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International Harvester CTS-11/12 R-Series Motor Truck

1. If plug is repair boss for fit and thread wear loose or threads are damaged threads or replace oil pan 5 Inspect crankshaft pulley and vibration damper assembly for evidence of rubber coming loose from pulley flange plate and inspect for wear Replace damper assem bly if either condition is encountered Do not submerge vibration damper assembly in hot cleaning solvents Inspect crank shaftfan drive pulleyfor wear in hub bore If inner diameter of bore is worn scored or Woodruff key way damaged replace pulley 6 Inspect engine gear case cover and re place if cracked or broken Remove old cover seal and install new seal 7 Check each of twelve engine valve tappets for irregular wear chipping cracking or scores Replace defective tappets 8 Inspect engine flywheel housing for cracks or breakage and replace if damaged In spect flywheel housing to crankcase pilot dowel holes for wear If wear is evident drill or ream the holes and install over size dowels Also inspect dowels for wear and replace if wear is evident 9 Inspect all capscrews and nuts for thread wear or breakage and replace as neces sary Usenew lockwashers when reassem bling engine 10 All gaskets and oil seals must be replaced at each overhaul or major repair ASSEMBLY OF ENGINE When all parts have been cleaned in Spected and repaired and necessary replace ment parts have been procured install engine cylinder block
2. 1 In city or light delivery service a wide seat collects carbon and particles of dirt that will produce variations or loss of compression resulting in poor idle and possible loss of general performance and economy 2 lt A wide seat in severe service operating in the presence of dirt or anexcess of carbon will produce a badly pitted seat which may be just as detrimentalto valve lifeas a too narrow seat Under these conditions a seat widthto the minimum limit would pos sibly be better however the source of trouble which is the dirt and excessive carbon should be eliminated making it possible to retain the wider seat Valve Seat Inserts Necessity for replacing valve seat inserts should be very rare however if a replace mentis made it is important that new inserts be peened securely in place using either in sert peening tool or a dull pointed chisel 1 4 wide to peen cylinder head metal over outer edge of valve seat insert installing tools are Valve insert available seat Valve seat inserts supplied for service are standard sizeand 030 oversize which permits a tight fit in cylinder head Repair of Valves l True up the ends of valve stem against face of grinder NOTE This refacing operation applies to the intake valves how ever in the case of the exhaust valves where slow rotating valve mechanism is used refacing of valve stems is not neces sary except when clearance adjustment is made See u
3. Crankshaft timing gear Fig 14 Removal of oil slinger Note that flange of slinger is bent outward A 22238 Fig 17 Removing camshaft with gear removed Camshaft may be removed witn gear attached Camshaft Woodruff key F A 22157 A 22152 Fig 15 Tappets are removed to permit removal of camshaft Fig I8 Removing camshaft Donated by John amp Susan Hansen For Personal Use Only te ES Crankshaft timing gear A 21936 using SE 1715 of puller to Gear puller prevent damage to puller threads crankshaft gear Lubricate threads Turn engine in overhaul stand and proceed with disassembly as follows 4 Each connecting rod is numbered as to its position in the engine and these numbers are located on the camshaft side of the en gine Fig 20 Remove self locking cap screws from connecting rod cap and re move cap Push connecting rod and piston assembly toward top of block but first remove ridge from top of cylinder wall if any Lift piston and connecting rodassem bly from top of cylinder block Replace cap on connecting rod Remove the re maining pistons following the same pro cedure Connecting rod bearing Oil hole Connecting rod Piston pin bushing Self locking bolt A 22174 Fig 20 5 The crankshaft bearing caps are numbered to identify their position and they must be reinstalled in their respective positions Remove self locking capscrews from e
4. Main Bearing and Connecting Rod Bearing Installation BEARING CRUSH Undersize precision type bearing shells should be installed when because of wear bearing to crankshaft running clearances are to be reduced Bearing caps must not be filed lapped or in any other man ner reworked Premature bearing failure will result from attempts to reduce journal to bearing running clearance by reworking of either bearing caps bearings or both because such reworking will alter the engineered fit of the bearing shells in their bores and destroy the specifically desired crush When installing precision type connecting rod or main bearings itis important that the bearing shells fit tightly in the rod or case bore To accomplish this the bearing manu facturer makes the diameter at right angles to the parting line slightly larger than the actual diameter ofthe boreinto whichthey areassem bled When the assembly is drawn up tight the bearing is compressed assuring a good contact between the bearing back and the bore This increased diameter is referred to as bearing crush Fig 64 To obtain proper bearing assembly with the correct crush care must be taken when tightening the clamping bolts to make sure they are drawn down alternately and evenly using a tension wrench and tightening as spec ified As a result of excessive bearing crush due to reworking the caps the rod or main bearing bore will possibly become distorted
5. 2 Insert oil pump drive shaft and body gear into oil pump body Install new Woodruff key in slot at top end of shaft Install oil pump spiral gear with gear hub down onto drive shaft Press spiral gear down onto shaft untill 32 clearance remains between gear hub and pump body when oil pump body gear is up against pump body Using hole in spiral gear as guide drill 1255 hole in shaft Drive new spiral gear pin into place Install a new guide on the end of the pump shaft use guide installing tool 3 Install idler gear on idler gear shaft In stall gasket and oil pump body cover and install four capscrews and lockwashers Test oil pump body gear and play to cover by using a feeler gauge between oil pump spiral gear hub and oil pump body End play must be from 0025 2 0055 If clear ance is in excess of 0055 remove one gasket from cover If clearance is less than 002 add one gasket between cover and body Recheck end play after making any alterations Insert oil pump into cyl inder block so that slot in top of shaft is 30 angle tothe side of the engine with the No 1 piston in firing order Fig 32 FRONT CYLINDER HEAD OF ENGINE Je OIL PUMP SHAFT SLOT CRANKCASE A 10976 Fig 32 L LINE MOTOR TRUCK SERVICE MANUAL 4 Insert oil pump float in oil pump body line up cotter pin holes install new cotter pin and fasten securely DISASSEMBLY CLEANING INSPECTION REPAIR AND ASSEMBLY
6. E gt y E 24 a H vd P Za i d b is Water pump A 2252 Fig 54 Installing Water Pump 6 INSTALL OIL FILTER Place oil filter and new gasket in place on cylinder block Install four capscrews and lockwashers in oil filter base NOTE Be sure filter assembly is thoroughly cleaned and a new cartridge is installed before replacement on engine 7 INSTALL ACCESSORIES Install carbu retor generator distributor and connect ing wires starter fuel pump ignition coil oil gauge and thermostat Tighten fan belt sufficiently to secure 1 2 depression on belt midway between generator pulley and fan pulley Install oilpan making sure that gaskets are in place when tightening the pan 8 FILL ENGINE WITH OIL After making certain that oil drain plug is securely in Stalled fil crankcase with oil After engine has been installed and placed in operation again recheck oil level and add as necessary tobring oillevel to full mark 9 INSTALL CYLINDER HEAD COVER If engine is not to be installed at this time install new cylinder head cover gasket and install cylinder head cover Install four flat washers and four nuts on cover ENGINE MOUNTINGS Figs 55 and 56 illustrate engine front and rear mountings Gear case cover Insulator upper Dia hole in crossmember Crossmember Ti d N Pa gt gt La Shy e e AN gt prie Washers Bolt Washers Bolt Lock wires mom Fig 55 Side rail E y Su
