are precision 25. Following same sequence, tighten all capscrews to
align bored with all camshaft bearing caps tight- 31 ft-lb (42 N×m).
ened in place. The caps are stamped #1 through #7,
for easy identification. Installing the caps in the Aged or missing
wrong positions will result in bearing and/or cam- O-rings may leak and
shaft failure. loss of pressure around the oil hole, resulting in
insufficient lubrication of the affected valve lifter
23. Install bearing caps. Top of each cap is stamped to roller and possible damage to the camshaft lobe.
identify its location. Starting at front of engine and
moving towards rear, install bearing caps 1 through 7. 26. Install new O-rings in circular recess around oil exit
holes at top of camshaft bearing caps (see
Bearing Cap Location Numbers
Figure 4.00-19).
#1 -- Front (Gear Train Side)
#2 -- Intermediate O-RING
#3 -- Intermediate
#4 -- Center
#5 -- Intermediate
#6 -- Intermediate
#7 -- Rear (Flywheel Side)
Position each cap so that the dowel pin holes in the feet
are aligned with the two dowels on the deck of the
bearing saddle. The dowels are offset, so the caps can
only be installed one way. If necessary, use a rubber
mallet to ensure that the caps are fully seated. BEARING CAP

NOTE: Align thrust ring notch (outside edge) with roll Figure 4.00-19. Camshaft Bearing Cap
pin located on front bearing cap (rear face). Inside
diameter lip on of the thrust ring seats in the groove 27. Slide a new thrust ring over camshaft end with
where the camshaft journal, bearing and bore converge. lipped side facing inward (see Figure 4.00-20). Position
ring flush against front face of front bearing cap. Fit
24. Starting at front of engine and moving towards rear, notch on outside edge of thrust ring, over roll pin
install capscrews in bearing caps (16 capscrews, 3/8 in. centered on face of cap (see Figure 4.00-21).
x 2-1/2 in. with lock washers) (see Figure 4.00-18).
Do not fully tighten. NOTE: Roll pin must protrude 1/8 in. (3 mm) from
bearing cap to hold thrust ring. Lip on inside diameter of
thrust ring seats in groove where camshaft journal and
bearing bore converge.

4.00 -- 8 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

GEAR HOUSING INSTALLATION

NOTCH LIP

Deposits left on gasket

surfaces will cause
leaks. Disregarding this information could result in
product damage.
1. Verify mating surfaces are completely smooth. Use a
fine toothed pattern file to lightly dress down any burrs or
high spots.

2. Slide new thrust washer onto camshaft end (see

Figure 4.00-23). Install thrust washer with small inside
OIL GROOVE
bevel (and smooth machined surface) facing inward.

Figure 4.00-20. Camshaft Thrust Ring

THRUST
WASHER

THRUST RING ROLL PIN

MATING
SURFACE

Figure 4.00-23. Thrust Washer

3. Verify all gaskets and gasket mating surfaces are

Figure 4.00-21. Outside Camshaft Thrust Ring
clean and free of grease and oil.
28. Install 8 shims (0.002 in. thickness each) on end of 4. Install new gear housing gasket. Gasket is made up
camshaft (see Figure 4.00-22). Replace any shims that of five separate pieces (two sets of side gaskets and one
are damaged. top). Fit dovetailed sections together to interlock gasket
strips (see Figure 4.00-24). If necessary, trim dovetails
for a better fit.
THRUST RING

GASKET STRIP

DOVETAIL

SHIMS
Figure 4.00-24. Gear Housing Flange
Figure 4.00-22. Shim Pack 5. Remove assembled gasket from rear gear housing.

FORM 6296 First Edition 4.00 -- 9

CRANKCASE ASSEMBLY

6. Apply 3M Scotch Gripâ 847 Rubber and Gasket 16. Using a sharp knife or razor, carefully trim exposed
Adhesive to rear gear housing surface. gasket flush with bottom of crankcase.

7. Install gasket onto gear housing. Gasket must

If the rear gear housing
extend past bottom edge approximately 1/32 in.
(0.79 mm). is not flush with the bot-
tom of the block, a faulty seal with the oil pan will
8. Push firmly down on gaskets to seat. To flatten result in oil leakage.
dovetails, place a block of wood over and lightly tap with
a hammer. 17. Verify bottom of rear gear housing is flush with
bottom of crankcase. Slide a metal straight edge across
9. Apply Permatexâ Aviation Form-A-Gasketâ Sealant both surfaces to determine if edges are level (see
to gasket dovetails (see Figure 4.00-25). Figure 4.00-26). Check crankcase on each side of
crankshaft bore.
DOVETAIL
CRANKCASE

FORM-A-GASKETâ STRAIGHT EDGE

SEALANT
Figure 4.00-26. Verify That Bottoms Are Flush
Figure 4.00-25. Rear Gear Housing Flange
18. Adjust rear housing if required. Verify bottom of rear
10. Inspect dowel pins on front face of block. Replace gear housing is flush with bottom of crankcase. Tighten
dowels if damaged or missing. 1/2 in. x 1-1/2 in. capscrews to 75 ft-lb (102 N×m).
11. Be sure dowels and pin holes in rear gear housing CAMSHAFT END PLAY MEASUREMENT
are free of dirt and grit.
NOTE: Fabricate a sleeve to simulate a camshaft gear
for measuring camshaft gear end play.

1. Measure lateral movement of camshaft. Mount dial

The rear gear housing weighs approximately 140 lb. indicator as shown. Position indicator button against
(64 kg). Use a suitable lifting device and exercise camshaft face (see Figure 4.00-27).
caution during removal or installation to avoid
severe personal injury or death.
DIAL
INDICATOR
12. Install rear gear housing onto dowel pins.

13. Install two 1/2 in. x 1-1/2 in. capscrews with lock
washers into bottom corners of block, one on each side
of crankshaft recess.

14. Remove lifting strap.

15. Install remaining 1/2 in. x 1-1/2 in. capscrews with

lock washers into rear gear housing. Do not fully tighten.

If the rear gear housing CAMSHAFT

gasket is left uncut, the
excess material will dig into the oil pan seal.
Figure 4.00-27. Measuring Camshaft End Play
Damage to the oil pan seal will result in oil leakage.
2. Install sleeve and camshaft gear nut on camshaft.
4.00 -- 10 FORM 6296 First Edition
 CRANKCASE ASSEMBLY

3. Holding camshaft in farthest rearward position, zero

dial indicator on face of rear camshaft journal. CAMSHAFT LOBE

4. Push camshaft forward as far as it will go.

5. Holding camshaft in farthest forward position, take

note of dial indicator reading. Verify camshaft end play is
0.005 -- 0.008 in. (0.127 -- 0.203 mm).
If end play is too small, add additional shims between
thrust ring and washer. Shims come in standard
thicknesses of 0.002 in. (P/N 153029). If the end play is
too great, remove shims as necessary.
6. Remove gear nut and sleeve from camshaft.

CAMSHAFT GEAR INSTALLATION MALLET HANDLE

1. Move camshaft forward. To keep camshaft from

moving backward, place a wooden block between Figure 4.00-29. Prevent Camshaft Rotation
camshaft cover plate and face of rear journal. Insert
blade of screwdriver between camshaft and wooden 3. Inspect Woodruff key for damage and distortion.
block. Wooden block should fit snugly in recess (see Replace key if necessary.
Figure 4.00-28).
4. Verify keyway on camshaft end is clean and undam-
aged. Install Woodruff key (see Figure 4.00-30). Lightly
SCREW DRIVER CAMSHAFT tap key to properly seat it. Verify key is level.

WOODRUFF
KEY

WOODEN
BLOCK
THRUST WASHER

Figure 4.00-28. Camshaft Installation

Figure 4.00-30. Gear Key
2. To prevent camshaft from turning, wedge rubber
covered mallet between front lobe and crankcase (see
Figure 4.00-29).
Always wear suitable insulated gloves when han-
dling the camshaft gear. If the gear slips from your
grasp and drops, do not attempt to catch it. The
sharp teeth of the gear combined with its weight
30 lb. (14 kg) and momentum may cause severe
lacerations. Handling the hot gear during assembly
can cause burns if insulated gloves are not worn.

FORM 6296 First Edition 4.00 -- 11

CRANKCASE ASSEMBLY

Do not drive a cold gear

onto the end of the cam- LOCK WASHER
shaft. Driving a cold gear onto the shaft may gall the
inside diameter of the gear, resulting in improper
installation and gear or camshaft damage.

Do not heat the cam-

shaft gear with a oxy-
acetylene torch. The nitriting on the gear will not
withstand the excessive heat generated by the
torch. Penetration of the case-hardening will also
result in brittle teeth leading to premature gear
failure. Uneven expansion also can lead to gear or CAMSHAFT
camshaft damage during installation. Gears ex- GEAR NUT
cessively heated with a torch should not be reinstal-
led. Figure 4.00-31. Camshaft Gear Nut And Washer

A new camshaft gear (P/N 200526E) has been released

VALVE LIFTER HOUSING INSTALLATION
for all VHP 12 cylinder engines without ESM. The new
gears are carburized and hardened to provide in- The valve lifter guides and valve lifter housing on VHP
creased dependability and service life. The new cam- Series Four GSI engines has been redesigned. The new
shaft gear is heated to a different temperature than the lifter housing has slotted oil drains on every other lifter
previous gear. See the installation procedures below. guide mounting flange (see Figure 4.00-32).

5. Camshaft Gear Installation:

·· Heat camshaft gear (P/N 200526D) in oven 1-1/2

to 2 hours at 500 -- 550° F (260 -- 288° C).

·· Heat camshaft gear (P/N 200526E) in oven 1-1/2

to 2 hours at 400 -- 450° F (204 -- 232° C).

NOTE: Do not install lock washer. The lock washer is no

longer required (see Figure 4.00-31).

6. Install camshaft gear and secure with nut.

7. Tighten camshaft gear nut to 433 -- 450 ft-lb

(587 -- 610 N×m). SLOTTED
OIL DRAIN

Figure 4.00-32. Valve Lifter Housing (P/N 200034E)

Current valve lifter guides (P/N 153003D) have a

protrusion with a flat end, previous lifter guides had a
round end (see Figure 4.00-33 and Figure 4.00-34).
Do not mix and match. New lifter guides must be used
with the new housing (P/N 200034E) and gaskets.

4.00 -- 12 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

VALVE LIFTER MOUNTING FLANGE 3/8² X 1-1/4²

GUIDE FERRYHEAD CAPSCREWS

3/8² X 1-1/2²
FLAT END FERRYHEAD CAPSCREWS

Figure 4.00-33. Current Valve Lifter Guides Figure 4.00-35. Valve Lifter Housing Assembly

6. Fasten together front and rear sections of valve lifter

VALVE LIFTER MOUNTING FLANGE housing with three 3/8 in. x 1-1/2 in. ferryhead caps-
GUIDE
crews, lock washers and hex nuts and 2 ferryhead
capscrews, 3/8 in. x 1-1/4 in. with lock washers (see
Figure 4.00-35).

7. Verify front and rear bottom surfaces are in alignment

with a straight edge. Readjust if necessary.

8. Tighten ferryhead capscrews to 31 ft-lb (42 N×m).

9. Apply Permatexâ Aviation Form-A-Gasketâ Sealant

to exposed gear housing gasket that mates with valve
lifter housing.
ROUND END
10. Apply Permatexâ Aviation Form-A-Gasketâ Seal-
ant to both legs of valve lifter housing gasket (where it
Figure 4.00-34. Previous Valve Lifter Guides
approaches the rear face of the gear housing).
1. Refer to “Valve Lifter Housing Gasket Installation” in 11. Apply a bead of RTV Silicone Rubber Adhesive
this section and install valve lifter housing gasket on Sealant along bottom seam where front and rear
engine block. sections are joined.
2. Valve lifter housing consists of a front and rear
section, however both sections are exactly the same.
Verify internal oil passages in both sections are com-
pletely free of dirt, grit and other accumulations. Visually The valve lifter housing assembly weighs approxi-
inspect passageways wherever possible or insert a mately 400 lb. (181 kg). Use a suitable lifting device
piece of drill welding rod to feel for obstructions. Use and exercise caution during removal or installation
compressed air to blow out all dirt and debris. to avoid severe personal injury or death.

3. Apply 3M Scotch Gripâ 847 Rubber and Gasket 12. Fasten lifting brackets to housing assembly. Install
Adhesive where front section mates with rear (see lifting chains and lift housing onto center of crankcase
Figure 4.00-35). (see Figure 4.00-36).

4. Place a new gasket on contact cement. Gently push Excessive oil leaks will
down on gasket to verify it is properly seated. occur if the tip of the front
5. Apply Permatexâ Aviation Form-A-Gasketâ Sealant gear housing gasket is creased or folded. Do not
to exposed side of valve lifter housing gasket. damage front gear housing gasket when installing
lifter housing.

FORM 6296 First Edition 4.00 -- 13

CRANKCASE ASSEMBLY

The ends of the longer

ferryhead capscrews
may contact the rear face of the camshaft gear if
installed in the holes closest to the block. Contact
will gouge the gear when the camshaft is rotated.

15. Secure valve lifter housing to gear housing using

three 3/8 in.--16 x 1-1/2 in. ferryhead capscrews and
lock washers (dry). Install two 3/8 in.--16 x 1-1/4 in.
ferryhead capscrews (shorter ones) in lower holes
(closest to crankcase). Tighten to 31 ft-lb (42 N×m) (see
Figure 4.00-39).

3/8²-16 X 1-1/2²
FERRYHEAD CAPSCREW

Figure 4.00-36. Valve Lifter Housing

13. Verify tip of front gear housing gasket (portion that

mates with valve lifter housing above top center
capscrew hole) was not folded over or pulled down when
valve lifter housing was installed (see Figure 4.00-37).

DAMAGED OR
CREASED GASKET

3/8²-16 X 1-1/4²
FERRYHEAD CAPSCREW

Figure 4.00-39. Front Gear Cover

16. Apply 3M Scotch Gripâ 847 Rubber and Gasket

Adhesive to rear face of lifter housing.

17. Place new gasket on adhesive. Gently push down

Figure 4.00-37. Front Gear Housing Gasket on gasket to verify that it is properly seated.

14. Remove lifting device. Secure housing to crank- 18. Install cover and secure with five 3/8 in.--16 x
case with 3/8 in.--16 x 3-1/4 in. capscrews and lock 1-1/2 in. ferryhead capscrews, lock washers and hex
washers (dry). Tighten to 31 ft-lb (42 N×m) (see nuts (see Figure 4.00-40).
Figure 4.00-38).
19. Secure cover to bottom half with two
3/8 in.--16 x 1-1/2 in. ferryhead capscrews and lock
washers (see Figure 4.00-40). Finger tighten only.
Tighten ferryhead capscrews to 31 ft-lb (42 N×m).

20. Install camshaft set screw in valve lifter housing

cover, if necessary. Set screw consists of a slotted
headless capscrew (3/8 in.--16 x 2-1/2 in.), washer and
lock nut (see Figure 4.00-40).

3/8²-16 X 3-1/2²
CAPSCREWS

Figure 4.00-38. Front Gear Cover

4.00 -- 14 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

UPPER CONNECTOR TUBE

HOUSING COVER FITTINGS

SET SCREW

Figure 4.00-40. Camshaft Set Screw Figure 4.00-42. Valve Lifter Housing -- Rear

NOTE: To adjust camshaft set screw, loosen lock nut

and turn set screw in until it contacts camshaft. Then
back out set screw 2 full turns and tighten lock nut.
Compressed air can pierce the skin and cause
Do not allow set screw to rotate more than 1/2 turn while
severe personal injury. Never use your hand to
tightening lock nut. Do not overtighten lock nut.
check for leaks or to determine air flow rates. Wear
21. Apply Loctiteâ 271 Adhesive Sealant (High safety glasses to shield your eyes from flying dirt
Strength) to threads of two male connector tube fittings and debris.
(7/8 in. tube OD). Install tube fittings in 3/4 in. pipe taps
at rear of valve lifter housing (see Figure 4.00-41). 23. Verify internal oil passages in valve lifter guides are
completely free of dirt, grit and other accumulations.
Visually inspect passageways wherever possible or
insert a piece of welding rod to feel for obstructions. Use
compressed air to blow out all dirt and debris.

NOTE: Always install new lifters with a new camshaft.

When installing used lifters with a used camshaft, lifters
must be installed into their original positions.

24. Insert valve lifters (camshaft followers) into slotted

lower bore of valve lifter guides (see Figure 4.00-43).
Slide on new valve lifter guide gaskets.

MALE CONNECTOR
TUBE FITTINGS

Figure 4.00-41. Valve Lifter Housing -- Rear

22. Apply Loctiteâ 271 Adhesive Sealant (High

Strength) to threads of two connector tube fittings. Install
plugs in pipe taps at front of valve lifter housing (see
Figure 4.00-42).