7. i 2 Mae de ii Tension spring STE Gasket z N NES SUE lt u TE m OVA uM 7A Orifice KISS js PCR RA A ETE Drain plug dem ANANN Hr ve SS BE NV KZ Plug S Gasket WO Relief valve spring Relief valve A 22635 Fig 58 Michiana Oi Filter center tube through the oil filter base Pressure at which the oil is discharged into the filter element is controlled by the pressure valve at the top of the center tube The orifice at the bottom of the center tube contains a 7 64 hole 2 Oil leaves the tube atthe center of the filter element and flows through the ele ment toward the ends The filtered oil re turns to the engine oil pan through the oil filter base 3 The filter element or cartridge should be replaced when the oil appears smoky or black The element is replaced by un screwing handle at the top of filter and lifting off cover The old filter element can then be removed and a new one in stalled Donated by John amp Susan Hansen For Personal Use Only ENGINES AANA Super Red Diamond DALIA L LINE MOTOR TRUCK SERVICE MANUAL Section C Page 26 4 Do not attempt to wash out the old filter CRANKSHAFT PULLEY TIMING MARKS element Replace with a new one The ignition timing mark and the timing 5 Remove drain plugin filter sump whenever pointer is located on the front of the engine at a new elementis installed and drain sump the crankshaft pulley To assure efficient operation of the
8. necting rod into position on crankshaft journal and install connecting rod cap and bearing NOTE Bearing cap can only be installed on connecting rod one way be cause of the construction of rod and cap Install two self locking capscrews and tighten to 50 foot pounds using tension wrench To check connecting rod bearing to crank shaft clearance follow procedure given for plastigage test Specified connecting rod bearing to crankshaft clearance is from 001 to 0035 Do not attempt to file con necting rod or bearing caps Follow theforegoing procedurefor install ing remaining connecting rods and pistons INSTALL OIL PUMP Place crankshaft and piston in position for firing on No 1 piston Insert oil pump assembly into opening in cylinder block rotate pump drive shaft so that tang in top of shaft is parallel to engine block This position will assure the oil pump drive shaft being in proper positionfor distributorinstallation Install and tighten two capscrews Place one piece oil pan gasket in place and install 25 capscrews around oil pan flange INSTALL CLUTCH Install clutch driven disc against flywheel so that the long por tion of the hub is toward the rear Place clutch in position on flywheel over clutch driven disc Locate clutch so that arrow on flange of clutch backing plate or cone is as near as possible to the letter L on the flywheel and install two or three mounting capscrews and lockwashers loose
9. GE LLL 2 Q CN Y H m NO Z EZA Relief valve Gasket B 4744 Lee Fig 43 Donated by John amp Susan Hansen For Personal Use Only ENGINES eg L LINE MOTOR TRUCK SERVICE MANUAL P Red Diamond NV Page l SUPER RED DIAMOND ENGINE A 23188 Fig Sectional view of Super Red Diamond Engine PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Red Diamond Section C Page 2 DESCRIPTION General The Model RD Super Red Diamond engine isa 4 cycle 6 cylinder in line overhead valve type engine Fig 1 The engine serial number is stamped on a pad at the front onthe left side of the crankcase just below the cylinder head The block has dry type replaceable liners for the cylinder The detachable cylinder head contains all valves valve guides and springs The cylinders are numbered from front fan and timing gear end to rear Engine crank shaft rotation is clockwise as viewed from the front end ofthe vehicle The intake and exhaust manifold carburetor and generatorare located on the right side of the engine The distribu tor starter fuel pump and oil filter are lo cated on the left side The oil filler inlet is located on the left side of engine at the front The bayonnet type oil level gauge is located on the left side The water pump is located at the front of engine Construction l The generator fan
10. GEAR SHAFT BODY IDLER GEAR SHAFT IDLER GEAR BODY GEAR GASKET OH FLOAT man COVER SCREEN A 10965 Fig 31 shaft so as to apply pressure of press at bottom of slot press oil pump drive shaft out of oil pump spiral gear Remove Woodruff key from shaft Remove oilpump body gear and oil pump drive shaft from oil pump body 4 Press oil pump gear onto oil pump drive shaft far enough to reveal retainer ring Remove ring from oil pump shaft Press oil pump body gear from shaft and remove Woodruff key from shaft Wash all parts in cleaning solvent Oil Pump Inspection Check the following parts carefully l Check the oil pump drive shaft for wear at points of contact with body If wear is perceptible the shaft must be replaced Diameter of shaft is from 4985 to 4990 inches Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Red Diamond Section C Page 14 2 Check the oil pump body for warpage dam age and wear Replace if body is warped or cracked or if shaft bore is worn so that clearance between shaft and bore is in excess of 005 Inspect all oilpump gears and replace if wear is perceptible Oil Pump Assembly l Press body gear onto oil pump drive shaft after placing new Woodruff key in slot of shaft Press gear onto shaft far enough to permit installation of retainer ring in groove in oil pump Press oil pump body gear down against ring
11. INSTALL ACCESSORIES Install carbur etor generator distributor and connecting wires starter fuel pump ignition coil gauge and thermostat Tighten fan belt sufficiently to secure 1 2 depression on belt midway between generator pulley and fan pulley FILL ENGINE WITH OIL After making certain that oil drain plug is securely in stalled fill crankcase with oil After en gine has been installed and placed in oper ation again recheck oil level and add as necessary to bring oil level to full mark INSTALL CYLINDER HEAD COVER If engine is not to be installed at this time install new cylinder head cover gasket and install cylinder head cover Install three flat washers and three nuts on cover ENGINE MOUNTINGS Fig 41 and 42 illustrate engine front and rear mountings ENGINE GEAR CASE COVER INSULATOR H A e RETAINER S SS Sam es ep A SS ER WAS HER WASHER ZI 2 5 e BOLT CROSSMEMBER LOCKWIRE A 16010 Fig 4 Front mounting Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Blue Diamond Section B Page 22 L LINE MOTOR TRUCK SERVICE MANUAL Cross member A 22527 Engine rear support Fig 42 OIL FILTER l The DeLuxe oil filter is used on the BD engines andincorporates a removable sump Fig 43 2 Water grit metal particles sludge and other contaminants that settle out of the oil are held in the sump away from th
12. Page 4 VALVE TIMING Intake opens before T D C TP TITEL Lue use lA Intake closes after T D C AAA 338 Exhaust opens before T D C oo te et hh nn oo PORE E 559 Exhaust closes after T D C rrr 159 Intake valve timing checking clearance eene enee RA eee eere tes tt t n s tm 9 t n on 020 OIL PUMP Body gear end clearance 4 4 4 bk teeta yo ROS oe Owe eon Kw dd BG Y ox S 0025 0055 Pump body to spiral gear clearance ce er ever revere t oo 0048 0088 Pump Shaft diameter ssri oko bow Bux L3 RA AAA AA AAA A 4885 4890 Pump Shaft cl drance in DOTE o see ek Sew RS Ew HOEK AE EE OS Ee V x o 005 OIL PRESSURE EK sensor EST E eosin eens e dea yor conse E E E 15 20 At R P M NM rrr ae Wow 3 4 xe AAA DEENEN Idling Maximurn ADS sosa sas AAA rrr 40 45 v2IH3WNY JO SILYLS QJLINN NI O3L1NI3d ENGINE MODELS Number of cylinders DOTE PI DIV OKe RE e eg Displacement cu in Rated h p A M A Brake h p maximum ACE Ds 26 6 su eo we Brake h p net Se ano er xo Torque maximum lbs ft AG TP os 923 Torque net lbs ft RS A PEN Maximum recommended speed r p m Governed speed r p m Compression ratio Firing order 4 2 3 Crankcase refill capacity bir PEDES Weight bare lbs Weight with standard accessories lbs CRANKSHAF T Main journal diameter Crankpin d