VALVE LIFTER VALVE LIFTER

GUIDE ROLLER

Figure 4.00-43. Valve Lifter Guide

FORM 6296 First Edition 4.00 -- 15

CRANKCASE ASSEMBLY

25. Lubricate valve lifter rollers with SAE 40 engine oil. ROCKER ARM OIL HEADER INSTALLATION
Apply a bead of oil between valve lifter body OD (roller
side) and guide bore sidewall (see Figure 4.00-43). NOTE: The VHP Series Four rocker arm oil supply
header does not use check valves like the standard VHP
26. Insert lifter guide assembly into lifter housing oil supply header.
backwards. Lifter guide should be exactly 180° out of
position. 1. Remove magnetic plug from pipe tees located on
each end of rocker arm oil header (see Figure 4.00-46).
27. Rotate lifter guide to final position, “hump” or Clean plugs in solvent, if necessary. Wipe plugs clean to
protrusion will now point to the outside of the engine (see ensure that all ferrous metal debris is removed. Apply
Figure 4.00-44). pipe thread sealant to each plug. Install plugs back in
pipe tees.

MAGNETIC OIL HEADER

PLUG

“HUMP” OR
PROTRUSION LIFTER GUIDE

Figure 4.00-44. Valve Lifter Housing

Figure 4.00-46. Rocker Arm Oil Header -- Front
28. Secure guides to valve lifter housing with
3/8 in.--16 x 1-1/8 in. capscrews and lock washers (see 2. Position rocker arm oil header assembly with tube
Figure 4.00-44). Do not tighten until after tube clamps clamps in center of crankcase vee. Verify free end of
have been installed. Then tighten to 31 ft-lb (42 N×m). front male elbow tube fitting points horizontally toward
left bank (see Figure 4.00-46) while rear male elbow
29. Lubricate inside diameter of upper valve lifter points to right.
guide bores to a depth of approximately 1/4 to 1/2 in.
(6 to 13 mm) with Parker Super O-Lubeä (see 3. Secure tube clamp with 3/8 in.--16 x 1-1/2 in. caps-
Figure 4.00-45). crews and lock washer. Tighten to 31 ft-lb (42 N×m) (see
Figure 4.00-47).

ROCKER ARM
OIL HEADER

VALVE LIFTER
BORE VALVE LIFTER
TUBE CLAMP GUIDE

Figure 4.00-45. Valve Lifter Bore

Figure 4.00-47. Rocker Arm Oil Header

4.00 -- 16 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

4. Install front and rear oil supply tubes between 1. Secure upper half of rear oil seal retainer in a vise
crankcase and rocker arm oil supply header. Rear tube with inside groove facing upward. Roll a new rope-type
uses a tube elbow and is supported with a clip (see seal into groove of retainer, leaving a half inch of
Figure 4.00-48). material on each side.

2. Use a wood dowel and press seal into groove. Inside

of seal should be firmly seated against bottom of groove
(see Figure 4.00-50).

SEAL

SUPPORT CLIP

Figure 4.00-48. Rear Header Supply Tube

5. Front tube uses a tee arrangement installed in

VISE DOWEL/ROD
crankcase (see Figure 4.00-49).
Figure 4.00-50. Rear Oil Seal Retainer -- Upper Half
PIPE TEE
3. Trim ends of seal square at a slight downward angle.
Low end of cut should be slightly higher than top of
retainer (see Figure 4.00-51).

Figure 4.00-49. Front Oil Supply Tube

REAR OIL SEAL RETAINER INSTALLATION

RETAINER
The two piece rope-type
seal in the rear oil seal
retainer must be correctly installed to prevent oil Figure 4.00-51. Cut Rope Type Seal
leakage and keep out dirt and dust. Oil leakage will 4. Repeat Steps 1 -- 3 to install rope-type seal in lower
occur if the ends of the wick-type seal are not half of retainer assembly.
slightly above flush on both the upper and lower
halves of the retainer. If the ends of the seal protrude 5. Thoroughly wipe machined areas where rear oil seal
too far, then the seal will bunch up upon installation retainer assembly mates with rear face of crankcase
and oil leakage will also occur. (see Figure 4.00-52). Verify mating surfaces are com-
pletely smooth. Use a fine toothed pattern file to lightly
dress down any burrs or high spots.

FORM 6296 First Edition 4.00 -- 17

CRANKCASE ASSEMBLY

SEAL END

FORM-A-SEAL GASKET

REAR MAIN
BEARING SADDLE GASKET

Figure 4.00-53. Rear Oil Seal Retainer -- Upper Half

13. Apply Permatexâ Aviation Form-A-Gasketâ Seal-

Figure 4.00-52. Rear Oil Seal Retainer -- Upper Half ant to exposed portions of rear oil seal retainer gasket
(see Figure 4.00-52).
6. Apply 3M Scotch Gripâ 847 Rubber and Gasket
Adhesive to crankcase surface that mates with upper NOTE: The lower half of the rear oil seal retainer is
and lower halves of rear oil seal retainer. installed after the crankshaft is in place. See “Rear Oil
Seal Retainer (Lower Half) Installation” in this section.
7. Place a new gasket on adhesive. Push down on
MAIN BEARING INSTALLATION
gasket to verify strip is properly seated. Gently pull each
leg of gasket until material extends past bottom edge of
crankcase approximately 1/32 in. (0.79 mm).

8. Position upper half of rear oil seal retainer against Compressed air can pierce the skin and cause
gasket and start fasteners (5 capscrews, 3/8 in. x 1 in., severe personal injury. Never use your hand to
with lock washers). check for leaks or to determine air flow rates. Wear
safety glasses to shield your eyes from flying dirt
9. Insert a dowel pin into two smaller holes on each side and debris.
of upper retainer. Use a hammer and a blunt tipped
center punch to ensure pins are fully seated in The main bearing
crankcase. saddles and caps must
be completely free of oil, dirt or other foreign
10. Apply 3M Scotch Gripâ 847 Rubber and Gasket material. Any dirt or debris caught between the
Adhesive onto upper retainer mating surface. If neces- bearing shell and crankshaft bore results in bearing
sary, cut ends of seal into a square shape (so material distortion, reduced service life and product
does not interfere with proper placement of gasket) (see damage.
Figure 4.00-53).
1. Thoroughly clean main bearing saddles and caps.
11. Place two new gaskets on adhesive. Inspect bearing running surface for burrs, nicks, minor
scuff marks or scratches, remove as necessary. Use
12. Apply Permatexâ Aviation Form-A-Gasketâ Seal- compressed air to blow away all dust and debris.
ant to exposed side of each gasket piece (see
Figure 4.00-52). 2. Check oil passage in front main bearing cap for
cleanliness. Insert a piece of welding rod into passage-
way to feel for obstructions. Front main bearing cap,
stamped with #1, is easily identified by oil pump idler
gear spindle bore (see Figure 4.00-55).

4.00 -- 18 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

.188² ± .015² BOTH SIDES

SPLIT OF ROLL PINS TO BE ASSEMBLED AS SHOWN

Figure 4.00-54. Install Roll Pins In Front Main Bearing Cap

6. Install new roll pins with split opposite bearing seat

BEARING TEMPERATURE SENSOR BORE
(SENSOR OPTIONAL) approximately 15 degrees below horizontal (see
Figure 4.00-54). Measure length of each pin to verify it
protrudes 0.188 in. (±0.015 in.) from face of main
OIL INLET bearing cap.

Do not touch the main

bearing running surface.
Acidic skin secretions can promote the start of
surface corrosion and wear.

7. Wipe main bearing shells clean. Inspect bearing

OIL
PASSAGE surfaces for burrs, nicks, minor scuff marks or
scratches, remove as necessary. Use compressed air to
SPOT FACE
OIL PUMP IDLER blow out all dust and debris.
GEAR SPINDLE BORE
8. Locate seven upper main bearing shells. All upper
Figure 4.00-55. Front Main Bearing Cap main bearing shells are fully grooved with a slotted oil
hole towards center (see Figure 4.00-56).
3. Verify four roll pins in front main bearing cap are
clean and straight.

4. Remove and discard pins if bent or damaged.

If installed incorrectly,
internal stress may
distort or damage the roll pins resulting in
dislocation of the thrust ring.

5. Verify four pin holes in front main bearing cap are

completely free of dirt and grit.

FORM 6296 First Edition 4.00 -- 19

CRANKCASE ASSEMBLY

WIDE SHELL FULL OIL HOLE

(FRONT, CENTER GROOVE UNGROOVED
AND REAR) WIDE SHELL
(FRONT, CENTER
AND REAR)

SLOTTED
OIL HOLE

LOCATING TANG LOCATING TANG

NARROW SHELL NARROW SHELL

(INTERMEDIATE) (INTERMEDIATE)

Figure 4.00-56. Main Bearing Shells -- Bearing Saddles Figure 4.00-57. Lower Ungrooved Main Bearing
Shells -- Bearing Caps
NOTE: The words “UPPER” and “LOWER” are marked
on the back of each shell to indicate its location. 15. Verify two locating tangs on parting edges of each
shell (opposite bearing running surface) are directly
9. Position fully grooved shells above bearing seats of above notches machined on inside edge of each main
seven main bearing saddles. Front, center and rear bearing cap.
bearing shells are about 1-1/8 in. (28.575 mm) wider
than four intermediate shells (see Figure 4.00-56). 16. Apply even pressure to parting edges of each
bearing shell to snap it into place.
10. Verify locating tang on parting edge of each bearing
(opposite bearing running surface) is directly above
notch machined on inside edge of bearing saddle. In addition to making
noise, loose fitting shells
11. Apply even pressure to parting edges of each can adversely affect the bearing’s ability to transfer
bearing and snap into place. heat. Excessive temperatures shorten bearing ser-
vice life and may cause damage to the crankshaft.
In addition to making
noise, loose fitting shells 17. Verify bearing shell fits tightly in each main bearing
can adversely affect the bearing’s ability to transfer cap.
heat. Excessive temperatures shorten bearing ser- NOTE: Oil starvation results in rapid wear of the oil
vice life and may cause damage to the crankshaft. pump idler gear bushing and spindle.
12. Verify bearing shells fit tightly in main bearing bore. 18. Verify oil hole in shell of front main bearing cap
matches up with supply hole to oil pump idler gear
NOTE: Oil starvation results in rapid bearing failure and spindle bore.
possible crankshaft damage.
CRANKSHAFT INSTALLATION
13. Verify slotted oil hole in each shell matches up with
oil supply hole centered in each main bearing saddle. Crankshaft Set Screws

14. Position ungrooved bearing halves onto main A missing crankshaft

bearing caps (see Figure 4.00-57). set screw will cause a
loss of engine oil pressure resulting in bearing
seizure and piston/sleeve damage.

1. Inspect crankshaft to verify all openings are plugged

and staked (see Figure 4.00-58 and Figure 4.00-59).

4.00 -- 20 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

6 1

5 4 3 2

Figure 4.00-58. Crankshaft Set Screw Locations (6)

NOTE: Wedge a pointed punch between the set screws

CRANKSHAFT and crankshaft threads and sharply strike the punch a
single blow to securely stake the set screws in place.
This operation distorts the threads to lock the set screws
in place.

5. Carefully check surface area for metal chips that may

have been produced from staking operation.

6. Apply oil to upper bearing halves in main bearing

bore. Use clean engine oil, and evenly spread oil up over
entire bearing surface.

SET SCREW 7. Before installing crankshaft in crankcase, use a

BORE clean cloth to clean the main and rod bearing journals.

Slide plastic or rubber

tubes over the main bear-
ing cap studs to avoid damage to the crankshaft
Figure 4.00-59. Crankshaft Set Screws
and/or studs during installation.

The crankshaft set 8. Slide protective plastic or rubber tubes over main
screws must be installed bearing cap studs.
prior to installing the crankshaft in the engine. A
crankshaft installed and operated with one or more
missing set screws will cause bearing seizure and
piston/sleeve damage due to low oil pressure. The crankshaft weighs approximately 1,850 lb.
(839 kg). Use a suitable lifting device and exercise
2. Carefully examine entire crankshaft to be certain all caution during removal or installation to avoid
openings are plugged with set screws. severe personal injury or death.

3. In addition, check area for metal chips resulting from 9. Guide crankshaft as it is lowered into main bearing
staking operation. saddle.
4. If a set screw is missing, proceed as follows: Coat 10. Align crankshaft oil grooves with upper half of rear
threads of set screw plugs with Loctiteâ 271. Install set retainer rope seal (see Figure 4.00-60).
screw plugs approximately three threads below surface.
Peen or stake screws into place. 11. Remove protective tubes from main bearing cap
studs.

FORM 6296 First Edition 4.00 -- 21

CRANKCASE ASSEMBLY

UPPER REAR OIL

SEAL RETAINER INSIDE THRUST RING

BEARING SHELL

OIL
GROOVES
#1 MAIN BEARING
JOURNAL

ROPE-TYPE
SEAL
GEAR
Figure 4.00-60. Crankshaft Placement MOUNT

Inside Crankshaft Thrust Ring Installation FRONT MAIN

BEARING SADDLE COUNTERWEIGHT

Do not mix or match Figure 4.00-61. Install Inside Thrust Ring

thrust rings. If reinstal-
ling thrust rings, ensure that the thrust rings are REAR OIL SEAL RETAINER (LOWER HALF)
installed in their original position. Mixing thrust INSTALLATION
rings may affect the crankshaft end play. Disregard-
ing this information could result in product damage 1. If not already accomplished, see “Rear Oil Seal
and/or personal injury. Retainer Installation” in this section for installing a new
rope-type seal.
1. Install one half of a new thrust ring into space
between bearing saddle and cheek of #1 main bearing
journal. Lip on inside diameter of thrust ring seats in Pinning the lower half of
groove where crankshaft journal, shell and bearing bore the rear oil seal retainer
converge (see Figure 4.00-61). to an upper retainer that is already tightened to the
crankcase will pinch or crack the legs of the retainer
gasket. Damage to the rear oil seal retainer gasket
To avoid damage to a will result in oil leakage.
crankshaft journal or fil-
let, always position the pry bar against a non-critical
2. Be sure five capscrews of upper rear oil seal retainer
surface, such as the crankshaft cheek, counter-
are loose (see Figure 4.00-62).
weight, or main bearing cap.
2. Use a pry bar to bump crankshaft towards rear if gap 3. Align dowels in lower half of rear oil seal retainer with
is too narrow to accommodate thrust ring. two pin holes in upper half. If necessary, use a rubber
mallet to tap mating flanges together.
3. Place one half of a new thrust ring (P/N 153031B)
flush against front face of #1 main bearing saddle. Lip on 4. Secure lower retainer to upper half with two caps-
inside diameter of thrust ring fits in groove where crews (7/16 in.--14 x 1-1/4 in.) and lock washers.
crankshaft journal, shell and bearing bore converge.
5. Secure upper half of retainer to crankcase with five
NOTE: The upper and lower halves of the thrust ring capscrews (3/8 in.--16 x 1 in.) and lock washers.
are interchangeable.
6. Secure lower half of retainer to crankcase with four
capscrews (3/8 in.--16 x 1 in.) and lock washers.

4.00 -- 22 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

RETAINER ROPE-TYPE
SEAL REAR MAIN
UPPER HALF BEARING CAP
DOWEL DOWEL
PIN PIN

REAR OIL
SEAL RETAINER

RETAINER Figure 4.00-63. Trim Rear Oil Seal Retainer Gasket

GASKET
MAIN BEARING CAPS INSTALLATION
RETAINER
LOWER HALF Current production VHP Series Four main bearing caps
and crankcases use a second “diamond” dowel pin to
improve alignment (see Figure 4.00-64). This tightening
procedure should be used on previous engines as well
LOCK WASHER as current production ones.
CAPSCREW DOWEL PIN NOTE: The new bearing caps can be used with
Figure 4.00-62. Rear Oil Seal Retainer Assembly previous production crankcases.

If the rear oil seal DIAMOND DOWEL

retainer gasket is left
uncut, the excess material will dig into the oil pan
seal. Damage to the oil pan seal will result in oil
leakage.

7. Using a sharp knife or razor, trim rear oil seal retainer

gasket flush with bottom of crankcase (see
Figure 4.00-63).

If the lower half of the

FULL DOWEL
rear oil seal retainer is
not flush with the bottom of the crankcase, a faulty
seal with the oil pan will result in oil leakage. Figure 4.00-64. Crankcase Diamond Dowel Location

8. Verify bottom of lower retainer is flush with bottom of NOTE: A new “high hex” nut (P/N 214045) replaces the
crankcase by sliding a metal straight edge across both previous production elastic stop nut on the bearing cap
surfaces. Check each side of seal retainer bore (see studs (see Figure 4.00-65). The final torque value
Figure 4.00-63). remains the same: 275 ft-lb (373 N×m). It is recom-
mended that previous style elastic stop nuts be replaced
with the new “high hex” nut (P/N 214045).

FORM 6296 First Edition 4.00 -- 23

CRANKCASE ASSEMBLY

CROSS--TIE BOLTS
Figure 4.00-65. High Hex Nut (P/N 214045)

NOTE: Do not mix the elastic stop nuts and high hex
nuts on one main bearing cap. Waukesha recommends Figure 4.00-67. Cross--Tie Bolts
that all nuts on a bearing cap be replaced with the new
style nut. 2. Tighten hex nuts and cross-tie bolts in proper
sequence listed in Figure 4.00-68.
NOTE: Generously apply engine oil to main bearing
cap studs, nuts and side bolts immediately before A. Tighten hex nuts 1 through 4 (in that order) to
installing them. Apply 3M Scotch-Grip â 847 Rubber and 75 ft-lb (102 N×m). If installing replacement caps
Gasket Adhesive to both sides of cross-tie bolt washers that will be aligned bored, tighten to only 30 ft-lb
to prevent oil leaks. (40 N×m). When installing more than one cap,
tighten nuts 1 through 4 to 75 ft-lb (102 N×m) on
1. Secure all main bearing caps with four washers, lock
all caps before tightening side bolts.
nuts, cross-tie bolts and washers (see Figure 4.00-66
and Figure 4.00-67). Use one washer on each cross-tie B. Tighten all full dowel (left side) cross-tie bolts
bolt. (five) to 250 ft-lb (339 N×m) starting from front of
engine.
NOTE: Verify crankshaft rotates freely after each
bearing cap is tightened. C. Tighten all diamond dowel (right side) cross-tie
bolts (six) to 250 ft-lb (339 N×m) starting from
front of engine.
LOCK NUT
D. Tighten hex nuts 1 through 4 to 275 ft-lb
WASHER (373 N×m) in two steps: first 175 ft-lb (237 N×m)
and then 275 ft-lb (373 N×m).

NOTE: The diamond dowel pin must be installed

parallel to the crankcase edge as depicted (see
Figure 4.00-68).

-- FULL DOWEL PIN -- DIAMOND DOWEL PIN

FULL DOWEL SIDE

3 2

Figure 4.00-66. Main Bearing

1 4

VIEW OF BEARING CAP (FROM BOTTOM)

Figure 4.00-68. Main Bearing Cap Tightening Pattern

4.00 -- 24 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

CRANKSHAFT END PLAY MEASUREMENT

CRANKSHAFT
HUB
Always check the
crankshaft endplay
before installing the crankshaft gear. Disregarding
this information could result in product damage
and/or personal injury.

1. Fabricate a sleeve to the same inside diameter as the

crankshaft gear. Sleeve should fit over the crankshaft PIN
easily. A second longer sleeve with a closed end should
be fabricated to fit over the end of the crankshaft, with
enough length to reach the sleeve positioned against
the thrust washer (see Figure 4.00-69).

Figure 4.00-70. Crankshaft End Play

To avoid damage to a
crankshaft journal or fil-
let, always position the pry bar against a non-critical
surface, such as the crankshaft cheek, counter-
weight or main bearing cap.
5. Insert a pry bar between counterweight and main
bearing cap (see Figure 4.00-71). Push on counter-
weight to move crankshaft back as far as it will go.

MAIN BEARING CAP

Figure 4.00-69. Tighten Front Main Bearing Cap

NOTE: The longer sleeve should be fabricated to allow

capscrews to be threaded through the closed end and
into the threaded holes in the crankshaft end. This will
allow the sleeves to be tightened against the thrust
PRY BAR
washer.

2. Position temporary sleeves against thrust washer as

described and tighten.

3. Remove capscrew (3/8 in.--16 x 1 in. with lock

washer) from lower right corner of rear oil seal retainer
assembly. Install a pin in bolt hole.
COUNTERWEIGHT
4. To measure lateral movement of crankshaft, mount a
dial indicator on pin. Position indicator button against Figure 4.00-71. Bump Crankshaft Towards Rear
crankshaft hub (see Figure 4.00-70).
6. Hold crankshaft in farthest rearward position and
zero dial indicator on crankshaft hub.

7. Insert a pry bar between main bearing cap and

crankshaft cheek. Push on cheek to move crankshaft
forward as far as it will go.

FORM 6296 First Edition 4.00 -- 25

CRANKCASE ASSEMBLY

8. Holding crankshaft in farthest forward position, take OUTSIDE CRANKSHAFT THRUST RING
note of dial indicator reading. Verify crankshaft end play INSTALLATION
is between 0.005 -- 0.016 in. (0.127 -- 0.406 mm).
1. Verify two roll pins in front face of #1 main bearing
NOTE: Adding shims will increase end play, removing journal are clean and straight (see Figure 4.00-74).
shims will decrease end play. Shims (P/N 153043A)
come in standard thickness of 0.003 in. (0.076 mm).
ROLL PIN
Add or remove shims as necessary (see
Figure 4.00-72). Figure 4.00-73 shows the standard
thrust ring measurements.

SHIMS (0.003² EA.) BEARING

#1 MAIN
JOURNAL
ROLL PIN

Figure 4.00-74. Roll Pins

CRANKSHAFT
GEAR
2. Remove and discard pins if bent or damaged.
THRUST WASHER

THRUST RING (BEARING) If installed incorrectly,

internal stress may
Figure 4.00-72. Crankshaft End Play
distort or damage the roll pins resulting in
dislocation of the thrust ring.

0.215 -- 0.217² 3. Verify pin holes are completely free of dirt and grit.

4. Install new roll pins (P/N 26800) with split opposite

crankshaft end (see Figure 4.00-75). Measure length of
each pin to verify it protrudes 0.312 in. ± 0.015 in.
(7.924 mm ± 0.381 mm) from face of crankshaft journal
(see Figure 4.00-76).
LIP
ROLL PIN

0.263-- 0.268²

Figure 4.00-73. Standard Crankshaft Thrust Rings --

PN 153031B

9. Remove dial indicator from crankshaft hub.

ROLL PIN
10. Remove pin from rear oil seal retainer and install
3/8 in.--16 x 1 in. capscrew and lock washer in bolt hole.
Figure 4.00-75. Install Roll Pins In Crankshaft
11. Remove fabricated sleeves from crankshaft end.

4.00 -- 26 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

CRANKSHAFT GEAR INSTALLATION

.312 ± .015² NOTE: Engines built before November 4, 2002, require
(7.924 ±0.381 mm)
(BOTH SIDES) the crankshaft endplate capscrews and front pulley
capscrews be retightened once a year. Engines built
after November 4, 2002, do not require this. See
#1 MAIN Vibration Damper/Rear Crankshaft Pulley Installation
BEARING JOURNAL
(Built After November 15, 2002) and Figure 4.00-159
for retrofit information. The crankshaft requires thrust
washer (P/N 153044C) for retrofit.

1. Slide thrust washer onto end of crankshaft with inside

bevel facing thrust ring (see Figure 4.00-79 and
Figure 4.00-80).
ROLL PINS

Figure 4.00-76. Roll Pin

NOTCH BEVEL
5. Position other half of thrust ring flush against front
main bearing cap (see Figure 4.00-77 and
Figure 4.00-78). Two roll pins fit into pin holes on
opposite sides of thrust ring. Lip on inside diameter of
ring seats in groove between crankshaft and main
bearing cap. If necessary, place a little grease on roll
pins to help hold thrust ring in place.

OIL GROOVES

ROLL
PIN
ROLL PIN HOLE
HOLE PULLER
HOLE

Figure 4.00-79. Crankshaft Thrust Washer

2. Move washer down crankshaft until it contacts thrust

ROLL PIN HOLES ring.

3. Position washer so notch on inside diameter slides

Figure 4.00-77. Crankshaft Thrust Ring (Half) Lip
past dowel pin on crankshaft circumference (see
Figure 4.00-79).
FRONT MAIN ROLL PIN
BEARING CAP 4. Fit two roll pins on face of #1 main bearing journal into
THRUST pin holes on opposite sides of thrust washer.
RING

Figure 4.00-78. Outside Thrust Ring -- Cap Side

FORM 6296 First Edition 4.00 -- 27

CRANKCASE ASSEMBLY

THRUST BEARING

CRANKSHAFT

THRUST WASHER
P/N 153044C

CRANKSHAFT GEAR
P/N 200012J

OIL SLINGER
P/N 153042
ROLL PIN
P/N 26800

NOTE: *Denotes new part.

Figure 4.00-80. Crankshaft Assembly

Do not drive a cold NOTE: Do not delay installation of the crankshaft gear
crankshaft gear onto the after it is removed from the oven. The gear shrinks as it
crankshaft. Driving the gear onto the shaft may gall cools, so it must be properly installed before its inside
the inside diameter of the gear, resulting in improper diameter decreases to the point where installation
installation and gear or crankshaft damage. becomes difficult. Any difficulty associated with installa-
tion of the crankshaft gear increases the risk of improper
Do not heat the crank- installation or damage to the crankshaft gear and/or
shaft gear with a oxyacet- crankshaft.
ylene torch. The nitrating on the gear will not
withstand the excessive heat generated by the
torch. Penetration of the case-hardening will also
result in brittle teeth leading to premature gear Always wear insulated gloves when handling
failure. Uneven expansion can cause the gear or heated gears. Use of bare hands will result in severe
crankshaft to be damaged during installation. Gears burns.
excessively heated with a torch should not be
reinstalled. 6. Align notch on inside diameter of heated crankshaft
gear with dowel pin on crankshaft end (see
NOTE: Two different crankshaft gears are in service. Figure 4.00-81). Verify timing marks (the letters “X” and
Each crankshaft gear requires a different temperature. “O”) face outward.
Verify the crankshaft gear is heated to the required
temperature.
CRANKSHAFT THRUST WASHER
A new crankshaft gear (P/N 200012K) has been re- GEAR
leased for all VHP 12 cylinder engines. The new gear is
carburized and hardened to provide increased depend-
ability and service life. Installation procedures remain
the same, except the gear is heated to a different
temperature than the previous gear.
5. Crankshaft Gear Installation:

·· Heat crankshaft gear (P/N 200012J) in oven

1-1/2 to 2 hours at 500 -- 550° F (260 -- 288° C).
DOWEL PIN
·· Heat crankshaft gear (P/N 200012K) in oven
1-1/2 to 2 hours at 400 -- 450° F (204 -- 232° C).
Figure 4.00-81. Crankshaft Gear Mount

4.00 -- 28 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

7. Slide gear down crankshaft end until it seats solidly

OIL PUMP
against thrust washer. IDLER GEAR

8. While gear cools, tap on gear face with a soft

hammer to ensure that it remains tight against thrust
washer.

9. After gear has cooled, verify gear fits snugly on

crankshaft without rocking or sliding.

10. Install oil slinger with open end toward front (see
Figure 4.00-80).

OIL PUMP IDLER GEAR

SPINDLE
1. Lubricate exterior surface of oil pump idler gear SCREW HEAD
spindle (see Figure 4.00-82). Use a quality high viscos-
ity oil. Figure 4.00-83. Secure Spindle Screw Head

FRONT WASHER 9. Keep oil pump idler gear from turning and tighten
WASHER NUT
spindle screw hex nut to 300 -- 325 ft-lb (407 -- 441 N×m)
(see Figure 4.00-84).

TORQUE WRENCH

CAPSCREW

IDLER GEAR
SPINDLE OIL PUMP GEAR

Figure 4.00-82. Oil Pump Gear Assembly

2. Slide spindle into hole at bottom of front main bearing

cap until it is seated solidly against inside counterbore. OIL PUMP
IDLER GEAR
Verify Waukesha part number faces outside toward front
of the engine.
Figure 4.00-84. Tighten Spindle Screw Hex Nut
3. Install oil pump idler gear onto spindle with tapered
end facing inward. CAMSHAFT IDLER GEAR INSTALLATION

4. With recessed side facing screw head, move thick

washer down spindle screw.
Always wear suitable safety gloves when handling
5. Insert screw into oil pump idler gear spindle until it the idler gears. The edges of the gear teeth are sharp
exits bore at rear of front main bearing cap. enough to cut flesh if mishandled. If the gear slips
6. Install thin washer on end of spindle screw. from your grasp and drops, do not attempt to catch
it. The sharp edges of the gear teeth combined with
7. Apply a small amount of Loctiteâ 271 Adhesive its weight 30 lb. (14 kg) and momentum may cause
Sealant (High Strength) to threads of spindle screw. severe lacerations.

8. Install spindle screw hex nut (Grade 8, 3/4 in.--16) A new camshaft idler gear (P/N 200115S) has been
with large chamfer facing outside, smaller chamfer in released for all VHP 12 cylinder engines without ESM.
toward bearing cap (see Figure 4.00-83). The new gear is carburized and hardened to provide
increased dependability and service life. Installation
procedures remain the same.

FORM 6296 First Edition 4.00 -- 29

CRANKCASE ASSEMBLY

1. Position camshaft idler gear in a suitable press with

shallow counterbore facing upward (see BEARING
RETAINER
Figure 4.00-85). Position a new ball bearing above hub. PLATE

SHALLOW COUNTERBORE

NYLOK
DEEP COUNTERBORE CAPSCREWS
Figure 4.00-85. Idler Gear

2. Exert uniform pressure against outer bearing race

Figure 4.00-87. Camshaft Idler Gear
until bearing makes solid contact with counterbore.
Since bearing is a slight interference fit in gear bore,
8. Use a piece of white chalk to highlight timing marks
minimum pressure is required to press bearing into
(“X’s” and “O’s”) on faces of cam, crank and idler gears
place.
(see Table 4.00-12) (oil pump idler gear is not timed).
3. Turn idler gear over so deep counterbore faces
9. With timing marks facing outward, push idler gear
upward. Position spacer in gear hub.
onto spindle until rear ball bearing race is fully seated.
4. Position a new bearing above gear hub. Exert Spacer separating front and rear ball bearings drops
uniform pressure against outer race of bearing until it down to halt complete installation of idler gear (see
makes solid contact with counterbore (see Figure 4.00-88).
Figure 4.00-86). Bearing is a slight interference fit, so
minimum pressure is required to press bearing into BEARING
SPACER
place. RETAINER
PLATE

NYLOK CAPSCREW
WIDE BEARING BORE

SPACER

Figure 4.00-86. Idler Gear

5. Position gear on a suitable workbench with threaded

holes around hub facing upward. Figure 4.00-88. Camshaft Idler Gear -- Upper

6. With beveled inside diameter of bearing retainer 10. When end of spindle contacts spacer, rotate idler
plate facing outward, align holes in plate with holes in gear to align timing marks.
gear.
11. Two “X’s,” positioned 180 degrees apart, are
7. Start six new 3/8 in.--16 x 1 in. Nylok capscrews in stamped on camshaft idler gear. One “X” (vertical) is
gear hub (see Figure 4.00-87). Alternately tighten stamped at base of a tooth, other (horizontal) is directly
capscrews. below a root (see Figure 4.00-89).

4.00 -- 30 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

ALIGN VERTICAL “X” BELOW TOOTH 13. With timing marks correctly aligned, pull up on ball
WITH “X” ON CAM GEAR ROOT bearing spacer and slide idler gear down spindle until
rear face contacts spindle shoulder. Lightly tap gear face
X with a soft rubber mallet to ensure that it is completely
seated.

14. Align holes in idler gear washer and lock washer

with those in idler gear spindle. (Use a new lock washer.)
Verify tapered hole in center of idler gear washer faces
inward. Finger tighten two capscrews (1/2 in.--20 x
1-1/4 in.), so flat of one is parallel with flat of other (see
6

Figure 4.00-91).
12

O
ROUNDED TAB
X

ALIGN HORIZONTAL “X” BELOW ROOT

WITH “X” ON CRANK GEAR TOOTH

Figure 4.00-89. Camshaft Idler Gear -- Timing Marks

12. Align camshaft idler gear so that vertical “X” on

tooth lines up with “X” on cam gear root (see
Figure 4.00-90), and horizontal “X” on root lines up with
Figure 4.00-91. Lock Idler Gear Capscrews
“X” on crank gear tooth.
15. With facing flats parallel, use a thin wall socket to
tighten first capscrew. If socket cannot be removed, then
make capscrew a little tighter to bring flats parallel again.
Tighten second capscrew in same manner. Socket can
only be removed when facing flats of two capscrews are
parallel.

16. Tighten two idler gear capscrews to 87 ft-lb

(118 N×m). Using a thin wall socket, follow “parallel flats”
CAMSHAFT tightening procedure described in Step 15.
IDLER GEAR
CAMSHAFT NOTE: It may be necessary to exceed the torque value
GEAR slightly in order to make the facing flats of the two
capscrews parallel. The flats must be parallel to install or
remove the thin wall socket.
TIMING
MARKS
17. Use a chisel and hammer to bend rounded tab on
each end of idler gear lock washer toward head of
adjacent capscrew. Bend each tab forward until it rests
Figure 4.00-90. Cam Gear/Camshaft Idler Gear Timing tightly against flat of capscrew (see Figure 4.00-91).