13. Si SL LLL PLLA SS Exhaust valve SS Valve seat SS b LILIPA Si d Gg 30 MO ATA 3 Y A 21889 Fig I9 Diagram showing valve installation Valve Assembly l Wipe valve faces and valve seats with a cleaning solvent to remove all dirt or for eign material Coat valve stems and valve faces with oil and install valves in same seats to which they were checked 2 Install valve springs with dampers Com press valve springs with a valve spring compressor and install valve spring re tainers and retainer locks Be sure that retainers and locks are correctly seated When overhauling engine with head and pan removed the following procedures are recom mended 1 Remove front motor to frame bracket by removing two nuts on top side Fig 20 Remove fan drive pulley nut and washer from end of crankshaft Install puller and remove crankshaft fan drive pulley from crankshaft Fig 21 Remove 4 capscrews holding motor mounting bracket to block Fig 22 2 Remove nuts and capscrews from engine gear case cover remove gear case cover and gasket Remove crankshaft oil slinger from end of shaft Fig 23 3 Remove two self locking capscrews from camshaft retainer thrust flange plate working through two holes in camshaft gear Fig 24 Pull camshaft and gear assembly from cylinder block Remove Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond
14. When a satisfactory match of valve seat and valve face angles has been ob tained the adjustment of both the valve refacer and the seat grinder should be locked in posi tion in order to eliminate this trial by error method on additional valves having the same angle Valve Seats The primary purpose of a valve seat is to seal the combustion chamber against pressure losses and to provide a path to dissipate the heat accumulated in the valve head so as to prevent burning of the seat and warping of the valve head The location of the valve seat on the valve face and its width controls the amount of valve head that protrudes into the combustion cham ber It is obvious that the greater the exposure within the combustion chamber the higher the valve temperature or in other words the more heat it willcollect High valve temperature and poor heat dissipation also produce excessive valve stem temperatures and hasten the accu mulation ofcarbon on the stem causing them to Stick in the guides Valve Seat Widths In general the width of exhaust seat should range betweenthe average and maximum spec ifications and the intake seats between the Low limit Zoe High limit 3 84 Preferred le Minimum seat Low limit 5 64 High limit Vea Preferred 3 32 Maximum seat A 22611 Fig Il Valve seat widths A A N A NM INTERNATIONAL Donated by
15. new lockwashers and nuts Re move aligning tool A 22489 Fig 7 Aligning timing gear cover using SE 1717 Aligning tool 11 INSTALL FAN DRIVE PULLEY AND VIBRATION DAMPER Heat crankshaft fan drive pulley and vibration damper as sembly in boiling water When heated quickly install assembly on crankshaft and install washer and fan drive pulley nut Tighten nut with wrench of about 36 lever age Vibration damper is used on the model SD 240 engine only Installing Connecting Rods and Pistons l Install one connecting rod and piston as sembly down through top of cylinder block having slot inpiston towards camshaft side of engine Pistons are also marked with an arrow indicating front of engine Use a piston ring compressor sleeve to com press piston rings and thus avoid possible ring damage Fig 72 2 Wipe base of connecting rod free of oil and dirt Place bearing shell upper half in connecting rod base being sure that oil hole aligns with oil hole in connecting rod and that locking tangs of bearing shell fit into recess Clean connecting rod cap bearing bore and clean back of bearing Place bearing shelllower half in connect ing rod cap making sure thattang of bear E Hammer handle md Ring compressor Fig 72 ing fits into recess in cap NOTE See instructions under Main Bearing and Con necting Rod Bearing Installation Coat bearing surfaces with oil Pull con
16. on dowels in crankshaft flange Install six self locking capscrews in flywheel and crankshaft flange and tighten to a tension of approximately 100 foot pounds using a tension wrench INSTALL GEAR CASE COVER PLATE Place plate and gasketat front end of engine cylinder block Install one capscrew and lockwasher INSTALL CAMSHAFT AND GEAR Coat camshaft with engine oil Insert camshaft into front end of engine block being care ful not to damage camshaft bearings Before completely entering camshaft ro tate shaft until marked teeth on crankshaft gear and camshaft gear index Fig 14 Install two capscrews and lockwashers in camshaft thrust flange working through large holes in camshaft gear Rotate crankshaft and camshaft to determine that gears do not bind or interfere Back lash must be from 000 to 002 0015 pre ferred INSTALL GEAR COVER CASE Place gasket in position on case cover Place crankshaft oil slinger over end of crank shaft and install Woodruff key for fan drive pulley incrankshaft Place gear case cover in position Install capscrews new lock washers and nuts INSTALL FAN DRIVE PULLEY AND VIBRATION DAMPER Heat crankshaft fan drive pulley and vibration damper assembly in boiling water When heated quickly install assembly on crankshaft and install washer and fan drive pulley nut Tighten nut with wrench ofabout 36 lever age Installing Connecting Rods and Pistons Is Install one connecting
17. the low limit of 002 to provide for the wear factor Cap clearance normally increases in service due to wear caused by impact of the half moon keys against the shoulder on the valve stem As the cap clear ance increases the rate of wear increases due to longer key travel which increases the im pact When rotating mechanism parts have been fitted the same combination or group of parts should be maintained once the engine is placed in service After the valves have been in oper ation over an extended period the keys tray show signs of wear at the point of contact with the valve stem As long as the 002 to 006 clearance is maintained this wearis not harm ful however when reinstalling keys make sure that both parts of the key set are in the same position with the wear facing in the same direction Fig 14 This willeliminate cocking of the spring retainer The valve keys can be reversed turned worn side down to utilize the unworn face of the keys thus reestablishing the specified cap clearance However when this practice is resorted to it is important that an accurate check be made to assure that desired cap clearance is present Check the rotating valve cap clearance using the special clearance gauge as follows PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Red Diamond Section C Page 7 Remove cap from exhau
18. 1 5005 00 0 0035 0020 0080 Thrust Flange 0015 desired 0070 0159 0012 003 7 15 85 aluminum alloy 003 3 190 1 1089 1 1091 0005 0006 0000 0002 1 2 LOS 6 18 12 CONT R 6602 1220 1225 1220 L225 1220 1225 0015 s0025 0050 0070 Thrust Flange 0015 desired DA NN to to Y y 0060 el OO 0012 0036 100 110 aluminum alloy 1 4998 1 5000 0003 0007 0001 tight 0001 loose 1 2 005 5 10 8 7 aded suoteotytvadsg a LZ 7 lt Q Q A A C Le Un T1 A C T1 lt gt LZ E gt pa SANTONA YvOIH3AY JO S31v1S GALINA NI O341NIHg Donated by John amp Susan Hansen For Personal Use Only ENGINE MODELS SD 220 SD 240 BD 269 RD 372 RD 406 PISTON RINGS Compression Rings Number used on each PIStOL uos 3o xx 3 PLE aa e l 1 3 32 2 1 8 Oil Rings Number used on each piston 1 O ar a xe 3 16 Ring diameter 3 9 16 Ring Gap Compression 016 026 UeEFlex z32 Fit in Groove Compression top i 0025 0040 2nd amp 3rd j GC 0030 Oil Control fourth 0015 0035 Plan eat s c4 siasii INTAKE VALVES Stem diameter so te Angle of face 309 Tappet clearance hot 018 020 Stem clearance in guide 0015 0035 Width of valve seat
19. 5 1000 2750 6 3 153624 9 942 1076 3 2495 3 2505 2 75 2 752 0013 0043 004 2 012 rear tocco 100 110 2 109 2 140 2 089 2 090 RD 406 RD 450 6 4 3 8 but 450 99 45 9 162 2 3000 146 2600 358 5 1200 354 0 1000 2600 6 2 153624 9 948 1082 3 2495 2 090059 2 151 EA 0013 0043 004 012 rear tocco 100 110 2 109 2 110 2 089 Li 090 CONT R 6602 6 4 7 8 5 38 602 00 153624 16 1638 1863 3 249 3 250 2 999 3 000 0022 0046 006 008 front tocco 105 115 2 1220 2 1425 2 1220 6 1625 z e Al m gt o E r TVANVW 39IAW3S AONYL YOLOW SANT suoryeorjroadg ededg SANIONI Donated by John amp Susan Hansen For Personal Use Only ENGINE MODELS SD 220 Third 2 069 2 070 EE aaa 1 4995 1 5005 DATO ow wok cROPOR dox gemer Camshaft bearing 0010 clearance 0035 Camshaft end play i e 0080 Thrust Thrust taken by J Pinge 0015 ft Camshaft gear backlash desired CONNECTING RODS Connecting rod bearing 0070 end clearance 013 Connecting rod bearing 0011 Clearance s Nr e Ap 0011 Connecting rod bolt nut tension ft lbs 45 55 PISTONS Material l a alloy Recommended piston clearance 003 PISTON PINS Length