FORM 6296 First Edition 4.00 -- 31

CRANKCASE ASSEMBLY

ACCESSORY IDLER GEAR INSTALLATION

CAMSHAFT
1. Follow Steps 1 -- 11 under “Camshaft Idler Gear GEAR
Installation.”
CAMSHAFT
IDLER GEAR
2. Align accessory idler gear so “O” stamped at base of
tooth lines up with “O” below crank gear root (see
Figure 4.00-92). ACCESSORY
IDLER GEAR
ALIGN “O” BELOW TOOTH
WITH “O” ON CRANK
GEAR ROOT

O
X

CRANKSHAFT GEAR

Figure 4.00-93. Accessory Idler Gear -- Lower

6
12

GEAR BACKLASH MEASUREMENT

O

Backlash is the distance or the amount of “play” between

the teeth of two meshed gears (see Figure 4.00-94).
Always check the backlash, regardless of whether the
gear is new or used. Refer to Table 4.00-12 for backlash
values.

GEAR BACKLASH
X
12

“12” BELOW TOOTH TO BE

ALIGNED WITH “12” BELOW
MAG DRIVE GEAR ROOT

Figure 4.00-92. Accessory Idler Gear -- Timing Marks

3. Follow Steps 12 -- 16 under “Camshaft Idler Gear

Installation” (see Figure 4.00-93).

Figure 4.00-94. Gear Backlash

If the backlash on a new

gear is not within specifi-
cation, recheck the part number to be sure that the
correct gear was installed. Use of tight or “bound”
gears or use of excessively worn gears, can lead to
severe engine damage.

If the backlash is not within specification, then the gear,

and/or the gear with which it mates, must be replaced.

4.00 -- 32 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

Table 4.00-12. Rear Gear Backlash Specifications

A A
X
X

2
X
6 6
12
12

5 X 5
O
O
3

4
1 -- CAM GEAR
2 -- CAM IDLER GEAR
3 -- CRANK GEAR
4 -- OIL PUMP IDLER GEAR
5 -- ACCESSORY IDLER GEAR
6 -- ACCESSORY (MAGNETO) DRIVE GEAR

MEASUREMENT INCHES (in.) METRIC (mm)

(A) Timing gears (helical gears)
Normal to tooth 0.008 -- 0.012 0.203 -- 0.305
In plane of rotation 0.0082 -- 0.0122 0.2083 -- 0.3099
Governor drive gears
Magneto shaft to intermediate shaft (spur gears)
60 and 72 tooth gears 0.005 -- 0.007 0.127 -- 0.178
42 and 90 tooth gears 0.003 -- 0.005 0.076 -- 0.127
Intermediate shaft to governor (spiral gears)
Normal to tooth 0.004 -- 0.006 0.102 -- 0.152
In plane of rotation (governor gear) 0.0057 -- 0.0085 0.1448 -- 0.2159
NOTE: The engine camshaft idler gear is a “Hunting--Tooth” design to minimize tooth wear. The fractional drive ratio between the crankshaft and
camshaft gears results in the idler gear timing marks re--aligning with the crankshaft and camshaft timing marks only once in every 154 crankshaft
revolutions . The most practical way to realign the timing marks, when timing a camshaft, is to remove the idler gear and re--assemble to its timed
position as previously described.

FORM 6296 First Edition 4.00 -- 33

CRANKCASE ASSEMBLY

Table 4.00-13. Oil Pump And Oil Pump Drive Gears

1
A A

F
2
6 6
5 5
3 E D

B
4 A
C
7 8
1 -- CAM GEAR G
2 -- CAM IDLER GEAR
3 -- CRANK GEAR
4 -- OIL PUMP IDLER GEAR
5 -- ACCESSORY IDLER GEAR
6 -- ACCESSORY (MAGNETO) DRIVE GEAR
7 -- OIL PUMP DRIVE GEAR
8 -- OIL PUMP DRIVE GEAR

MEASUREMENT INCHES (in.) METRIC (mm)

Idler gear between crankshaft gear and oil pump drive gear
(A) Backlash with crankshaft gear
Normal to tooth 0.007 -- 0.012 0.178 -- 0.305
In plane of rotation 0.0072 -- 0.0122 0.1829 -- 0.3099
(B) Backlash with oil pump drive gear
Normal to tooth 0.015 -- 0.020 0.381 -- 0.508
In plane of rotation 0.0153 -- 0.0204 0.3886 -- 0.5182
(C) End play (including clamp load compression of spindle) 0.008 -- 0.025 0.203 -- 0.635
(D) Bushing inside diameter (machined in assembly) 1.5005 -- 1.5015 38.1127 -- 38.1381
(E) Idler spindle (hollow) outside diameter (free state) 1.4965 -- 1.4970 38.0111 -- 38.0238
(F) Running clearance between spindle (free state) and bushing 0.0035 -- 0.005* 0.0889 -- 0.127
Oil pump drive gears
(G) Backlash between external oil pump drive gears
Backlash, normal to tooth 0.009 -- 0.011 0.203 -- 0.254
Backlash in plane of rotation 0.0082 -- 0.010 0.2083 -- 0.254
NOTE: * Outside diameter will be slightly larger and running clearance will be slightly smaller because of idler spindle capscrew clamp load.

4.00 -- 34 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

Table 4.00-14. Oil Pump Clearances

D D
B B
C C

E E
H
F F
G G
D¢ D¢
B¢ B¢
C¢ C¢

MEASUREMENT INCHES (in.) METRIC (mm)

Oil Pump Clearances
(A) Hub clearance with oil pump body 0.022 – 0.040 0.559 – 1.016
Drive shaft bushing inside diameter
(B) In body 1.3745 – 1.3755 34.9123 – 34.9377
(B¢) In cover 1.2505 – 1.2515 31.7627 – 31.7881
Drive shaft diameter
(C) Body section 1.3720 – 1.3725 34.8488 – 34.8615
(C¢) Cover section 1.2480 – 1.2485 31.6992 – 31.7119
Running clearance between shaft and bushing
(D) In cover 0.002 – 0.0035 0.0508 – 0.0889
(D¢) In body 0.002 – 0.0035 0.0508 – 0.0889
Oil pump Idler gears
(E) Bushing inside diameter 1.0005 – 1.0015 25.4127 – 25.4381
(F) Shaft diameter 0.9980 – 0.9985 25.3492 – 25.3619
(G) Running clearance 0.002 – 0.0035 0.051 – 0.0889
(H) Radial clearance between outside diameter of pumping gears and oil pump body bores 0.002 – 0.008 0.051 – 0.203

FORM 6296 First Edition 4.00 -- 35

CRANKCASE ASSEMBLY

Camshaft Idler Gear To Crankshaft Gear Accessory Idler Gear To Crankshaft Gear
1. Mount a dial indicator with a magnetic base next to 1. Mount a dial indicator with a magnetic base next to
camshaft idler gear (see Figure 4.00-93). Position the accessory idler gear. Position indicator point against
indicator point against inside face of any idler gear tooth. inside face of any idler gear tooth.

2. Turn camshaft idler gear until contact with stationary 2. Turn accessory idler gear until contact with station-
crank gear prevents further movement. ary crank gear prevents further movement.

3. Holding idler gear in position, zero dial indicator. 3. Holding idler gear in position, zero dial indicator.

4. Turn camshaft idler gear in opposite direction until 4. Turn accessory idler gear in opposite direction until
movement is again halted by contact with crank gear. movement is again halted by contact with crank gear.

5. Take note of dial indicator reading. Verify camshaft 5. Take note of dial indicator reading. Verify accessory
idler gear to crank gear backlash is 0.008 -- 0.012 in. idler gear to crank gear backlash is between 0.008 --
(0.203 -- 0.305 mm). 0.012 in. (0.203 -- 0.305 mm).

Severe engine damage Severe engine damage

may result from opera- may result from opera-
tion with “tight” or excessively worn gears. tion with “tight” or excessively worn gears.

6. Back off point of dial indicator, rotate idler gear 6. Back off point of dial indicator, rotate accessory idler
180 degrees and recheck backlash. gear 180 degrees and recheck backlash.

Camshaft Idler Gear To Camshaft Gear Oil Pump Idler Gear to Crankshaft Gear
1. Mount a dial indicator with a magnetic base next to 1. Mount a dial indicator with a magnetic base next to oil
camshaft idler gear. Position indicator point against pump idler gear. Position indicator point against inside
inside face of any idler gear tooth. face of any idler gear tooth.

2. Secure cam gear against movement. 2. Turn oil pump idler gear until contact with stationary
crank gear prevents further movement.
3. Turn idler gear until contact with stationary cam gear
prevents further movement. 3. Holding idler gear in position, zero dial indicator.

4. Holding idler gear in position, zero dial indicator. 4. Turn oil pump idler gear in opposite direction until
movement is again halted by contact with crank gear.
5. Turn idler gear in opposite direction until movement
is again halted by contact with stationary cam gear. 5. Take note of dial indicator reading. Verify oil pump
idler gear to crank gear backlash is between 0.008 --
6. Take note of dial indicator reading. Verify camshaft 0.012 in. (0.203 -- 0.305 mm).
idler gear to cam gear backlash is between 0.008 --
0.012 in. (0.203 -- 0.305 mm).
Severe engine damage
may result from opera-
Severe engine damage tion with “tight” or excessively worn gears.
may result from opera-
tion with “tight” or excessively worn gears. 6. Back off point of dial indicator, rotate oil pump idler
gear 180 degrees and recheck backlash.
7. Back off point of dial indicator, rotate idler gear
180 degrees and recheck backlash.

4.00 -- 36 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

MAGNETO DRIVE ASSEMBLY INSTALLATION

MOUNTING ROUNDED CUTS
1. Remove 3/4 in. NPT square head pipe plugs from FLANGE
taps #2 and #3 in right bank main oil header. Oil header
tap #1 is at front of engine, while tap #8 is at rear.

2. Apply pipe thread sealant to threads of a 1/2 in. to

1/8 in. reducing bushing. Install bushing in oil header tap
#2 (for connection of oil header pressure tube to
prechamber safety fuel shutdown valve).
BOLT HOLE
3. Apply pipe thread sealant to threads of a 1/2 in. to
1/4 in. reducing bushing. Install bushing in oil header tap
#3 (for connection of governor drive oil supply and
overspeed governor oil header pressure tube connec-
Figure 4.00-95. Magneto Drive Assembly
tions).

4. Check six magneto drive mounting studs for nicks, 10. Install 1/2 in.--20 hex nuts with lock washers onto
cracks, galled or stretched threads and other obvious studs. Alternately tighten to 80 ft-lb (108 N×m).
damage. Replace as necessary.
11. Remove two side bolts (3/8 in.--13 x 1 in. with lock
5. Each magneto drive mounting stud has both fine and washers) from magneto drive adapter cover, if installed
coarse threads separated by a smooth boss. Apply (see Figure 4.00-96).
Loctiteâ 242 Removable Threadlocker to coarse
threaded side. SIDE BOLT SIDE BOLT

Do not install magneto

drive mounting studs
with a pipe wrench or similar device. Use a collet
style stud driver to prevent damage to studs.

6. Install six studs in rear right bank side of rear gear

housing. Drive each stud into flange until last coarse
thread is turned into casting.

7. Verify gaskets and gasket mating surfaces are clean

and completely free of grease and oil. Deposits left on
gasket surfaces will cause leaks.

8. Slide a new gasket on mounting studs.

Figure 4.00-96. Remove Adapter Cover Side Bolts

12. Secure magneto drive support bracket to crank-

The magneto drive assembly weighs approximately case with three 1/2 in.--13 x 1-1/8 in. capscrews, lock
70 lb. (32 kg). Use a suitable lifting device and washers and flat washers. Slide bracket forward until it
exercise caution during removal or installation to contacts magneto drive adapter cover.
avoid severe personal injury or death.
13. Slide two longer fasteners (3/8 in.--16 x 1-1/2 in.
9. Locate bolt hole between two rounded cuts in flange with lock washers and flat washers) through slots in
of magneto drive housing (see Figure 4.00-95). With magneto drive support bracket. Install spacers (5/32 in.)
bolt hole at 10 o’clock position and overspeed governor on capscrews and thread them into magneto drive
mounting pad facing upward (but tilting toward the right), adapter cover.
move magneto drive down mounting studs until outer lip
on spindle side fits squarely in hole in rear gear housing. 14. Alternately tighten capscrews (5) to secure magne-
to drive support bracket to block and to magneto drive
adapter cover (see Figure 4.00-97).

FORM 6296 First Edition 4.00 -- 37

CRANKCASE ASSEMBLY

15. Secure cover plates with 3/8 in.--16 hex nuts and
lock washers. Tighten to 30 ft-lb (41 N×m).
Always wear suitable safety gloves when handling
MAGNETO DRIVE the magneto drive gear. The edges of the gear teeth
ASSEMBLY are sharp enough to cut flesh if mishandled. If the
gear slips from your grasp and drops, do not
attempt to catch it. The sharp edges of the gear teeth
combined with its weight 80 lb. (36 kg) and momen-
tum may cause severe lacerations.

3. Rotate magneto drive shaft so keyway slot and “A”

marked on shoulder face of shaft are at top (see
Figure 4.00-99 and Figure 4.00-100).
SUPPORT NOTE: An “A” is marked on both the front and rear of
BRACKET
the magneto drive gear.
COVER PLATE 4. With timing marks facing outward, slide magneto
drive gear onto drive shaft (see Figure 4.00-99). Align
Figure 4.00-97. Mount Magneto Drive Installation magneto drive gear so “A” marked on magneto drive
shaft and “A” marked on magneto drive gear lines up,
MAGNETO DRIVE GEAR INSTALLATION and number “12” stamped below magneto drive gear
A new magneto drive gear (P/N 200426J) has been root lines up with “12” at base of accessory idler gear
released for all VHP 12 cylinder engines without ESM. tooth (see Figure 4.00-98, Figure 4.00-99 and
The new gear is carburized and hardened to provide Figure 4.00-100).
increased dependability and service life. Installation
procedures remain the same. “A” MARKED
ON SHAFT
1. Use a piece of white chalk to highlight timing marks
(the number “12”) on face of magneto drive and
accessory idler gears.

2. Bar engine over, so that “12” on accessory idler gear

is facing mag drive gear shaft (see Figure 4.00-98).

ALIGN “O” BELOW TOOTH WITH

“O” ON CRANK GEAR ROOT
O

REAR GEAR
HOUSING

Figure 4.00-99. Drive Shaft

6 12

5. Install six magneto drive gear capscrews

(7/16 in.--20 x 3 in. with lock washers) (see
Figure 4.00-100). Tighten capscrews in an alternating
pattern (see Figure 4.00-101).

6. Tighten magneto drive gear capscrews to 78 ft-lb

(106 N×m).
X
12

“12” BELOW TOOTH TO BE

ALIGNED WITH “12” BELOW
MAG DRIVE GEAR ROOT

Figure 4.00-98. Accessory Idler Gear -- Timing Marks

4.00 -- 38 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

Magneto Drive Gear to Accessory Idler Gear

LINE UP #12 ON ACCESSORY Backlash, Measure
IDLER WITH #12 ON IDLER GEAR
DRIVE GEAR
1. Mount dial indicator with magnetic base onto rear
gear housing flange next to magneto drive gear. Position
indicator point against inside face of gear tooth.

2. Secure accessory idler gear against movement.

3. Turn magneto drive gear until contact with stationary

idler gear prevents further movement. Holding magneto
drive gear in position, zero dial indicator.

4. Turn drive gear in opposite direction, until movement

is halted by contact with stationary idler gear.

5. Take note of dial indicator reading. Verify magneto

drive gear to accessory idler gear backlash is between
LINE UP “A” ON 0.008 -- 0.012 in. (0.203 -- 0.305 mm).
MAGNETO DRIVE DRIVE GEAR WITH
GEAR “A” ON DRIVE SHAFT
6. Back off point of dial indicator, rotate magneto drive
gear 180 degrees and recheck backlash.
Figure 4.00-100. Magneto Drive Gear Alignment

Severe engine damage

may result from opera-
tion with “tight” or excessively worn gears.

NOTE: If the backlash on a new gear is not within

specification, recheck the part number to be sure that
the correct gear was installed. If the correct gear is
installed, then the distance between the teeth gradually
increases as the gear wears, eventually resulting in
excessive backlash. If the backlash is not within
specification on a new or used gear, then the gear,
6 1 and/or the gear with which it mates, must be replaced.

CYLINDER LINER INSTALLATION

4 3

2 5
Cylinder liner weighs approximately 63 lb. (28 kg).
Use a suitable lifting device and exercise caution
during removal or installation to avoid severe
personal injury or death.

1. Make sure crankcase counterbore is clean.

NOTE: Prior to assembling the O-rings into the liner

grooves, the grooves should be cleaned of any preser-
vative oil. Remove all traces of the oil from the grooves.
Failure to remove petroleum based oils will cause the
Figure 4.00-101. Magneto Drive Gear ethylene propylene rings to swell when they come in
Tightening Pattern contact with the oil.

FORM 6296 First Edition 4.00 -- 39

CRANKCASE ASSEMBLY

2. Lubricate O-rings and crankcase O-ring bores with NOTE: Pull the pencil around the liner circumference at
Parker Super-O-Lubeä silicone lubricant P/N 475029 least twice.
(see Table 1.15-7). Install O-rings into liner grooves by
hand (see Figure 4.00-102). 4. Install liner into crankcase. If liner will not seat
properly, pick up sleeve, rotate and try again.

NOTE: It is only necessary to snug the screws down in

Step 5 to allow the liner to fully seat down against the
crankcase counterbore.

5. Using crossbar from liner puller (P/N 499233), clamp

cylinder liner down against crankcase counterbore.

6. Measure liner projection (see Figure 4.00-104)

above crankcase deck. Refer to Table 1.20-2 for proper
liner projection value.

MEASURE LINER PROJECTION

ABOVE CRANKCASE DECK

UPPER AND
MIDDLE O-RINGS

CYLINDER
LOWER O-RING LINER
WALL CRANKCASE
DECK

Figure 4.00-104. Liner Projection

Figure 4.00-102. Cylinder Liner O-rings
NOTE: If the O-rings become twisted during installation
3. With O-rings installed in grooves, turn O-rings using of the sleeve, this may be enough to cause the cylinder
a pencil to remove twists and properly seat rings in liner liner to exceed out of round tolerance. When cylinder
grooves (see Figure 4.00-103). liner is repositioned, ensure that the O-rings are not
twisted.
RED O-RING
7. Measure bore diameter 2 in. and 8 in.
BLACK O-RING (51 mm and 203 mm) down from top of sleeve. Liner
must be round within tolerances listed in Table 1.20-2. If
liner bore is out of round, reposition liner and recheck
tolerance.

8. Repeat Steps 1 through 7 for remaining cylinder

sleeves.

Figure 4.00-103. Spiraling O-rings

4.00 -- 40 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

PISTON RING ASSEMBLY

Proper engine break--in is required after installation of
new piston rings. Table 4.00-15 lists the correct break-- Compressed air can pierce the skin and cause
in schedule for VHP Series Four engines. severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
Table 4.00-15. Engine Break-In Schedule rates. Wear safety glasses to shield your eyes from
TIME flying dirt and debris.
SPEED ± 10
STEP LOAD (MINUTES)
RPM 1. Use compressed air to remove any dirt or dust that
MINIMUM
1 Idle No Load Warm--Up may have settled in the oil drain holes and piston ring
grooves (see Figure 4.00-105).
2 900* 25% 15
3 1200* 50% 20
4 1200* 75% 20
Run Rated Load And Speed --
5
Break--In Complete
NOTE: *Run at rated speed for electrical power generation
application.

Do not mix parts from OIL DRAIN RING

previous four ring piston HOLES GROOVES
configurations with the three ring pistons. Mixing
parts will result in severe engine damage or high oil
consumption.

Use the proper piston

ring expander pliers.
These engine model specific pliers were created to
eliminate damage caused to piston rings by twisting Figure 4.00-105. Piston Oil Drain Holes
and over-expanding. Proper piston ring installation L5794GSI (P/N 205104D) AND
is critical in achieving long bottom end overhaul life L5774LT, L5794 (P/N 202004C) (4-RING PISTONS)
(see Table 4.00-16).
1. Remove expander spring from oil control ring (see
Table 4.00-16. Piston Ring Expander Pliers Figure 4.00-106). Carefully inspect ring for burrs or
TOOL P/N ENGINES SERVED metal fragments from machining process.
P/N 474041 Series Four With 9-3/8 in. Cylinders
2. Install spring into bottom piston ring groove.
P/N 474042 Series Four With 8-1/2 in. Cylinders

To avoid stretching the

Always install new expander spring, install
piston rings. Piston the spring and oil control ring separately. Excessive
rings take a definite set and must not be reused if the stretching may adversely affect spring tension and
engine has been operated in excess of 50 hours. reduce ring performance.
Deglaze the cylinder liner before installing new
rings. Disregarding this information could result in 3. Install oil control ring over spring. Place ring gap
product damage and/or personal injury. opposite mated ends of expander spring (see
Figure 4.00-106). Verify ring rotates freely on piston.
Ring designs and
materials vary between
engine models. Be sure that the replacement ring
set is the one specified for the engine. Disregarding
this information could result in product damage
and/or personal injury.

FORM 6296 First Edition 4.00 -- 41

CRANKCASE ASSEMBLY

OIL CONTROL
RING

MATED ENDS OF
EXPANDER SPRING

EXPANDER
SPRING

RING END GAP

Figure 4.00-106. Oil Control Ring

Do not install the 2nd

NI-RESIST INSERT
and 3rd compression PISTON
rings upside down. Upside down rings will scrape
“TOP” OR PART
oil up into the combustion chamber, resulting in NUMBER
high oil consumption and sticking valves.
COMPRESSION
RING
4. Install 2nd and 3rd intermediate rings with word “Top”
or part number facing piston crown (up) (see “TOP” OR PART
Figure 4.00-107 and Table 4.00-17). Verify ring rotates NUMBER
BEVEL
freely on piston. 2ND
INTERMEDIATE
RING
5. Install top compression ring with word “Top” or part
number facing piston crown (up) (see Figure 4.00-107). “TOP” OR PART
NUMBER
Verify ring rotates freely on piston. BEVEL

6. Rotate piston rings using palms of both hands. Rings 3RD

must rotate freely without sticking. INTERMEDIATE
RING
7. Stagger ring gaps around piston. Rotate each ring to
position gap 90 degrees from gap in ring above it.
OIL
CONTROL
RING

Figure 4.00-107. Four Ring Configuration

4.00 -- 42 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

Table 4.00-17. Piston Rings

Top ring: Barrel--faced chrome plated, compression (marked “TOP” with Part Number).
Second/Third ring: Tapered face compression (marked “TOP” with Part Number, mark is optional).
Oil ring: Conformable grooved oil ring with expander (marked “TOP” with Part Number).
PISTON TOP RING 2ND RING 3RD RING OIL RING
L5794GSI (P/N 205104D)
L5774LT, L5794LT (P/N 202004C) P/N 204205J P/N 204105T P/N 204105T P/N 47605E

(A) Ring gap 0.030 – 0.040 in. 0.055 – 0.070 in. 0.055 – 0.070 in.
Ring gauge 8.5 in. (215.9 mm) (0.7 – 1.0 mm) (1.397 – 1.778 mm) (1.397 – 1.778 mm) N/A

0.302 – 0.318 in. 0.300 – 0.315 in. 0.300 – 0.315 in.

(B) Ring width (7.6708 – 8.0772 mm) (7.62 – 8.001 mm) (7.62 – 8.00 mm) N/A

0.1810 – 0.1815 in. 0.1835 – 0.1850 in. 0.1835 – 0.1850 in.

(C) Ring thickness (4.595 – 4.611 mm) (4.6609 – 4.699 mm) (4.6609 – 4.699 mm) N/A

(D) Side clearance 0.0075 – 0.009 in. 0.004 – 0.0065 in. 0.004 – 0.0065 in.
(between ring and groove) (0.1905 – 0.2286 mm) (0.1016 – 0.1651 mm) (0.1016 – 0.1651 mm) N/A

L5794GSI (P/N 205304V) P/N 204205J P/N 204105X NONE P/N 47605S
(A) Ring gap 0.030 – 0.040 in. 0.049 – 0.064 in.
Ring gauge 8.5 in. (215.9 mm) (0.7 – 1.0 mm) (1.2446 – 1.6256 mm) N/A N/A

0.302 – 0.318 in. 0.300 – 0.315 in.

(B) Ring width (7.6708 – 8.0772 mm) (7.62 – 8.001 mm) N/A N/A

0.1810 – 0.1815 in. 0.1850 – 0.1865 in.

(C) Ring thickness (4.595 – 4.611 mm) (4.699 – 4.7371 mm) N/A N/A

(D) Side clearance 0.0073 – 0.0092 in. 0.0015 – 0.0045 in.

(between ring and groove) (0.1854 – 0.2337 mm) (.0381. – 0.1143 mm) N/A N/A

L7044 GSI (P/N 205504L, P/N 205604L) P/N 10005L P/N 202205C NONE P/N 202005G
(A) Ring gap 0.032 – 0.043 in. 0.065 – 0.080 in.
Ring gauge 9.375 in. (238.125 mm) (0.8 – 1.1 mm) (1.651 – 2.032 mm) N/A N/A

0.302 – 0.318 in. 0.302 – 0.317 in.

(B) Ring width (7.6708 – 8.0772 mm) (7.6708 – 8.0518 mm) N/A N/A

0.1834 – 0.1839 in. 0.1850 – 0.1865 in.

(C) Ring thickness (4.658 – 4.672 mm) (4.699 – 4.7371 mm) N/A N/A

(D) Side clearance (P/N 205504L) 0.0081 – 0.0096 in. 0.0025 – 0.005 in.
(between ring and groove) (0.2057 – 0.2438 mm) (0.0635 – 0.1270 mm) N/A N/A

(D) Side clearance (P/N 205604L) 0.0056 – 0.0071 in. 0.0025 – 0.005 in.
(between ring and groove) (0.1422 – 0.1803 mm) (0.0635 – 0.1270 mm) N/A N/A

FORM 6296 First Edition 4.00 -- 43

CRANKCASE ASSEMBLY

L5794GSI (P/N 205304V) AND

L7044GSI (P/N 205604L) (3 RING PISTONS) NI-RESIST INSERT
PISTON

“TOP” OR PART
NUMBER
Compressed air can pierce the skin and cause TOP
severe personal injury or death. Never use your COMPRESSION
RING
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from “TOP” OR PART
flying dirt and debris. NUMBER

1. Use compressed air to remove dirt or dust from oil 2ND

drain holes and piston ring grooves. INTERMEDIATE
RING
2. Remove expander spring from oil control ring (see
Figure 4.00-106). Carefully inspect ring for burrs or
metal fragments from machining process.

To avoid stretching the

OIL CONTROL
expander spring, install RING
the spring and oil control ring separately. Excessive
stretching may adversely affect spring tension and
reduce ring performance.

3. Install spring into bottom piston ring groove. Figure 4.00-108. Three Ring Piston
4. Install oil control ring over spring. Place ring gap
opposite mated ends of expander spring (see PISTON AND CONNECTING ROD INSTALLATION
Figure 4.00-106). Verify ring rotates freely on piston.

Use the proper piston Always wear safety glasses when removing or
ring spreader to prevent installing piston pin retaining rings. Verify the
excessive ring twist and expansion. Over expan- correct retaining ring pliers is used and it is in good
sion may cause the ring to crack opposite the ring condition. If the retaining ring slips off the pliers
gap. Defective or distorted rings result in blow-by of when being installed or removed, it can be propelled
exhaust gases, increased oil consumption and with enough force to cause a serious eye injury.
lower service life on valves and other components. Disregarding this information could result in severe
personal injury.
5. Install intermediate ring with word “Top” or part
number facing piston crown (up) (see Figure 4.00-108 NOTE: The rounded edge of the retaining rings should
and Table 4.00-17). Verify ring rotates freely on piston. be oriented towards the piston pin.
6. Install top compression ring with word “Top” or part 1. Install one piston pin retaining ring into piston (see
number facing piston crown (up) (see Figure 4.00-108). Figure 4.00-109).
Verify ring rotates freely on piston.
2. Lubricate a piston pin and insert it part way into
7. Rotate piston rings using palms of both hands. Rings opposite piston pin boss.
must rotate freely without sticking.

8. Stagger ring gaps around piston. Rotate each ring to

position gap 120 degrees from gap in ring above it.

4.00 -- 44 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

LOCATING TANG

PISTON PIN ROD CAP

FULLY GROOVED
(NO OIL HOLES)

LOCATING TANG

ROD BLADE

RETAINING
RING

Figure 4.00-109. Piston Assembly

UNGROOVED OIL HOLES

Connecting rod weighs 62 lb. (28 kg). Use a suitable

lifting device and the aid of an assistant when
removing or installing the connecting rod to prevent
severe personal injury or death.
Figure 4.00-110. Connecting Rod Bearings
3. Position connecting rod between piston pin bosses.
Push pin through connecting rod and into position PARTING EDGES
against retaining ring.

4. Install second retaining ring into piston.

Do not touch the rod

bearing running surface.
Acidic skin secretions promote the start of surface
corrosion and wear in the affected area.

The bearing shells and

rod bore must be com-
pletely free of oil, dirt or other foreign material. Any
dirt or debris caught between the bearing shell and
bore results in bearing distortion and reduced Figure 4.00-111. Connecting Rod Shell
service life.
7. Apply even pressure on edges of bearing to press it
5. Wipe rod bearing bore and bearing shells clean. into place. Locating tang on edge of shell must fit
squarely in notch machined in roll pin side of cap (see
6. Position fully grooved bearing shell above bearing Figure 4.00-112).
seat on rod cap (see Figure 4.00-110). Shell diameter is
slightly larger than connecting rod bore (see
Figure 4.00-111).

FORM 6296 First Edition 4.00 -- 45

CRANKCASE ASSEMBLY

NOTE: Stagger the piston ring openings 120 degrees,

NOTCH ROLL PIN
prior to installing the ring compressor on the piston.

NOTE: Proper use of the piston ring compressor is

especially important when installing the three ring
piston, due to piston ring tangential load.

BEARING RUNNING
13. Install piston ring compressor (P/N 494085 for
SURFACE 8-1/2 in. bore or P/N 494206 for 9-3/8 in. bore) on piston
(see Figure 4.00-113).
ROD CAP

INCORRECT

OIL GROVE PISTON RING

COMPRESSOR

BEARING SHELL

Figure 4.00-112. Installing Bearing Shell

8. Position ungrooved bearing shell above bearing seat

on rod blade. Locating tang centered on parting edge of
bearing shell must be directly above notch centered in
roll pin side of blade. Apply even pressure on edges of
bearing to press it into place.

9. Verify two oil holes in shell match up with holes in rod

bearing bore.

If the bearing shells fit

loosely in the rod bearing CORRECT
bore, poor heat transfer will result in excessive
temperatures that shorten bearing service life. A
spun bearing may damage the crankshaft journal.
PISTON RING
10. Verify bearing shells fit tightly in bearing bore. COMPRESSOR

11. Lubricate piston, piston rings, cylinder sleeve,

crankshaft and bearings with clean engine oil.

12. Using engine barring device, bar engine over until

crankshaft connecting rod journal is oriented towards
Figure 4.00-113. Piston/Connecting Rod Assembly
midpoint of crankcase door opening, on same side of
engine as piston being installed.
14. Install a piston puller (P/N 474018 for 8-1/2 in. bore
or P/N 474019 for 9-3/8 in. bore) to two threaded holes
Ensure that the piston in piston pin crown.
ring compressor is prop-
erly installed on the piston to prevent it from falling NOTE: Looking at the rod centerline, note that one “leg”
off and causing damage to equipment and/or of the rod bore is longer than the other (see
personal injury. Figure 4.00-114). The long “leg” of the rod bearing bore
must face inside toward the camshaft during installation.

4.00 -- 46 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

3
1
STAMP

THIS SIDE TOWARDS

CAMSHAFT DURING
INSTALLATION

ROD CAP

Figure 4.00-114. Connecting Rod Position

15. Using a suitable lifting device and aid of an 4 2

assistant, slowly lower piston into cylinder bore. As
piston ring compressor touches top circumference of Figure 4.00-115. Connecting Rod Cap Capscrew
cylinder sleeve, piston must be pushed down through Tightening Sequence -- Roll Pin Equipped
piston ring compressor and into cylinder sleeve. Hold
piston ring compressor against crankcase to prevent 17. Tighten four connecting rod capscrews in proper
rings from slipping out between piston ring compressor numerical sequence, as follows:
and crankcase.
A. Lubricate threads of four ferryhead connecting
rod capscrews with engine oil.

B. Locate number “1” stamped in connecting rod

Both the connecting rods and rod caps are marked
cap. Hand tighten a capscrew in this hole first.
to identify their location in the engine. For example,
Hand tighten remaining capscrews in positions 2
connecting rods are marked 1R, 1L, 2R, 2L, etc.
through 4 (see Figure Figure 4.00-115).
Do not mix connecting rod and rod caps. Disregard-
ing this information could result in severe personal C. Following same numerical sequence, tighten
injury or death. capscrews to 50% of final torque value.

D. Repeating tightening sequence, tighten caps-

Use the aid of an assis-
crews to 185 ft-lb (251 N×m).
tant when lowering the
piston and connecting rod assembly into the 18. Repeat Steps 1 through 17 for each piston
cylinder sleeve to prevent damage to the cylinder assembly.
sleeve, crankshaft, connecting rod journal and/or
personal injury. 19. Refer to Table 1.20-7 and verify connecting rod end
play is 0.029 -- 0.041 in. (0.7366 -- 1.044 mm).
16. Install connecting rod cap. Verify rod blade and cap
are marked with same cylinder location number (see
Figure 4.00-115).