20. 8 10 5 16 18 Coil bracket to cylinder head 14 16 5 16 18 Fuel pump to crankcase o 8 10 5 16 18 Oil pan to cra nkCase 45 999 E os 14 16 5 16 18 Distributor adapter to crankcase 14 16 5 16 18 Oil pump cover lo body 4 9 9X x2 x s 14 16 5 16 18 Vibration damper to pulley 16 18 5 16 18 Oil pump body to crankcase o o 14 16 5 16 24 Generator mounting s s es seses rs 8 10 5 16 24 Col mounting aa we oo 3 a Os 16 18 3 8 16 Manifold to cylinder head 25 30 3 8 16 Engine support bracket to crankcase 25 30 3 8 16 Generator bracket to crankcase 25 30 3 8 16 Intake to exhaust manifold 25 30 3 8 16 Water pump to crankcase o o 25 30 3 8 16 Cylinder head COVE ss 40 46 6 60400 48 25 30 3 8 16 Gear case cover to crankcase 25 30 3 8 16 Camshaft thrust flange wis 25 30 3 8 24 Connecting rod bolt 45 55 3 8 24 Carburetor to manifold S 23 28 3 8 24 Intake to exhaust manifold 23 28 5 16 24 Gear case cover to plate oo o o o 9 11 7 16 14 Flywheel housing 0 50 60 7 16 14 Oil pressure relief valve TU 15 15 7 16 20 Flywheel to crankshaft 55 65 1 2 13 Starting molor A eg AR A ries ees Bw x 75 85 1 2 13 Cylinder head capsc
21. AT ZS Rocker arm Wrong installation Cap to valve stem clearance 002 to 006 ae mien Valve cap OS ES Spring om ZOON Valve key lock QQ3 y Exhaust valve A 23206 Fig IU is the distance the spring retainer is The slow This lowered before the valve is moved valve rotating motion is caused by vibration of the valve the flowing of exhaust gases around the valve head and a slight rotating motion imparted to the valve by the valve spring Checking Clearance Between Valve Stem and Cap Operation of the rotating valve feature re quired that clearance between the valve stem face and valve cap be maintained at all times If no clearance exists after assembly re move cap wash and wipe clean then recheck clearance Examine the keys to see if they are resting against the shoulder of the valve stem properly If they are in proper position re place the cap and check again If clearance still does not exist remove all parts and ad just clearance by grinding valve stem tip If clearance is too great remove enough stock from lower face or skirt of the cap to reduce clearance to the proper limits NOTE Because of manufacturing tolerances in both valve stem ends and the valve cap it is possible to select a new capand valve combination with the required clearance Maximum service lift and efficiency is largely dependent upon cap clearance which should be set at the time of installation at or very near
22. For Personal Use Only ENGINES Super Red Diamond Section C Page 12 L LINE MOTOR TRUCK SERVICE MANUAL slinger in position behind rear bearing Place two half moon lock rings in groove in shaft and press shaft into bearing and spacer from rear until rear bearing rests firmly against slinger and ring locks 2 Place seal clamp ring seal spring seal spring guide flexible seal and retainer and carbon seal thrust washer into posi tion in impeller Hold them in position while installing snap ring in impeller groove 3 Install water pump shaft and bearing assembly into body and hold in place by inserting snap ring in groove in front of front bearing 4 Support water pump shaft at front end press impeller and seal assembly onto rear end of water pump shaft Press im peller only flush with end of shaft b Placenew gasketin position on water pump body and install cover plate and four cap screws 6 Place fan assembly in position on front of pulley and install six capscrews and lock washers Intake and Exhaust Manifolds When disassembling and assembling the manifolds the following procedures are used l After removing eight nuts eight flat washers four capscrews and three bolts from exhaust flange remove both intake and exhaust manifolds as a unit Fig 27 Remove two manifold pilot rings Fig 28 NOTE Let manifolds cool before starting above operations this will help to prevent manifold war
23. If any valve guide shows excess clearance or out of round condition press guide from cylinder head with a special remov ing tool Fig 17 Install new guide and press into cylinder head until approxi mately 1 1 4 remains above the top sur face of cylinder head Fig 18 Check valve guides after installation to 3758 to 3743 with Go and No Go gauge Ream valve guides to 3743 3758 after assem bly in cylinder head 3 If aninspectionhas indicated the necessity replace the valve seat 4 Grind the valve seats in cylinder head to 30 on exhaust and 30 on intake Reconditioning Valves and Seats One of the principal difficulties experienced in reconditioning valves is obtaining nearly identical angles on the valve seat and valve face The importance of these angles in the grinding operation cannot be overemphasized because it is impossible to produce a flat or square seat by lapping The grinding stones on both the valve refacing machine and valve seat grinder should Press ram Valve guide remover Cylinder head Valve guide Ven ds Fig 17 Use SE 1722 Valve stem guide tool L LINE MOTOR TRUCK SERVICE MANUAL be dressedbefore startinga reconditioning job You will be unable to determine how closely the angle of the seat will match the valve face until the valve and seat have been ground and a check made with a very light tint of Prussian blue If a full seat width contact around the ent
24. RINGS Compression rings Number used on each piStoh iss asped ead eS RE ER ON oA X ROO b E OH Ow E 3 1 3 32 pA Sos A AAA EEE AAA AA AR a e AAA SAA A 2 1 8 OIL RINGS Number used on each piston rsss ros ad wo CRE ETE de E Dw we eR EES io 5am Ou ee e 1 SICA NARDI AREA AAA AAA ONU ON 3 16 III 3 13 16 RING GAP GOInDPeBS ION era AAA A 010 026 ara Aq rrr 0003 027 FIT IN GROOVE Compression top ee Wo seg AAA EE EECHER 0025 0040 Second and third corras ALA a ee aw do BEEN E 0015 0030 Oil control fourth celere a a de 0015 0035 VALVES EXHAUST INTAKE Stem diameter csse e 372 372 Anple of EEN E EE ERA 309 159 Tappet clearance hol 4445 2 949 eR HOGS 023 023 Stem clearance in guide o TIT 003 002 Width Of valve Seat 6605426 8 enanos Eon ee do y des 5 64 7 64 3 64 5 64 Slo Roto valve cap to stem clearance 4 DUISDOD Nr E e VALVE TAPPET Clearance in DIOCK cocaina 0015 003 VALVE SPRINGS Free len x 4 x xx oa SEES EAS GR E X AAA EIA eU 2 187 Length valve open ees 20879 ROW Rue iW AAA AA 1 468 Pounds pressure valve open 4 44444 eee eee hehehe hh hh nee nn 186 196 Valve Rocker Arm Clearance in Shaft beh E st oe AA 0015 004 CTS 12 MARCH 1953 Supplemental pages for CTS 11 PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only ENGINE Specifications R LINE MOTOR TRUCK SERVICE
25. Recheck end play after making any alterations Insert cil pump into cyl inder block so that slotin top of shaft is at right angles to the side of the engine with the number one piston in firing order Connect oil pump outlet to pump and tighten coupling Insert oil pump float in oil pump body line up cotter pin holes install new cotter pin and fasten securely DISASSEMBLY CLEANING INSPECTION REPAIR AND ASSEMBLY OF SUB ASSEMBLIES Cleaning the Cylinder Block Remove allold gasket materialfrom block clean both inside and outside of block with steam or cleaning solvent Remove all dirty oil sludge scale and carbon from cylinder block Cylinder Block Inspection La La Inspect cylinder walls for cracks Weld cracks or replace block if necessary Check top surface for trueness with a straight edge Test by attempting to in serta 012 feeler gauge ribbon between the straight edge and the cylinder block If this is possible either surface grind or replace the cylinder block Inspect camshaft bearings for damaged or Scored condition and inspect for wear Replace if damaged or if worn beyond clearance limit of 0035 Measure cylinder walls with an inside reading micrometer to determine taper out of round or worn condition Themeas urements must be made not only at top of the cylinder bore just below ring groove but at several places around the inside circumference of the bore Bore should be chec