FORM 6296 First Edition 4.00 -- 47

CRANKCASE ASSEMBLY

OIL PAN 6. Verify oil elbow inlet and outlet flanges are clean. Old
gasket material or adhesive left on mating surfaces may
Oil Pickup Screen Installation cause air or unfiltered oil to leak into elbows.
1. Inspect pickup screen for tears or holes (see
7. Finger tighten oil elbow inlet flanges (two capscrews
Figure 4.00-116). Replace screen if damaged.
per elbow, 3/8 in.--16 x 2 in. with lock washers) to pickup
screen assembly. Inlet flange is on shorter end of elbow.

8. Position pickup screen assembly in oil pan.

9. Apply 3M Scotch Gripâ 847 Rubber and Gasket

Adhesive to oil elbow outlet flanges. Place new gaskets
on flanges.

10. Finger tighten oil elbow outlet flanges (two caps-

OIL crews per elbow, 3/8 in.--16 x 1-1/8 in. with lock
ELBOW washers) to front of oil pan.

11. Alternately tighten all capscrews to 31 ft-lb

(42 N×m).
GASKET
Oil Pan Seal Installation
NOTE: All 12 cylinder VHP engines built after June 12,
2002, are equipped with a new oil pan and O-ring seal.
Prior oil pans cannot be machined to accept the new
O-ring. The oil pan casting and O-ring groove dimen-
sions have been improved to eliminate oil leakage
BAFFLE between the oil pan and cylinder block. The new O-ring
GASKET features a one--piece design and no longer requires
splicing (see Figure 4.00-117 and Figure 4.00-118).

Do not use the new

O-ring (P/N 166192H/K)
in place of the red silicon seal used on older oil pans
OIL TUBE with narrow grooves. The new O-rings are larger in
diameter and will not fit properly in the older
grooves resulting in oil leakage.

Oil Pan O-ring Seal (P/N 166192H/K) Installation

1. Verify oil pan flange and seal groove are clean.
SCREEN
2. Place new O-ring seal into oil pan groove (see
Figure 4.00-117).
Figure 4.00-116. Oil Pickup Screen Assembly
Oil Pan Seal (Previous) Installation
2. Inspect baffle box for broken welds, split seams or
cracks around oil tube holes. Replace baffle if damaged. 1. Place new seal into oil pan groove. Locate break in
seal material along right front side of oil pan where
3. Apply 3M Scotch Gripâ 847 Rubber and Gasket groove is straight (in area between first and second oil
Adhesive on oil tube flanges. Place new gaskets on pan doors) (see Figure 4.00-118).
flanges.
2. Back seal up slightly in groove to obtain a little slack.
4. Install oil tubes in screening element. Place baffle This step ensures that both ends meet without any
over screen aligning holes with those in flange gaskets. stretching of material once seal is cut.

5. Obtain two new gaskets for oil elbow inlet flanges 3. Hold both ends of the seal side-by-side and cut them
and apply gasket adhesive to one side. Press sticky side diagonally at a 45 -- 60 degree angle.
of gasket onto baffle aligning holes with those in box.

4.00 -- 48 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

O-RING

OIL PAN

Figure 4.00-117. Current Oil Pan O-ring Seal (P/N 166192H/K)

SEAL

OIL PAN

Figure 4.00-118. Previous Oil Pan Seal

FORM 6296 First Edition 4.00 -- 49

CRANKCASE ASSEMBLY

4. Apply a small amount of Loctiteâ 5699 Grey High Oil Pan Cover Plate Installation
Performance RTV Silicone Gasket Maker (Loctiteâ Item
No. 18581) to one end of seal. Press ends together. Use Deposits left on gasket
two oil pan bolts to hold seal in place until adhesive is dry surfaces will cause
(see Figure 4.00-119). leaks. Verify that the gasket and gasket mating
surfaces are clean and completely free of grease
and oil.
OIL PAN BOLTS OIL PAN
SEAL
1. Slide two fasteners through holes in diamond-
shaped cover plate (1/2 in.--13 x 1-1/2 in. with lock
washers). Hang a new gasket on capscrews.

2. Position cover plate over flange on rear right corner

of oil pan. Tighten capscrews. Repeat procedure on rear
left corner.

Oil Level Dipsticks Installation

Deposits left on gasket

surfaces will cause
SEAL ENDS
leaks. Verify that the gasket and gasket mating
OIL PAN
surfaces are clean and completely free of grease
and oil.
Figure 4.00-119. Oil Pan Seal -- Front Right

1. Slide two new Nylok capscrews through holes in oil

5. Apply a 2 in. (50.8 mm) long bead of Loctiteâ 5699
gauge support. Position a new gasket on capscrews.
Grey High Performance RTV Silicone Gasket Maker
(Loctiteâ Item No. 18581) to oil pan flange on outside of 2. Install gauge support on right side of engine between
seal ends (see Figure 4.00-120). second and third oil pan doors.

3. Install a new O-ring on neck of oil level gauge (see

RTV SILICONE SEAL ENDS
RUBBER ADHESIVE
Figure 4.00-121). Apply Parker Super-O-Lubeä sili-
cone lubricant to O-ring. Install gauge in oil gauge
support. Repeat procedure on left side.

LOW FULL

Figure 4.00-120. Apply Sealant

6. Apply a 6 in. (152.4 mm) long bead of RTV Silicone

Rubber Adhesive Sealant to oil pan flange on inside of
seal ends. O-RING

Figure 4.00-121. Dipstick

4.00 -- 50 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

Expansion Plug Installation

1. Apply Loctiteâ Hydraulic Sealant around edge of
new expansion plug (see Figure 4.00-122). While the crankcase is suspended, do not put
hands, arms, feet or any other body part beneath it.
Stand back as far as possible and exercise extreme
OIL PAN caution. Disregarding this information could result
in severe personal injury or death.

The crankcase at this point in assembly may weigh

as much as 13,000 lbs. (5897 kg). To avoid serious
personal injury or death, always consider the
weight of the engine when selecting hoisting chains
and lifting equipment. Never exceed the maximum
capacity rating of the lifting device. Inspect the
lifting equipment for physical damage or defects
before use. Remain alert to potential hazards.

EXPANSION NOTE: All 12 cylinder VHP engines built after June 12,
PLUG
2002, are equipped with the new oil pan and O-ring seal.
Figure 4.00-122. Expansion Plug Location Prior oil pans cannot be machined to accept the new
O-ring. The oil pan casting and O-ring groove dimen-
2. With concave side facing inward, position plug sions have been improved to eliminate oil leakage
against opening in oil pump mounting flange. Correct between the oil pan and cylinder block. The new O-ring
opening (lower left corner) is easily identified by features a one--piece design and no longer requires
counterbore. splicing (see Figure 4.00-117 and Figure 4.00-118).

3. Using a suitably sized brass drift and a brass faced

Do not use the new
hammer, seat plug squarely in opening.
O-ring (P/N 166192H/K)
4. Reach into oil pan and push against back of plug to in place of the red silicon seal used on older oil pans
verify that it is tightly and squarely seated against with narrow grooves. The new O-rings are larger in
counterbore. diameter and will not fit properly in the older
grooves resulting in oil leakage.
CRANKCASE OIL PAN INSTALLATION
Oil Pan (Previous)
1. Clean bottom of crankcase to ensure no dirt, grit or
debris will interfere with oil seal.
Always lift the crankcase using the approved lifting
eyes. The 12 cylinder VHP Series Four engine is 2. On previous oil pans, fill in cross cuts at the rear
equipped with two pairs of lifting eyes, one pair at corners of the oil pan with Loctiteâ 5699 Grey High
the front, the other pair at the rear. Follow approved Performance RTV Silicone Gasket Maker (Loctiteâ Item
rigging procedures. Always use the proper spread- No. 18581).
er bar to ensure that no undue strain is placed on the
lifting eyes and hoisting chains. Disregarding this NOTE: Current oil pans have a continuous groove for
information could result in severe personal injury or the oil pan seal. These oil pans do not have cross cuts at
death. the corners of the oil pan.
3. Inspect area where oil pan seal bends around rear
corners of oil pan. Use Loctiteâ 5699 Grey High
Performance RTV Silicone Gasket Maker (Loctiteâ Item
No. 18581) to fill any small gaps between seal and
inside wall of groove.

FORM 6296 First Edition 4.00 -- 51

CRANKCASE ASSEMBLY

Oil Pan (Current) P/N 200214K NOTE: All torque values assume “dry” fasteners. Do
not oil capscrews before installing.
1. Clean bottom of crankcase to ensure no dirt, grit or
debris will interfere with oil seal. 5. Secure oil pan to crankcase with twenty eight 3/4--10
x 2-1/2 in. capscrews with washers. Capscrews are
2. Apply Loctiteâ 5699 Grey High Performance RTV located around perimeter of oil pan, twelve on each side
Silicone Gasket Maker (Loctiteâ Item No. 18581) to and four in rear (see Figure 4.00-126). Do not tighten.
gear housing seam (see Figure 4.00-123). Bead should
not exceed 0.375 in. (9.5 mm) in width. 6. Secure oil pan to gear housing with two 5/8--11 x
2-1/4 in. capscrews with washers located at position 26
and 7 (see Figure 4.00-125 and Figure 4.00-126).
SILICONE SILICONE
BEAD BEAD Do not tighten.

5/8-11 X 2--1/4 5/8-11 X 2--1/4

CAPSCREW CAPSCREW

GEAR HOUSING

Figure 4.00-123. Front of Crankcase

GEAR HOUSING
NOTE: If the front gear cover is already installed on the
engine apply silicone to the oil pan/gear cover seam Figure 4.00-125. Front of Crankcase
(see Figure 4.00-126). If the gear cover is not installed
on the engine when installing the oil pan, then wait until Front of Crankcase Initial Torque
the gear cover is going to be installed before applying
7. Tighten 3/4--10 x 2-1/2 in. capscrews (1 through 6 in
the silicone.
sequence) to 125 -- 150 ft--lbs (169 -- 203 N×m) (see
3. Apply silicone bead to crankcase and rear oil seal Figure 4.00-126).
retainer seam (see Figure 4.00-124). Bead should not
8. Tighten 5/8--11 x 2-1/4 in. capscrew (position 7) to
exceed 0.375 in. (9.5 mm) in width.
65 -- 85 ft-lb (88 -- 115 N×m).

9. Tighten 3/4--10 x 2-1/2 in. capscrews (8 through 25 in

REAR OIL SEAL
RETAINER sequence) to 125 -- 150 ft-lb (169 -- 203 N×m).

10. Tighten 5/8--11 x 2-1/4 in. capscrew (position 26) to

65 -- 85 ft-lb (88 -- 115 N×m).

11. Tighten 3/4--10 x 2-1/2 in. capscrews (27 through

30 in sequence) to 125 -- 150 ft-lb (169 -- 203 N×m).
Final Torque
12. Tighten 3/4--10 x 2-1/2 in. capscrews (1 through 6 in
sequence) to 260 -- 280 ft-lb (352 -- 379 N×m).

13. Tighten 5/8--11 x 2-1/4 in. capscrew (position 7) to

SILICONE BEAD 140 -- 160 ft-lb (190 -- 217 N×m).

Figure 4.00-124. Rear of Crankcase 14. Tighten 3/4--10 x 2-1/2 in. capscrews (8 through 25
in sequence) to 260 -- 280 ft-lb (352 -- 379 N×m).
4. Using a suitable lifting device lower crankcase onto
locating dowels and oil pan.

4.00 -- 52 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

15. Tighten 5/8--11 x 2-1/4 in. capscrew (position 26) to

REAR 140 -- 160 ft-lb (190 -- 217 N×m).
27 28 29 30
16. Tighten 3/4--10 x 2-1/2 in. capscrews (27 through
30 in sequence) to 260 -- 280 ft-lb (352 -- 379 N×m).
14 20
FRONT FLYWHEEL HOUSING INSTALLATION
NOTE: Ensure that the camshaft rear cover plate is
13 19 installed prior to installing the front flywheel section.

1. Install two 1-1/2 in. long dowel pins into rear face of
engine block to a depth of 3/4 in. (20 mm).
12 18
2. Thoroughly wipe flanges where front flywheel hous-
ing mates with rear face of block (see Figure 4.00-127).
Dirt, grit or other debris will prevent proper seating.
11 17 Verify mating surfaces are completely smooth. Use a
fine toothed pattern file to lightly dress down any burrs or
high spots.

10 16

The front flywheel housing weighs approximately

9 15 205 lb. (93 kg). Use a suitable lifting device and
exercise caution during removal or installation to
avoid severe personal injury or death.

8 1

21 2

FRONT FLYWHEEL
HOUSING MATING FLANGE

22 3

23 4

24 5
DOWEL PIN HOLES DOWEL PIN HOLES

Figure 4.00-127. Crankcase -- Rear

25 OIL PAN TO GEAR 6
COVER SEAL 3. Attach a suitable lifting device to front flywheel
housing.
26 7
4. Position flywheel housing on dowel pins (see
Figure 4.00-128).
FRONT
5. Start two 5/8 in.--11 x 1-1/2 in. capscrews with lock
Figure 4.00-126. Current Oil Pan (P/N 200214K) washers in top center segment (position nine and ten) of
flywheel housing (see Figure 4.00-128).

FORM 6296 First Edition 4.00 -- 53

CRANKCASE ASSEMBLY

FIRST CAPSCREWS 2. Heat new ring gear to approximately 350° F

(176° C).

3. Install ring gear evenly onto flywheel. Once cooled,

12 9 10 13 flywheel ring gear will be held to flywheel by shrink fit.
11 14
4. Check flywheel balance. Balance must be within
4 in.-oz. (0.028 N×m). Any metal removed must be
6 1 3 8 removed from outer rim.

TIMING TAPE INSTALLATION

2 5 7 4 Check the condition of the timing tapes. Replace the
tapes if torn, deteriorated or peeling.
DOWEL PINS
(2) 1. Remove old timing tapes and discard.

2. Thoroughly clean rim of flywheel to remove all oil,

grease and dirt.

Figure 4.00-128. Tightening Sequence 3. Peel adhesive backing off a new timing tape. Avoid
kinking tape when protective paper is removed.
6. Start remaining twelve 5/8 in.--11 x 1-1/2 in. caps-
crews with lock washers in flywheel housing. Do not touch the adhe-
sive surface on the tim-
7. Alternately tighten four 5/8 in.--11 x 1-1/2 in. caps- ing tape or its bonding ability will be adversely
crews adjacent to dowel pins to 150 ft-lb (203 N×m) (see affected.
Figure 4.00-128). Tighten all remaining capscrews to
150 ft-lb (203 N×m). 4. Carefully align “TDC” mark on timing tape (see
Figure 4.00-130) with “#1RB TDC” mark on rim of
8. Remove lifting device from flywheel housing. flywheel (see Figure 4.00-129). Be sure tape is read-
able when facing flywheel from rear. Place top of tape
RING GEAR INSTALLATION (inside edge) directly behind letter “T” in “TDC” on rim of
1. Position flywheel on flat surface. flywheel. To get tape on straight, use machining lines for
reference.

ALIGN TDC MARKS ON

TWO TAPES AT THESE
Always wear protective equipment when installing LOCATIONS
or removing components with an interference fit. #1 RB TDC
Installation or removal of interference components
may cause flying debris. Failure to use protective
equipment may result in severe personal injury or
death. TDC

Always wear protective equipment when installing #6 LB TDC

or removing heated or frozen components. Some
components are heated or cooled to extreme
temperatures for proper installation or removal.
Direct contact with these parts could cause severe
personal injury or death.
PAINTED MARK
AT 5 O¢CLOCK
NOTE: If the shop oven is not large enough, a torch POSITION
may be used to hear the ring gear. If the torch is used, Figure 4.00-129. Flywheel Timing Tape Locations
make sure to heat the ring gear evenly to ensure the ring
gear will not bind during installation.

4.00 -- 54 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

NOTE: Disregard the “TDC” marking on the rim of the

flywheel, it’s the reference mark for 6 cylinder models.
5. Use a smooth roller or another blunt object to tightly
press tape into place.

6. Align “TDC” mark on a second timing tape (same part

number) with “#6LB TDC” mark on rim of flywheel (see
Figure 4.00-129). Press tape into place, overlapping a
portion of first tape with end of second.
ATTACH
THIS TAPE
FIRST FLYWHEEL INSTALLATION
1. Rotate crankshaft until keyway in crankshaft gear is
at top (see Figure 4.00-131).

#1 RB #1 RB
TDC TDC

CAMSHAFT
IDLER GEAR

KEYWAY

Figure 4.00-131. Orient Crank Gear

The flywheel weighs approximately 900 lb. (408 kg).