26. Section A L LINE MOTOR TRUCK SERVICE MANUAL Page 10 two capscrews holding the gear case cover toward top of block but first remove ridge late to block remove plate and gasket from top of cylinder wall if any Lift Fig 25 Remove crankshaft timing gear piston and connecting rod assembly from using a special gear puller Fig 26 top of cylinder block Fig 27 Replace NOTE Lubricate puller screw to pre cap on connecting rod Remove the re vent damage to screw threads maining pistons following the same pro Turn engine in the overhaul stand and pro cedure ceed with disassembly as follows 4 Each connecting rod is numbered as to its position in the engine and these numbers T are located on the camshaft side of the Nore mai tae ConnechogsTod Cap are aligned with the rods by means of tongue engine Remove self locking capscrews from connecting rod cap and remove cap Push connecting rod and piston assembly and groove construction Fig 28 Front motor mounting support y Timing gear cover M e A 21942 Crankshaft E l vibration damper ig 23 Gear case cover removed showing tim A 21940 ing gear details Front motor i mounting bracket own stat A 21943 var EA s AHIA D uU Fig 24 Timing gear timing marks and camshaft thrust plate details SCH Capscrews Camsha t timing gear ara A BB Generator acci e SE 7 oo MER ESL fervi mE A 21944
27. Tool when removing the rocker arm bushing Support arm on the SE 1033 support block Select a hole in the support block to properly support the rocker arm at the same time permit the bushing to clear the support block when being removed Use the support block when in stalling and burnishing the new bushing Cylinder Head and Valves the rocker The following instructions are to be ob served when reconditioning cylinder head and valves Remove push rods Fig 8 Remove caps from end of exhaust valve stems remove cylinder head bolts and lift off cylinder head and gasket Place cylinder head on bench l Compress valve spring with a valve com pressor and remove valve spring retainer locks Remove retainer Remove outer spring and inner spring Remove valve Press ram Bushing installing tool Rocker arm Press plate A 21898 UB T E ES Alum E gt id ur ci 7s 2 Fig 6 Showing method of installing new Rocker Arm Bushing Press ram Burnishing tool Rocker arm Press plate o AAA a NAS SR s v A 21894 Fig 7 Burnishing Rocker Arm Bushing Use SE 879 Burnishing Tool E ai A 22225 Fig 8 spring spacer NOTE Valve springs are installed with close coiled ends toward the cylinder head Remove all valve springs as outlined Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Red Diamon
28. and water pump are driven by V type belts from a driven pul ley mounted on the front end of the crank Shaft The distributor mounted at the left side of the engine is driven by the cam shaft through the oil pump 2 The exhaustandintake manifolds are bolted to each other and to the right side of the engine head The intake manifold is cast in one piece The exhaust manifold is made ofthree parts whichare heldtogether by expansion clamps and seal 3 A vibration damper is provided atthe front end of the crankshaft 4 The cylinder block and crankcase are cast in one piece and carry the crankshaft main bearings Water circulation pas sages completely surround the cylinders in the crankcase and also provide coolant to the cylinder head 5 Oilis supplied under pressure by the oil pump tothe engine lubrication system Oil spray from the revolving cranksha t is distributed to the cylinder walls pistons and other moving parts inside the engine 6 Exhaust valve seats are of alloy and are pressed into place These valve seats lengthen the period between valve recondi tioning operations Valves and valve seats are cooled by continuous circulation of water through the cylinder head L LINE MOTOR TRUCK SERVICE MANUAL 7 The detachable cylinder head is bolted to the crankcase and a gas tight and water tight seal is maintained by means of a gasket 8 The crankshaft is a drop forging of heat treated steel Itis count
29. bearing cap Tighten the self locking capscrews to approxi mately 105 foot pounds D Remove the bearing cap The flatten ed plastic material will be found ad hering to either the bearing shell of the crankshaft E To determine the bearing clearance compare the width of the flattened plastigage at its widest point with the graduations on the envelope Fig 38 The number within the graduation on the envelope indicates the clearance in thousandths of an inch NOTE Do not turn crankshaft during the above procedure Gauge Plastigage flattened A 21932 Fig 38 Checking bearing clearance When using the virgin lead method use the following procedure a Virginlead wire of approximately 010 thickness should be used If wire of 010 thickness is not available and thicker wire must be used it must be rolled to approximately 010 thick ness b Remove one bearing cap Place 1 2 piece of virginlead length wise on top of crankshaft bearing journal c Install cap and bearing shell half In stall bearing cap bolts and tighten to 30 to 40 foots pounds tension PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL S ENGINES Super Blue Diamond Section B Page 19 d Rock the crankshaft back and forth two or three times Further tighten bolts to 60 to 70foot pounds and again rockthe crankshaft two or three
30. because PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Silver Diamond Section A Page 21 more force is required to draw the cap and housing together DIFFERENCE BETWEEN DIAMETERS A AND VA IS BEARING CRUSH C MN r T AA SY WITH BEARING CAP DRAWN UP TIGHT DIAMETERS A AND B ARE EQUAL A 16009 DIAMETER A AT RIGHT ANGLES TO PARTING LINES GREATER THAN DIAMETER B Fig 64 Rods caps or blocks must not be filed lapped or in any other manner reworked in order to reduce clearance While such prac tice will make a tighter fit at top and bottom it will result in an out of round bore and bear ing shell distortion New bearing shells will have to be installed eventually and that is when additional trouble starts In general a visual inspection of the part ing faces of the rod or caps under a magnify ing glass will provide sufficient proof of any attempt at reworking Under the glass the parting line surface of standard parts will show the manufacturing cutter tool marks and will not have a polished or extremely smooth appearance On the other hand reworked parts will have a polished surface and if a file was used will show the even pattern of the file teeth Seriousness of this condition is in dir ect proportion to the amount of reworking BEARING SPREAD Main and connecting rod bear
31. bell housing 6 Remove engine rear mounting bolts from both sides of engine support pads 7 Remove engine front mounting bolts from support bracket these are the bolts at the front crossmember NOTE The engine front support bracket is removed with the engine 8 Remove radiator mounting bolts and lift out radiator support and core assembly 9 Disconnect engine exhaust pipe at mani fold ENGINE DISASSEMBLY Install the engine in a suitable rotating engine overhaul stand NOTE Many of the disassembly operations can be performed with the engine in the chassis However the fol lowing disassembly outline is performed with the engine removed from the chassis to clear ly illustrate each of the units Except where indicated no attempt has been made to pre scribe a particular sequence for removing the various units since some can be readily re moved with the engine in the chassis The ex tent of the service required on a particular unit will govern the necessity for its removal L LINE MOTOR TRUCK SERVICE MANUAL Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond Section A Page 5 Removing Rocker Arms The following steps are tobe followed when removing the rocker arm cover and rocker l arm assembly Carburetor and air cleaner previously removed l Remove three capscrews from rocker arm cover Remove air cleaner line and re move cover Fig 5 A 21929 e 4
32. block and that locking tangs on bearings fit into recesses Follow same procedure place bearing shell cap halves in bearing caps Place a film of engine oil on bearing shell surfaces and lift crank shaft to align itself in the bearings and also provide lubrication Place bearing caps and bearing lower halves over crank shaft journals Be sure bearing caps are properly installed with numbers to cam shaft SOFT MALLET STRIKE LIGHTLY AND SQUARELY BEARING WOOD BLOCK 3954 7 T T 44 7 UREA TARA A ULA ES HITS LHE Teel LOK SS SOFT MALLET STRIKE LIGHTLY AND SQUARELY BEARING WOOD BLOCK ETE OLY LLL he eoa y 777 Dan Be 9 ITA INCREASING SPREAD A 16095 Fig 45 2 In order that an accurate measurement can be made to check all bearing clear ances a material similar to plastigage or virgin lead can be used 3 Use the following instructions when using plastigage a Remove oil from bearing cap insert and exposed half of crankshaft journal b Place a piece of plastigage the full width of the bearing insert c Reinstall the bearing cap Tighten the self locking capscrews to approxi mately 105 foot pounds d Removethe bearing cap The flattened plastic material willbe found adhering to either the bearing shell or the crank sha t Donated by John amp Susan Hansen For Personal Use Only PALA S R on ied L LINE MOTOR TRUCK SERV
33. in engine overhaul stand for re assembly Main Bearing and Connecting Rod Bearing Installation It is essential that main bearings be in alignment with the crankshaft journals The model RD engines have the main bearing caps piloted in the crankcase Fig 42 All bolts should be carefully examined before installa tion BEARING CRUSH Undersize precision type bearing shells should be installed when because of wear bearing to crankshaft running clearances are to be reduced Bearing caps must not be filed lapped or in any other manner reworked Donated by John amp Susan Hansen For Personal Use Only CRANKCASE TONGUE AND GROOVE METHOD OF BEARING CAP ALIGNMENT BEARING CAP A 16096 Fig 42 Illustrates tongue and groove method of Behring Cap Alignment with crankcase Premature bearing failure will result from attempts to reduce journal to bearing running clearance by reworking of either bearing caps bearings or both because such reworking will alter the engineered fit of the bearing shells in their bores and destroy the specifically de sired crush When installing precision type connecting rod or main bearings itis important that the bearing Shells fit tightly in the rod or case bore To accomplish this the bearing manu facturer makes the diameter at right angles to the parting line slightly larger than the actual diameter of the bore into which they are assem bled When the assembly is drawn up
34. limits The shaft is mountedinfour precision type replaceable shell bearings the number four rear bearing taking up the thrust 9 Thepistons are made of analuminum alloy are cam ground and are fitted with three compression rings and one oil control ring The full floating type piston pins are held in place in the pistons at the ends of the pins by snap rings 10 The camshaft is machined from a solid drop forging and mounted in four special replaceable bearings 11 The flywheel is bolted and doweled to the crankshaft flange The timing mark is located on the front crankshaft pulley ENGINE REMOVAL The engine with transmission removed can be lifted from chassis without disturbing the fender and grileassembly by using a suit able chain sling and a floor crane Disconnect the following electrical cir cuits hose connections and various units as outlined Fig 2 and Fig 3 Radiator filler cap S ps 1 eere al filler cap Oil level gauge A 22165 Fig 2 E Air hose to Ce Be MER A 21587 Fig 3 l Drain engine oil pan Drain all coolant from engine cooling system by opening the drain cock on side of engine as well as the radiator drain cock Remove radiator fil ler cap when draining cooling system 2 Disconnect upper and lower radiator hose connections Disconnect engine air clean er and remove air cleaner Disconnect vacuum line at manifold 3 Disconnect engine
35. manifolds visu ally for cracks or breakage Place manifolds on surface plate and check for warpage If cracked or broken replace or weld If slightly warped true up on surface grinder but replace if warpage is extreme Manifold Assembly Place new gasket between the intake and exhaust manifolds and install two capscrews and two nuts Mount manifolds together loose ly before installing on engine This will assure proper alignment of the units with each other and with the engine cylinder head Oil Pump Removal and Overhaul After oil pump has been removed the fol lowing steps are to be used for disassembly l Remove cotter pin holding float to oil pump Fig 44 Remove float from pump Remove two capscrews holding pump in block Remove oil pump BW SL Cue E Float assembly E Oil pump 2 E CN gt 4 ae TEES KK E SE ext Cotter pin M H A 21948 Fig 44 2 Remove four capscrews and lockwashers from oil pump cover plate Then lift cover and gasket from oil pump body Fig 45 3 Lift out oil pump idler gear from idler gear shaft Fig 46 PRINTED IN UNITED STATES OF AMERICA L LINE MOTOR TRUCK SERVICE MANUAL Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond Section A Page 15 Spiral gear A 21564 Sf fs es AX i TM SLT rd d T i d B e T ZS Soft support i block Fig 47 Support oil pump shaft to prevent bend
36. must be replaced 6 Inspect piston pins for wear and if wear is perceptible replace pins Replace piston pins which show signs of corrosion or etching 7 With properly fitting adapter Fig 35 press old piston pin bushing from con necting rod Place new piston pin bushing in position align oil hole in bushing with oil holein connecting rod Fig 36 install bushing witha 0035 to 0055 press fit Burnish bushing into place in the connect ing rod Fig 37 then ream pin bushing to provide a hand push fit Press ram Adapter Re all l a f Ma Connecting rod Press plate 4 ks Lew H 1 cile MES Y D DES E f E po f up DNS WW 44 hem A mm ee Mz N d pee E gt d Ls M ES sal Se de bushing Select proper hole in SE 1033 Support Plate Fig 35 Use SE 1036 6 to remove Press ram 9 Adapter Press plate be Connecting rod MEDIUM o A 22457 Fig 36 Installing new bushing in rod 8 With reamer ream piston pin bosses in piston to provide a tight fit of from 0000 to 0002 with piston pin Piston Fitting Whenfitting pistons inthe cylinder sleeves usea 003 feeler ribbon 1 2 wide between the piston and cylinder 909 from the piston pin hole and in line withthe thrustface ofthe piston L LINE MOTOR TRUCK SERVICE MANUAL INTERNATIONAL Press n 7 Burnishing
37. ofthe head Checkvalve guides after installation to 002 to 004 for ex haust and 0015 to 0035 on intake with Go and No Go gauge Ream valve guides to 3435 3455 after assembly in cylinder head 3 If inspection indicates necessity replace valve seat 4 Grind valve seats in cylinder head to 45 on both exhaust and intake Reconditioning Valves and Seats One of the principal difficulties experi enced in reconditioning valves is obtaining valve face The importance of these angles in ihe grinding operation cannot be overempha sized because it is impossible to produce a flat or square seat by lapping The grinding stones on both the valve refacing machine and valveseat grinder should be dressed before starting a reconditioning job You will be unable to determine how closely the angle of the seat will match the valve face until the valve and seat have been ground and a check made with a very light tint of Prussian blue If a full seat width contact around the entire circle of seated valve is not shown the angles do not match It will then be necessary to redress the valve seat grinding stones changing the angle sufficiently to correct the error The correction should be made on the valve seat and not on the valve No more material should be removed from the valve face than is necessary totrue it up and remove the burned or pitted portion New valves should not be refaced but should be checked for trueness
38. plate REAL eroe Vo deri iA ie aking i Rae cM MAS ns Fig 8 Showing method of installing new rocker arm bushing Press ram Burnishing tool Press plate A 21894 Fig 9 Burnishing rocker arm bushing Use SE 931 Burnishing Tool Re bushing Rocker Arms With properly fitting adapter or special tool equipment provided Figs 7 8 and 9 press old rocker arm bushing from rockerarm Place new rocker arm bushing in position Align oil hole in bushing with oil hole in rock er arm which is located 30 from top of rock erarm towardrocker arm adjusting nut Using installing tool press new bushing into rocker arm Burnish bushing into place in the rocker arm then ream rocker arm bushing to provide 0015 to 004 clearance Ream dimension is 1D05 1D20 Cylinder Head and Valves The following instructions are to be fol lowed when reconditioning cylinder head and valves Remove push rods remove cylinder head bolts andlift off cylinder head and gasket Place cylinder head on bench 1 Compress valve spring with a valve com pressor and remove valve spring retainer locks Remove retainer Remove valve spring and damper and separate valve spring damper from valve spring Re move all valve springs as outlined and remove valve spring damper from each spring 2 Invert cylinder head Remove all valves from their valve guides and fromthe head keeping eachvalve ina suitable rack which will assure re