ATTACH THIS Use a suitable lifting device and exercise caution
SECOND TAPE during removal or installation to avoid severe
OVER THE
FIRST TAPE personal injury or death.

2. Mount lifting bracket to flywheel using three outside

bolts holes shown (see Figure 4.00-132). Painted mark
on flywheel should be at 5 o’clock position.

#6 LB #6 LB
TDC TDC

Figure 4.00-130. Timing Tape

FORM 6296 First Edition 4.00 -- 55

CRANKCASE ASSEMBLY

5. Attach a suitable lifting device to flywheel lifting

FLYWHEEL LIFTING bracket.
BRACKET
NOTE: The painted mark indicates an offset hole. This
offset hole ensures the correct installation of the
flywheel.

6. With painted mark at 5 o’clock position, slide flywheel

down guide pins until it makes solid contact with
crankshaft hub (see Figure 4.00-134).

GUIDE PIN
(3 O’CLOCK POSITION

PAINTED MARK

LIFTING
Figure 4.00-132. Lifting The Flywheel BRACKET

3. Thread two guide pins into crank hub in 3 o’clock and

9 o’clock positions (see Figure 4.00-133).

LIFTING BRACKET BOLT HOLES GUIDE PIN PAINTED MARK

(9 O’CLOCK POSITION) (5 O’CLOCK POSITION)

Figure 4.00-134. Mount Flywheel

7. Lightly lubricate flywheel capscrews. Use a quality

high viscosity oil.

8. Tighten four lower capscrews (5/8 in.--11 x 2 in. with

hardened washers) to hold flywheel flat against hub of
crankshaft (see Figure 4.00-135).

GUIDE PIN GUIDE PIN

CRANK HUB
GUIDE PIN HOLES PAINTED MARK AT
5 O¢CLOCK POSITION

Figure 4.00-133. Flywheel Mounting

Handle the flywheel

with care. As a precision
machined component, the condition of the flywheel
is critical to satisfactory engine performance. Disre-
garding this information could result in product
damage and/or personal injury.
4 LOWER
CAPSCREWS
4. Thoroughly wipe face and rim of crankshaft hub.
Thoroughly wipe counterbore at back of flywheel. Dirt,
Figure 4.00-135. Remove Lifting Bracket
grit or other debris will prevent proper seating. Verify that
all mating surfaces are completely smooth. Use a fine 9. Remove lifting bracket from flywheel.
toothed pattern file to lightly dress down any burrs or
high spots.
4.00 -- 56 FORM 6296 First Edition
 CRANKCASE ASSEMBLY

10. Remove two guide pins from crankshaft hub (see 9 10

Figure 4.00-135).
8 2
11. Install eight remaining flywheel capscrews
(5/8 in.--11 x 2 in. with hardened washers). 7 1

12. Alternately tighten flywheel capscrews to

171 -- 175 ft-lb (232 -- 237 N×m). 6 11

REAR FLYWHEEL HOUSING INSTALLATION DOWEL PINS (2)

5 12
1. Install two 1-1/8 in. dowel pins into rear face of front
flywheel housing (at the 2 o’clock and 7 o’clock posi-
tions) to a depth of 1/2 in. (13 mm). STRAIGHT EDGE
4 13

2. Thoroughly wipe mating flanges of front and rear

flywheel housings. Dirt, grit or other debris will prevent 3 14
16 15
proper seating. Verify mating flanges are completely
smooth. Use a fine toothed pattern file to lightly dress Figure 4.00-136. Flywheel Housing Tightening Pattern
down any burrs or high spots.
FLYWHEEL FACE RUNOUT
1. Verify flywheel and rear flywheel housing (bore and
face) are clean. Figure 4.00-137 shows measurements
The rear flywheel housing weighs approximately that are required for proper flywheel mounting.
110 lb. (50 kg). Use a suitable lifting device and
exercise caution during removal or installation to 2. Dress down any burrs or high spots using a fine
avoid severe personal injury or death. toothed pattern file. Surface imperfections may result in
false indicator readings.
3. Attach a suitable lifting device to rear flywheel
housing.

4. With straight edge down, hang rear flywheel housing

on dowel pins.

5. Release tension on lifting chain, so full weight of

housing is supported by dowels.

Be sure the lifting device

does not place too much
tension on the rear flywheel housing as it is bolted
down. Too much tension on the lifting chain will pull
the housing into an egg shape, resulting in a bore
runout that exceeds specification.

6. Tighten two capscrews (1/2 in.--13 x 1-1/2 in. with

lock washers) on each side of dowel pins (see
Figure 4.00-136).

7. Start remaining twelve capscrews in rear flywheel

housing. Tighten to 75 ft-lb (102 N×m) using pattern
shown (see Figure 4.00-136).

8. Remove lifting device.

9. Remove two capscrews between dowel pin and

starter bore on left side (for mounting of oil filler bracket).
Remove single capscrew between timing pointer and
dowel pin on right side (for mounting bulkhead connec-
tor bracket).

FORM 6296 First Edition 4.00 -- 57

CRANKCASE ASSEMBLY

Flywheel Housing Rear Face Runout Measure

1. Mount a dial indicator with a magnetic base onto flat
D face of flywheel (top center) (see Figure 4.00-138).
Position indicator button against face of flywheel
housing. Zero dial indicator gauge.
B

DIAL INDICATOR BUTTON

(FLYWHEEL HOUSING FACE)

A G F C

MAGNETIC BASE
(FLYWHEEL FACE)

Figure 4.00-138. Flywheel Housing Rear Face Runout

E 2. Apply pressure to front of crankshaft to remove

crankshaft endplay. Rotate crankshaft counterclock-
wise a full 360 degrees. Write down indicator reading
every 90 degrees.

3. Note four dial indicator readings. Verify flywheel

housing face runout does not exceed 0.012 in.
(0.305 mm) total indicator reading.
In examples A and B of Figure 4.00-139, total indicator
A= PILOT BEARING BORE RUNOUT reading is 0.002 in. (0.051 mm), indicating flywheel
B= FACE RUNOUT ON WHEEL housing face runout is well within specification.
C= HOUSING BORE RUNOUT
D= HOUSING FACE RUNOUT In examples C and D of Figure 4.00-139, flywheel
E= FLYWHEEL CLUTCH OR COUPLING MOUNTING
FACE RUNOUT housing is out of specification with a total indicator
F = FLYWHEEL CLUTCH OR COUPLING reading of 0.014 in. (0.356 mm) and 0.013 in.
PILOT DIAMETER RUNOUT
G = FLYWHEEL HOUSING REAR FACE TO (0.330 mm), respectively.
CRANKSHAFT FLANGE

Figure 4.00-137. Flywheel Face Runout -- Flywheel

Measurements

4.00 -- 58 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

Flywheel Clutch Or Coupling Mounting Face

EXAMPLE A EXAMPLE B
.000 .000
Runout Measure
Procedures to measure the flywheel clutch or coupling
mounting face runout are the same as in “Flywheel Face
+.004 +.004 --.004 --.004 Runout On Wheel Measure.” Refer to Figure 4.00-137
(E) for location of the dial indicator. Total indicator
reading must not exceed 0.016 in. (0.406 mm).
+.002 --.002
Flywheel Housing Bore Runout Measure
EXAMPLE C EXAMPLE D 1. Mount a dial indicator with a magnetic base onto flat
.000 .000
face of flywheel (see Figure 4.00-141). Position indica-
tor button against flywheel housing bore ID. Zero dial
--.007 +.007 --.004 --.007 indicator gauge.

DIAL INDICATOR BUTTON

+.002 +.006 (FLYWHEEL HOUSING BORE)
Figure 4.00-139. Total Indicator Reading (TIR) In Inches

Flywheel Face Runout On Wheel Measure

1. Mount a dial indicator with a magnetic base on face of
flywheel housing (top center) (see Figure 4.00-140).
Position indicator button against flat face of flywheel.
Zero dial indicator gauge.

MAGNETIC BASE
(FLYWHEEL HOUSING FACE)

MAGNETIC BASE
(FLYWHEEL FACE)

Figure 4.00-141. Flywheel Housing Bore Runout

2. Apply pressure to front of crankshaft to remove

crankshaft endplay and rotate crankshaft counter-clock-
wise a full 360 degrees. Jot down indicator reading
every 90 degrees.
DIAL INDICATOR BUTTON
(FLYWHEEL FACE) 3. Note four dial indicator readings. Verify flywheel
housing bore runout does not exceed 0.012 in.
Figure 4.00-140. Flywheel Face Runout On Wheel (0.305 mm) total indicator reading.

2. Apply pressure to front of crankshaft to remove Flywheel Clutch Or Coupling Pilot Diameter
crankshaft endplay, and rotate crankshaft counterclock- Runout Measure
wise a full 360 degrees. Write down indicator reading 1. Refer to Figure 4.00-137 (F) for location of dial
every 90 degrees. indicator.
3. Note four dial indicator readings. Verify flywheel 2. Mount a dial indicator with a magnetic base on face of
housing face runout does not exceed 0.016 in. flywheel housing (top center). Position indicator button
(0.406 mm) total indicator reading. against clutch or coupling pilot diameter ID. Zero dial
indicator gauge.

FORM 6296 First Edition 4.00 -- 59

CRANKCASE ASSEMBLY

3. Apply pressure to front of crankshaft to remove 3. Apply pressure to front of crankshaft to remove
crankshaft endplay and rotate crankshaft counterclock- crankshaft endplay and rotate crankshaft counterclock-
wise a 360 degrees. Write down indicator reading every wise a 360 degrees. Write down indicator reading every
90 degrees. 90 degrees.

4. Note four dial indicator readings. Total indicator 4. Note four dial indicator readings. Verify flywheel bore
reading must not exceed 0.005 in. (0.130 mm). runout does not exceed 0.005 in. (0.127 mm) total
indicator reading.
Flywheel Pilot Bearing Bore Runout Measure
BARRING DEVICE INSTALLATION
1. Remove one capscrew from side of flywheel housing
and mount a solid horizontal bar that crosses flywheel 1. With straight edge facing block, fasten barring device
bore (see Figure 4.00-142). to starter bore on left side of front flywheel housing
(3 capscrews, 5/8 in. x 1-1/4 in. with lock washers) (see
Figure 4.00-144).
FLYWHEEL FLYWHEEL HOUSING
BEARING
BORE
FRONT FLYWHEEL
HOUSING

BARRING
DEVICE

SUPPORT BAR
CRANKCASE
Figure 4.00-142. Horizontal Support Bar
Figure 4.00-144. Front Flywheel Housing -- Rear Left
2. Mount a dial indicator with a magnetic base on bar
directly over flywheel bearing bore. Position indicator OIL FILLER BRACKET INSTALLATION
button against flywheel bore ID (see Figure 4.00-143).
1. Fasten oil filler bracket to left side of rear flywheel
Zero dial indicator gauge.
housing (2 capscrews, 1/2 in. x 1-3/4 in. with lock
washers). Use two open bolt holes between starter bore
DIAL INDICATOR and lower dowel pin (see Figure 4.00-145). Rounded
BUTTON cut in bracket accommodates rib in rear flywheel
(FLYWHEEL BORE)
housing.

MAGNETIC BASE
(SUPPORT BAR)

Figure 4.00-143. Flywheel Pilot Bearing Bore Runout

4.00 -- 60 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

REAR FLYWHEEL LITHOPLEX

HOUSING GREASE

OPEN
BOLT
HOLES

DOWEL PIN
OIL SPRAY TUBE

Figure 4.00-145. Mount Oil Filler Bracket -- Rear Left

Figure 4.00-147. Camshaft Idler Gear

2. Wrap U-bolt around oil filler pipe and fasten it to oil OIL SLINGER/FRONT OIL SEAL/GEAR COVER
filler bracket (3/8 in. flat washers, lock washers and hex INSTALLATION
nuts) (see Figure 4.00-146).
1. With concave side facing outward, position oil slinger
3. Fasten chain of oil filler cap to bracket and screw cap down front of crankshaft until it contacts crankshaft gear
on inlet pipe. (see Figure 4.00-148).

OIL FILLER OIL FILLER CAP OIL

BRACKET SLINGER

O-RING

U-BOLT

CRANKSHAFT
CRANKSHAFT GEAR

OIL FILLER PIPE Figure 4.00-148. Oil Slinger/O-Ring

Figure 4.00-146. Oil Filler Pipe/Bracket -- Rear Left 2. Slide new O-ring down shaft until it contacts slinger
(see Figure 4.00-148).
GEAR TRAIN LUBRICATION
3. Position gear cover on a flat surface with concave
1. Using a small paintbrush, apply Lithoplexâ Grease side facing down. Be sure machined area within gear
No. 2 (Multipurpose Lithium Complex Formula Contain- cover crankshaft bore is clean and smooth (see
ing Molybdenum Disulfide) to teeth of each gear in gear Figure 4.00-149). Use compressed air to blow out all
train: cam, camshaft idler, accessory idler, accessory dust and debris.
(magneto) drive, crank and oil pump idler gears (see
Figure 4.00-147). Verify oil spray tubes are aligned
properly (see Figure 4.00-3).
FORM 6296 First Edition 4.00 -- 61
CRANKCASE ASSEMBLY

9. Be sure mating flanges of gear cover and rear gear

CRANKSHAFT housing are clean and smooth.
BORE

10. Lay gear cover on a flat surface with concave side

facing up.

11. Aligning holes in gasket with those in gear cover,

assemble a new gasket on flange around outside edge
of gear cover. Gasket is made up of seven separate
pieces. Fit dovetailed sections together to interlock
gasket strips. If necessary, trim dovetails to find best fit.

12. Remove assembled gasket from gear cover flange.

13. Apply 3M Scotch Gripâ 847 Rubber and Gasket

Adhesive to gear cover flange.
Figure 4.00-149. Gear Cover
14. Reassemble gasket on flange. Gently push down
4. Apply an even coat of Permatexâ Aviation Form-A- on gaskets to verify strips are properly seated.
Gasketâ Sealant over width of machined area.
15. Push firmly down on gaskets to properly seat them.
5. Thoroughly wipe new front oil seal with a clean cloth. To flatten dovetails, place a block of wood over them and
Verify expander spring is in place behind seal lip. lightly tap with a hammer.
Carefully check seal for defects. Replace if damaged.
16. Apply Permatexâ Aviation Form-A-Gasketâ to six
6. With Waukesha P/N facing upward (lipped side areas where dovetails interlock.
inward), position front oil seal over gear cover crank-
shaft bore (see Figure 4.00-150). 17. Inspect area where silicon oil pan seal bends
around front corners of oil pan. Use Loctiteâ 5699 Grey
High Performance RTV Silicone Gasket Maker (Loc-
FRONT OIL titeâ Item No. 18581) to fill any small gaps between oil
SEAL
pan seal and inside wall of groove (see
Figure 4.00-151).

Figure 4.00-150. Front Oil Seal

7. Press seal into bore to a depth of 3/8 in. (9.5 mm)

LOCATING
(see Figure 4.00-152). Use large end of tapered crank- OIL PAN SEAL DOWEL
shaft pulley sleeve as a seal installation tool. If the seal is
installed incorrectly it will leak. Figure 4.00-151. Oil Pan Seal

8. Verify front oil seal is squarely seated in bore.

Deposits left on gasket

surfaces will cause leaks.