39. ram Bushing removing tool lt Press plate s A A MM Fig 10 Use SE 1036 Bushing Removing Tool when removing the rocker arm bushing Support the rocker arm on the SE 1033 support block Select a hole in the support block to properly support the rocker arm at the same time permit the bushing to clear the support block when being removed Use the support block when in stalling and burnishing the new bushing A 21895 L LINE MOTOR TRUCK SERVICE MANUAL Bushing installing tool Rocker arm Press plate sem LT KR Fig J Installing new rocker arm bushing Press ram Burnishing tool Press plate A 21894 Fig I2 Use SE 93 Burnishing bar Cylinder Head and Valves The following instructions are to be fol lowed when reconditioning cylinder head and gasket Remove push rods remove cylinder head bolts and lift off cylinder head and gasket Fig 13 Place cylinder head on bench A Cylinder head Spar plugs W Engine EI mounting support rj a ame A 21908 Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond L LINE MOTOR TRUCK SERVICE MANUAL Dees Page 7 l Compress valve spring with a valve com 2 Inspect exhaust valve seat rings for loose pressor and remove valve spring retainer locks Fig 14 Remove retainer Re move valve spring and damper and separ ate valve spring damper rom valve spring Not
40. recesses Follow same procedure place bearing shell cap halves in bearing caps Piace a film of engine oil on shell surfaces and lift crankshaft to align itself in the bear ings and also provide lubrication Place bearing caps and bearing lower halves over crankshaft journals Be sure bear ing caps are properly installed with num bers to camshaft 2 In order that an accurate measurement can be made to check all bearing clear ances plastigage can be used 2 Use the following instructions when using plastigage a Remove oil from bearing cap insert and exposedhalf of crankshaft journal b Place a piece of plastigage the full width of the bearing insert c Reinstall the bearing cap Tighten the self locking capscrews to approxi mately 80 foot pounds d Remove the bearing cap The flattened plastic material will be found adher ing to either the bearing shell or the crankshaft e To determine the bearing clearance compare the width of the flattened plastigage at its widest point with the graduations on the envelope Fig 67 Ihe number within the graduation on the envelope indicates the clearance in thousandths of an inch NOTE Do not turn crankshaft during the above procedure Gauge Plastigage flattened 4 A 21932 Fig 67 4 If clearance is not within 001 to 004 either use undersize bearing regrind shaft or replace shaft Check crankshaft for end play which is tak
41. removed the following procedures are re commended l Remove fan drive pulley nut and washer from end of crankshaft Install puller and remove crankshaft fan drive pulley and damper assembly from crankshaft 2 Remove nuts and capscrews from engine gear case cover remove gear case cover Remove crankshaft oil slinger from end of shaft Push twelve tappets up into retain ing clips to permit camshaft removal Remove nut from end of camshaft and re move camshaft gear with puller NOTE Camshaft may be removed without remov ing timing gear by removing thrust plate retainer screws 3 Remove capscrewsfrom camshaft retainer thrust flange plate Remove camshaft Remove two capscrews holding the gear case cover plate to block remove plate and gasket Remove crankshaft timing gear using a gear puller NOTE Lubri cate puller screw to prevent damage to screw threads Donated by John amp Susan Hansen For Personal Use Only ENGINES _ Supera e amond LLINE MOTOR TRUCK SERVICE MANUAL Section C Page 10 Turn engine in the overhaul stand and pro ceed with disassembly as follows Fig 20 Fig 20 4 Each connecting rod is numbered as to its position in the engine and these numbers are locatedon the camshaft side of the en gine Remove self locking capscrews from connecting rod cap and remove cap Fig 21 Push connecting rod and piston assembly toward top of block Lift piston and connecting rod assembly fr
42. the oil filler pipe To service separate the two halves of the valve unit and remove the weight Clean all parts When installing the ventilator metering valve on filler pipe point arrow up Screw unit into filler pipe Connect vacuum line leading to the intake manifold Fig 59 pper Metering orifice Large section i of metering Za pin in orifice 4 restricts flow Small section of metering pin in orifice of air Grooves Grooves Z Weight Position of weight with low Position of weight with high manifold vacuum below 3 manifold vacuum above 3 to 4 inches mercury to A inches mercury 4 23449 Fig 59
43. tight the bearing is compressed assuring a good con tact between the bearing back and the bore This increased diameter is referred to as bearing crush Fig 43 DIFFERENCE BETWEEN DIAMETERS A AND B IS BEARING CRUSH C WITH BEARING CAP DRAWN UP TIGHT DIAMETERS A AND B ARE EQUAL DIAMETER A AT RIGHT ANGLES TO PARTING LINES GREATER THAN DIAMETER B A 16009 Fig 43 PRINTED IN UNITED STATES OF AMERICA L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Red Diamond Section C Page 19 To obtain proper bearing assembly with the correct crush care must be taken when tightening the clamping bolts to make sure they are drawn down alternately and evenly using a tension wrench and tightening as specified Asa result of excessive bearing crush due to reworking the caps the rod or main bearing bore will possibly become distorted because more force is required to draw the cap and housing together Rods caps or blocks must not be filed lapped or in any other manner reworked in order to reduce clearance While such prac tice will make a tighter fit at top and bottom it will result inan out of round bore and bear ing shell distortion New bearing shells will have to be installed eventually and that is when additional trouble starts In general a visual inspection of the part ing faces of the rodor caps under a magnifying glass will provide sufficient proofofany attempt at reworking
44. times Tighten bolts to 105 foot pounds and remove bearing cap e The virgin lead will now be compres sed exactly in accordance with the amount of bearing to crankshaft clear ance Peel offflattened piece of virgin lead wire and measure with microm eter Thickness of flattened piece of wire isexact amount of bearing clear ance present Repeatabove operations on all bearings If clearance is not within 0013 0043 either use undersize bearing regrind shaft or replace shaft Checkcrankshaftfor end play which is taken up by number four main bearing End clearance should be from EES TO 00D INSTALL FLYWHEEL HOUSING Place flywheel housing in position over two fly wheel housing to cylinder block dowels and tap into place with soft hammer Install six capscrews and lockwashers in flywheel housing If either block or flywheel housing is replaced the flywheel housing will have to be aligned with a dial indicator When correctly aligned run out of bore should not exceed 005 Fig 39 NOTE If pos sible align flywheel housing while engine is in overhaul stand and with engine in vertical position flywheel housing up 9 A 22526 Fig 39 Donated by John amp Susan Hansen For Personal Use Only ENGINES S Bl Di d se Sys L LINE MOTOR TRUCK SERVICE MANUAL Page 20 7 INSTALL ENGINE FLYWHEEL Place into recess in cap NOTE See instruc 10 1l engine flywheel and ring gear into position
45. tool 3 1 i Connecting rod Press plate 2j 4 md vds oisQ44 22463 Fig 37 Burnish Bushing using SE 789 Tension scale Thrust face of piston EES Seep 4 22160 mE Fig 38 Checking piston fit using feeler gauge ribbon SE 1007 gauge set is available Fig 35 Apply a tension pull on scale to the feeler ribbon and check clearance to specifica tions as outlined in the chart below Feeler Gauge Ribbon Checking Thickness Tension on Scale Desired Tension Connecting Rod and Piston Assembly l Withpistonheatedtoapproximately 200 F support connecting rod in vise push piston pin into piston bosses while piston is hot Fig 36 When assembling piston on rod the slot in the piston skirt must be toward the camshaft side of the engine which is the numbered side of the connecting rod Installpiston pin retainer in piston at each Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Red Diamond Section C Page 17 Piston pin Piston Connecting rod REN A 22466 Fig 39 end of pin making sure that retainers seat fully and with tension in grooves Test connecting rod and piston assembly on a connecting rod aligner and correct any mis alignment Place piston and connecting rod in vise Test each piston ring for proper gap by placing in cylinder and measuring gap with feeler gauge Gap s