4.00 -- 62 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

EXPANDER SPRING/SEAL
MACHINED SURFACES
GEAR COVER

LIP
CRANKSHAFT BORE
3/8²
DEPTH

FRONT OIL SEAL

MACHINED SURFACES

Figure 4.00-152. Front Oil Seal Installation

E D

B C
LEAVE CAPSCREWS OUT (5)

OIL PAN TO GEAR COVER -- 6 CAPSCREWS GEAR COVER TO REAR HOUSING -- 13 CAPSCREWS
REAR HOUSING TO GEAR COVER -- 15 CAPSCREWS DOWEL PIN HOLES -- 2

Figure 4.00-153. Gear Cover Tightening Pattern (A -- F)

FORM 6296 First Edition 4.00 -- 63

CRANKCASE ASSEMBLY

GUIDE PIN LOCATION GUIDE PIN LOCATION

CAPSCREWS (4)

Figure 4.00-154. Installing Gear Cover

With the locating dowels A. Secure bottom flange of gear cover to front of oil
in place, installation re- pan (6 capscrews, 1/2 in.--13 x 1-3/4 in. with flat
quires that the gear cover be slid horizontally along washers). Tighten capscrews to 75 ft-lb
the top of the oil pan. Sliding the cover in this (102 N×m).
manner will pull up and damage the silicon oil pan
seal. B. Install 9 capscrews (1/2 in.--13 x 3 in. with lock
washers) in right side of rear gear housing.
18. Remove two dowel pins from gear cover, if installed C. Install 6 capscrews (1/2 in.--13 x 3 in. with lock
(see Figure 4.00-153). washers) in left side of rear gear housing. Leave
three bolt holes open for mounting of prelube
pump/motor mounting bracket (see
Figure 4.00-153).
The gear cover weighs approximately 160 lb.
(73 kg). Use a suitable lifting device and use caution D. Install 5 capscrews (1/2 in.--13 x 1-3/8 in. with
during removal or installation to avoid severe lock washers) in left side of front gear cover.
personal injury or death. Leave one bolt hole open for mounting of safety
guard (see Figure 4.00-153).
19. Attach a suitable lifting device to gear cover. E. Install 5 capscrews (1/2 in.--13 x 1-3/8 in. with
lock washers) in right side of front gear cover.
20. Position gear cover against flange of gear housing.
Leave one bolt hole open for mounting of safety
Lower cover into position so that it does not slide along
guard and water pump drain pipe bracket (see
top of oil pan.
Figure 4.00-153).
21. Insert two guide pins in dowel pin holes (see F. Install 3 capscrews (1/2 in.--13 x 1-3/8 in. with
Figure 4.00-154). Guide pins ensure gear cover is lock washers) at top of front gear cover.
properly situated before fasteners are installed.
24. Remove two guide pins and install dowel pins. Use
22. Snug four capscrews (1/2 in.--13 x 1-3/8 in. with a hammer and a blunt tipped center punch to ensure
lock washers) in locations shown (see Figure 4.00-154). pins are fully seated in rear gear housing flange.
Remove lifting chain.
25. Remove lifting device.
23. Install 34 gear cover capscrews in following pattern
26. Tighten capscrews to 70 ft-lb (95 N×m).
(see Figure 4.00-153).
4.00 -- 64 FORM 6296 First Edition
 CRANKCASE ASSEMBLY

FRONT GEAR COVER PLATES INSTALLATION 4. To prevent leaks gasket and gasket mating surfaces
must clean and free of grease and oil.
1. With Waukesha P/N facing outside, install two
fasteners (3/8 in.--16 x 7/8 in. with lock washers) in 6 in. 5. Position a new gasket on mounting studs.
diameter cover plate. Position a new gasket on caps-
crews. Finger tighten cover plate over upper left hole in 6. Position cover plate on mounting studs and install
gear cover (see Figure 4.00-155). Install remaining four fasteners. If engine is equipped with engine mounted
capscrews. Tighten in an alternating pattern. Microspin oil filter, gear cover is base for front breather
oil separator (see Figure 4.00-156).
6² DIAMETER
COVER PLATE
COVER PLATE

OIL SEPARATOR
5-1/4² DIAMETER MOUNTING
COVER PLATE

Figure 4.00-155. Gear Cover Plates -- Front Left Figure 4.00-156. Rear Gear Housing -- Front Left

2. With Waukesha P/N facing outside, install two CRANKSHAFT ENDPLATE RETIGHTENING
fasteners (3/8 in.--16 x 7/8 in. with lock washers) in PROCEDURE FOR ENGINES BUILT BEFORE
5-1/4 in. diameter cover plate. Position a new gasket on NOVEMBER 15, 2002
capscrews. Finger tighten cover plate over lower left NOTE: Crankshaft endplate capscrews and pulley
hole in gear cover. Install remaining four capscrews. capscrews on all 12 cylinder VHP engines built before
Tighten capscrews to 31 ft-lb (42 N×m) in an alternating November 15, 2002, must be retightened annually if not
pattern. retrofitted. See “Vibration Damper/Rear Crankshaft
GEAR HOUSING OIL SEPARATOR COVER PLATE Pulley Installation Built After November 15, 2002” and
INSTALLATION Figure 4.00-159 for retrofit information.
Loose crankshaft endplate or damper capscrews may
1. Check six rear gear housing cover plate mounting
prevent the vibration damper form absorbing the
studs for nicks, cracks, burrs, galled or stretched
torsional vibrations of the crankshaft. This condition
threads and other obvious damage. Replace as neces-
may lead to crankshaft failure.
sary.
NOTE: If there are no loose capscrews, the endplate
2. Each cover plate stud has fine and coarse threads capscrews and front pulley capscrews should be
separated by a smooth center boss. Apply Loctiteâ 242 retightened as described in Step 1 and Step 2 below. If
to first three threads on coarsely threaded side. loose capscrews are found see “Retightening Crank-
shaft Endplate And Front Pulley (Loose Capscrews
Do not install cover plate Found) For Engines Built Before November 15, 2002.”
studs with a pipe wrench
or similar device. Use a collet type stud driver for 1. Tighten endplate capscrews to 410 ft-lb (556 N×m)
installing studs to avoid damage to the studs and (see Figure 4.00-157). The assembly is properly tight-
threads. ened only after full torque is applied to each bolt without
any rotation of the torque wrench.
3. Install studs in flange on left side of rear gear
housing. Install each stud until last coarse thread is
turned into housing. Use a collet type stud driver for best
results.

FORM 6296 First Edition 4.00 -- 65

CRANKCASE ASSEMBLY

CAPSCREWS ENDPLATE
CRANKSHAFT ENDPLATE

WASHER

LOCK WASHER

CAPSCREW

FRONT PULLEY Figure 4.00-158. Crankshaft Endplate

CAPSCREWS FRONT PULLEY
2. Re--install endplate capscrew with washer and new
Figure 4.00-157. Crankshaft Endplate And Front lock washer (P/N 21048). Do not fully tighten.
Pulley Capscrews
3. Repeat Step 1 and Step 2 for the remaining two
2. Tighten front pulley capscrews to 80 -- 84 ft-lb (108 -- endplate capscrews.
114 N×m) in a crisscross pattern.
4. Tighten endplate capscrews to 410 ft-lb (556 N×m).
RETIGHTENING CRANKSHAFT ENDPLATE AND Repeat torque sequence as necessary. Each time
FRONT PULLEY (LOOSE CAPSCREWS FOUND) sequence is repeated, assembly is driven further up
FOR ENGINES BUILT BEFORE onto tapered pulley sleeve. Assembly is properly
NOVEMBER 15, 2002 tightened only after full torque is applied to each bolt
without any rotation of the torque wrench.
NOTE: The following procedures are to be used if loose
capscrews are found. 5. Remove one front pulley capscrew and lock washer.
Discard lock washer.
Loose crankshaft endplate or damper capscrews may
prevent the vibration damper form absorbing the 6. Re--install capscrew with new lock washer
torsional vibrations of the crankshaft. This condition (P/N B355) and wrench tighten.
may lead to crankshaft failure.
7. Repeat Step 5 and Step 6 for remaining nine front
pulley capscrews.

Always consider the weight of the item being lifted 8. Tighten front pulley capscrews to 80 -- 84 ft-lb (108 --
and use only properly rated lifting equipment and 114 N×m) in a crisscross pattern.
approved lifting methods. Failure to take adequate
VIBRATION DAMPER/REAR CRANKSHAFT
precautions can result in serious personal injury or
PULLEY INSTALLATION BUILT AFTER
death.
NOVEMBER 15, 2002

Do not machine the rear

crankshaft pulley spacer
Do not remove more than one endplate capscrew at to remove the wear groove. Reducing the outside
a time. Replace the endplate capscrews one at a diameter of the spacer will adversely affect the
time to prevent the vibration damper from sliding off sealing performance of the front oil seal.
the crankshaft. Failure to take adequate precau-
tions can result in serious personal injury or death.

1. Remove one endplate capscrew, lock washer, and

washer (see Figure 4.00-158). Discard lock washer. Always consider the weight of the item being lifted
and use only properly rated lifting equipment and
approved lifting methods. Failure to take adequate
precautions can result in serious personal injury or
death.

4.00 -- 66 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

CRANKSHAFT THRUST WASHER*

P/N 153044C

OIL SLINGER

O--RING
P/N 118013Z

PULLEY SPACER*
P/N 15106E
REAR PULLEY
P/N 200695N OR 200695P

WASHER
P/N B355
FERRYHEAD
TAPERED SLEEVE CAPSCREW
P/N 152161B P/N 28744

VIBRATION DAMPER
P/N 199331

PULLEY SLEEVE*
P/N 153163E
ENDPLATE
P/N 153162B WASHER
P/N B931A
SPACER*
P/N 214160 CAPSCREW*
NOTE: *Denotes new part required for retrofit. P/N 28796

Figure 4.00-159. Vibration Damper/Crankshaft Pulleys

NOTE: Engines built before November 4, 2002, require NOTE: To seat the pulley sleeve and tapered sleeve,
the crankshaft endplate capscrews and front pulley the end plate is installed and capscrews fully tightened.
capscrews be retightened once a year. Engines built The endplate is then removed and the rear pulley
after November 4, 2002, do not require this. Previous installed.
engines can be retrofitted (see Figure 4.00-159). Differ-
ent combinations of pulleys and spacers may be 5. Install endplate and secure with three spacers,
installed on the engine. Engine may have a stub shaft washers, and 7/8 in.--14 x 3-1/2 in. capscrews. Tighten
installed in place of front pulley. Remove all components capscrews using an alternating pattern in three steps to
through the thrust washer from the crankshaft as 250 ft-lb (339 N×m). DO NOT over tighten.
applicable.
6. Remove capscrews, washers, spacers, endplate,
1. Apply Parker Super O--Lubeä to O--ring and slide and pulley sleeve.
onto end of crankshaft until it contacts the oil slinger.
7. Install rear pulley on tapered sleeve. Mating surfaces
2. Install pulley spacer with outside taper (inside of pulley and tapered sleeve must be clean and dry.
chamfer) towards oil slinger (see Figure 4.00-159).
8. Install pulley sleeve and endplate with the three
3. Install tapered sleeve against small end of pulley spacers, washer, and 7/8 in.--14 x 3-1/2 in. capscrews.
spacer. Mating surfaces of tapered sleeve and crank- Tighten capscrews in an alternating pattern using three
shaft must be clean and dry. steps to 515 ft-lb (698 N×m).

4. Install pulley sleeve against small end of tapered 9. Before continuing, note the following:
sleeve.
· If your engine is installed with a rear pulley only (no
front pulley or stub shaft), continue with Step 10.

FORM 6296 First Edition 4.00 -- 67

CRANKCASE ASSEMBLY

· If your engine is equipped with a rear and a front 2. Install vibration damper to rear pulley with 10
pulley, continue with “Installation Of Optional Front ferryhead capscrews and 10 washers. Tighten caps-
Pulley.” crews (oiled) to 80 -- 84 ft-lb (108 -- 114 N×m) in a
crisscross pattern.
· If your engine is equipped with a stub shaft, continue
with “Installation Of Optional Stub Shaft.” INSTALLATION OF OPTIONAL STUB SHAFT

10. Install vibration damper to rear pulley with 10

ferryhead capscrews and 10 washers. Tighten caps-
crews (oiled) to 80 -- 84 ft-lb (108 -- 114 N×m) in a Always consider the weight of the item being lifted
crisscross pattern. and use only properly rated lifting equipment and
approved lifting methods. Failure to take adequate
INSTALLATION OF OPTIONAL FRONT PULLEY
precautions can result in serious personal injury or
Different combinations of pulleys and spacers may be death.
installed on the engine. Complete the steps in this
section to install Option Codes 1140A and 1140B. NOTE: If retrofitting engine, do not reuse or machine
stub shaft. The stub shaft must be replaced because it
has a thicker flange design for longer capscrews and
new spacer.
Always consider the weight of the item being lifted
and use only properly rated lifting equipment and 1. Align mounting holes of stub shaft and vibration
approved lifting methods. Failure to take adequate damper with rear pulley (see Figure 4.00-162).
precautions can result in serious personal injury or
death. 2. Secure stub shaft and vibration damper to rear pulley
using washers and 1/2 in.--13 x 3-1/4 in. ferryhead
1. Align vibration damper, front pulley, and pulley capscrews (oiled). Tighten capscrews to 80 -- 84 ft-lb
spacers shown per option code ordered. See (108 -- 114 N×m) in a crisscross pattern.
Figure 4.00-160 for Option Code 1140A; and see
Figure 4.00-161 for Option Code 1140B.

OPTION CODE 1140A OPTION CODE 1140A

WITH OPTION CODE 1141

PULLEY SPACER
P/N 199808C

WASHER
P/N B355

FRONT PULLEY
P/N 200295B
PULLEY SPACER
P/N 199808A
FERRYHEAD
CAPSCREW
P/N 28627
PULLEY SPACER
P/N 199808C

FERRYHEAD
WASHER CAPSCREW
P/N B355 P/N 28622

Figure 4.00-160. Installation Of Optional Front Pulley -- Option Code 1140A

4.00 -- 68 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

OPTION CODE 1140B

FRONT PULLEY
P/N 200295H

WASHER
P/N B355
PULLEY SPACER
P/N 199808A

FRONT PULLEY
P/N 200295H

FERRYHEAD
WASHER CAPSCREW
P/N B355 P/N 28607

OPTION CODE 1140B

FERRYHEAD
WITH OPTION CODE 1141 CAPSCREW
P/N 28791

Figure 4.00-161. Installation Of Optional Front Pulley -- Option Code 1140B

OPTION CODE 8005

OPTION CODE 8006

WASHER
P/N B355

WASHER
P/N B355

STUB SHAFT*
P/N 153384R
FERRYHEAD
CAPSCREW
KEY P/N 28168
FERRYHEAD
STUB SHAFT* P/N B2564
CAPSCREW
P/N 153384S P/N 28168
NOTE: *Denotes new part.

Figure 4.00-162. Optional Stub Shaft -- Option Code 8005 And 8006

FORM 6296 First Edition 4.00 -- 69

CRANKCASE ASSEMBLY

LIFTING DEVICES
The current production cylinder front lifting eye requires
the use of a spacer between the crankcase and lifting
eye (see Figure 4.00-163). The intercooler support
brackets have the rear lifting devices incorporated in the
bracket design (see Figure 4.00-166).

Engine mounted oil cooler support brackets and surge

tank support brackets have the front lifting devices
incorporated in the bracket design (see Figure 4.00-164
and Figure 4.00-165). Engines built after Janu-
ary 15, 2001, are equipped with the new lifting eyes.

1. Tighten lifting eye capscrews to 75 ft-lb (102 N×m). Figure 4.00-165. Surge Tank Support Bracket

FRONT
LIFTING EYE

SPACER

Figure 4.00-166. Intercooler Support Bracket

Figure 4.00-163. Front Lifting Eye
Waukesha requires the use of 9-1/2 ton W.L.L. (Working
Load Limit) standard anchor shackles with screw pins
when lifting 12 cylinder VHP Series Four engines
equipped with the new lifting devices (see
Figure 4.00-167).

Figure 4.00-164. Bracket/Lifting Eye

Figure 4.00-167. Typical Lifting Shackle

4.00 -- 70 FORM 6296 First Edition

 CRANKCASE ASSEMBLY

PRESSURE BLOCK
PRESSURE
The pressure block is installed on the right side of the BLOCK
crankcase. Pressures available on the block are crank-
case oil pressure (4 locations) and right and left manifold
pressures.

1. Apply pipe thread sealant and assemble plugs and

tube fittings to pressure block (see Figure 4.00-168).

PRESSURE
BLOCK
PLUG

TUBE
ELBOW
CRANKCASE OIL
PRESSURE TUBE

Figure 4.00-170. Pressure Block

4. Intake manifold pressure tubes are installed after

TUBE
ELBOW intake manifolds are installed. See Section 5.15 Air
Induction System for more information.

TUBE RING GEAR INSTALLATION

CONNECTOR
1. Position flywheel on a flat surface (see
Figure 4.00-168. Crankcase Pressure Block Assembly Figure 4.00-171).

2. Apply pipe thread sealant and install reducing

bushing and tube connector in crankcase. Install
pressure block on side of crankcase (see
Figure 4.00-169).

OIL HEADER

RING GEAR

INSTALL REDUCING FLYWHEEL

BUSHING BLOCKS

Figure 4.00-171. Flywheel Ring Gear

Figure 4.00-169. Pressure Block Location

3. Install pressure block on crankcase with two

1/2 in.--13 x 2 in. capscrews. Install oil pressure tube
between crankcase and pressure block (see
Figure 4.00-170).

FORM 6296 First Edition 4.00 -- 71

CRANKCASE ASSEMBLY

Always wear protective equipment when installing

or removing components with an interference fit.
Installation or removal of interference components
may cause flying debris. Failure to use protective
equipment may result in severe personal injury or
death.

Heated components can cause severe burns.

Do not handle heated parts with bare hands. Failure
to use protective equipment may result in severe
personal injury or death.

NOTE: If the shop oven is not large enough, a torch

may be used to heat the ring gear. If the torch is used,
make sure to heat the ring gear evenly to ensure the ring
gear will not bind during installation.

2. Heat new ring gear to approximately 350° F

(176° C).

3. Install ring gear evenly on flywheel. Once cooled,

flywheel ring gear will be held to flywheel by shrink fit.

4. Check flywheel balance. Balance must be within

4 in.-oz. (0.028 N×m). Any metal removed must be
removed from outer rim.

4.00 -- 72 FORM 6296 First Edition