46. vaseline or heavy engine oil to the bearing surfaces then reassemble the caps and tighten the bolts It will be noted that a small quantity of the petrolatum or vaseline may be squeezed out when the bearing caps are tightened however a sufficient quantity will remain which will serve as a cushion or filler between the bearings and crankshaft journals thereby reducing the tend ency of the cap and bearing to shift The petrolatum or vaseline willalso serve as a lubricant when the engine is first started and will dissolve and mix with the regular engine lubricating oil after a few revolutions Under no circumstances should anything other than petrolatum or vaseline or heavy engine oil be used due to the possibility of chemical reactions which would cause damage to the bearing material BEARING CRUSH Undersize precision type bearing shells should be installed when be cause of wear bearing to crankshaft running clearances are to be reduced Bearing caps mustnotbe filed lapped or in any other manner reworked Premature bearing failure will result from attempts to reduce journal to bearing running clearance by reworking of either bearing caps bearings or both because such reworking will alter the engineered fit of the bearing shells in their bores and destroythe specifically desired crush When installing precision type connecting rod or main bearings itis important that the bearing shells fit tightly in the rod or cas
47. with Steam or cleaning solvent Remove all dirty oil sludge scale and carbon from cylinder block Check core plugs for in dication of leakage Remove and replace plugs that show signs of leaking or rust ing through Use installing tool for core plug replacement Fig 51 using SE 1725 Installing tool with SE 158 B handle Fig 51 Installing core plug Cylinder Block Inspection l Inspect cylinder walls for cracks Weld the cracks or replace block if necessary 2 Check top surface for trueness with a straight edge Test by attempting to in sert a 012 feeler gauge ribbon between the straight edge and the cylinder block If this is possible either surface or re place the cylinder block 3 Inspect camshaft bearings for damaged or scored condition and inspect for wear Replace if damaged or if worn beyond clearance limit of 006 4 Measure cylinder walls with an inside reading micrometer to determine taper out of round or worn condition The measurements must be made not only at top of the cylinder bore just below ring groove but at several places around the inside circum erence of the bore Bore Should be checked at the bottom below ring wear surface to determine the amount of taper Rebore if worn beyond 008 clearance PRINTED IN UNITED STATES OF AMERICA L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Silver Diamond Section Page 17 Replacing Camshaft Bushings l If camshaft bearing r
48. 1 64 3 64 EXHAUST VALVES Stem diameter 370 Angle of face o 300 Tappet clearance hot 018 020 Stem clearance in guide 002 004 Width of valve seat 3 64 5 64 Slo roto valve cap to Siena clearance ss sms VALVE TAPPET Clearance in block 0015 003 VALVE SPRINGS Free lenght IU P e se aa 2 11 16 QUIET uw mures ll sims 0015 2 003 2 11 16 e e BCG COL 0015 003 001 003 2 11 2 9 32 16 2 33 64 002 2 006 3 3 3 3 1 3 32 1 3 32 1 3 32 1 3 32 2 1 8 2 1 8 2 1 8 2 1 8 1 3 16 3 16 3 16 3 16 3 9 16 3 9 16 4 3 d n 4 3 8 016 026 016 026 025 035 025 035 0025 0025 0040 0040 0040 0040 00551 0055 0015 0015 0020 0020 0030 0030 00351 0035 0015 0015 0015 0015 0035 0035 0035 0035 2372 342 434 2434 30 45 15 15 018 020 018 020 018 020 018 020 0015 2 0035 0015 2 0035 0015 2 0035 0015 2 0035 1 64 3 64 5 64 7 64 5 64 7 64 5 64 7 64 370 341 434 434 30 450 450 450 018 020 018 020 018 020 018 020 002 004 002 004 002 004 002 004 3 64 5 64 5 64 7 64 3 32 1 8 3 32 1 8 002 006 001 003 2 11 32 2 9 16 CONT RD 450 R 6602 3 4 1 3 32 2 1 8 1 1 3 16 4 3 8 025 035 013 023 00
49. 2 Using 280 grit hone stones and having both sleeve and stones coated with vegetable shortening work hone up and down in the cylinder bore approximately 20 strokes This operation should bringthe bore to the desired size 3 Still using 280 grit hone stones but having lubricant only on the stones pass the hone up and down in the bore about 5 times This operation will not increase the bore diameter but will merely serve to remove the sharp ridges and leave the desired type of surface finish NOTE In steps land 2 the hone should be quite snug in the bore In step 3 the tension should be a little less CAUTION Extreme care must be taken to assure thatno abrasive remains in the en gine 4 After engine has been reassembled it Should be allowed to run in for two or three hours at a fast idle approximately 1200 r p m Replacing Camshaft Bushings If camshaft bearing replacement is neces Sary remove and installnew bushings with Special camshaft bearing installation tool Noreamingis required Fig 27 illustrates the use of camshaft bearing installing tool Bushing arbors aJ a gt AG b Nut Fig 27 Using the installing tool Camshaft bushings A 22149 SE 1724 Camshaft Bushing Connecting Rod and Piston Disassembly l Remove piston pin retainers from each piston and remove piston rings from pis ton ring grooves 2 Heat pistonin boiling water or piston heat er Place pi
50. 40 0055 0055 0070 0020 0025 0035 0035 00151 0015 0035 0035 e 999 9 979 0015 0035 434 4973 159 309 018 020 020 0015 2 0035 1 0008 0021 5 64 7 64 1 16 3 32 434 EREM 459 459 018 2 020 020 002 004 0035 005 3 32 1 8 5 64 7 64 002 006 002 006 001 003 0019 0002 2 11 32 2 3 4 2 9 16 2 13 16 c odeq TVANVW JOMAS JONYL YOLOW ANITI suoi eorjroedg SANIONI z m 20 z O gt r lt _ __ _ __ __ _ _____ _ yz ENGINE MODELS SD 220 SD 240 BD 269 RD 372 RD 406 RD 450 Length valve open Inner Lbs pressure valve open inner VALVE ROCKER ARM CLEARANCE IN SHAFT VALVE TIMING Intake opens before A 2x43 3a Intake closes after Exe uu emm uus Exhaust opens before EDO na xm vor xo Exhaust closes after TD 6245868 4 Intake valve timing clecking clearance OIL PUMP Body gear end clear ANCE LE Pump body to spiral gear clearance Pump shaft diameter Pump shaft clearance in bore OIL PRESSURES Minimum lbs EE ue E E Maximum lbs ATI PO d cw wox c CYLINDER HEAD Cylinder head bolt ft 1bs 9 s gt e 9 e e e 9 p 1 683 141 149 0015 004 109 460 480 go 023 0025 0055 4885 4890 005 15 20 idling 40 45 1200
51. 6 18 Crankshaft rear oil seal lower 18 22 5 16 24 Generator mounting E 20 24 5 16 24 Carburetor to manifold Holley 20 24 3 8 16 Starting motor mounting 0 25 30 3 8 16 Oil pump body to crankcase 25 30 3 8 16 Camshaft thrust washer 25 30 3 8 16 Damper to pulley hub o 30 35 3 8 16 Fuel pump to crankcase 25 30 3 8 16 Rocker arm bracket to head o 25 30 3 8 16 Gear case to crankcase dd moe a 25 30 3 8 16 Generator bracket to case s 25 30 3 8 16 Water pump to cylinder head 25 30 3 8 16 Oil pan to crankcaSe ae ebe AN ENK EEN 25 30 3 8 16 Oil Sle 2 9204000 EP T 25 30 3 8 24 Gear case cover to crankcase plates EE 25 30 3 8 24 Carburetor to manifold Zenith 23 28 3 8 24 Gear Case COVE repanse eww de 23 28 3 8 24 Manifold to cylinder head 9 23 30 7 16 20 Intake to exhaust manifold 55 65 7 16 20 Intake to exhaust manifold m SEN 55 65 7 16 20 Connecting rod capscrew place type TE 75 85 7 16 20 Carburetor to manifold 40 45 1 2 13 Oil filter mounting sosa 75 85 1 2 13 Cylinder head capscrew oil DRECHEN 100 110 1 2 13 Cylinder head capscrew Long 100 110 1 2 13 Cylinder head capscrew short 100 110 1 2 13 Flywheel hou
52. CC SUPER RED DIAMOND ENGINE L 185 L 190 L 193 L 194 LC 190 RD 372 Engine MODELS lt L 190 L 194 L 195 LC 190 LF 190 L 200 L 204 RD 406 Engine L 200 L 204 L 205 LC 200 L 210 LF 210 RD 450 Engine Page DESCRIPTION 0 43x 30994 X 4 RE OEE HES eK dede FO EURO US AAA Z ENGINE REMOVAL co sesos cds AAA 2 ENGINE DISASSEMBL Y Connecting rods and pistons LEIA EE T woe DAA 10 Cylinder head and valves Vr E E E 4 9 Flywheel and housing oo ee Rd cs rc 10 11 Main Daring ue 3 6bok 444 HEE SS Xov AS ROW wow cw Cox EO e RE X e eS 10 Manitold uro c9 uk OR Rh RU Oo CURL TRO ORO decr AAA GR Por ne 12 13 Cil sump overhaul 64344665 Ree runas ia ee doo ue EUR AAA 13 14 Rocker APIS 33 4x4 AAA AI dw Fou FR XC CA Y wo C Xo AA 3 4 Water pump overhaul e666 we used NAAA AA LI 12 REPAIR OF SUB ASSEMBLIES AND ASSEMBLING Camshaft bushings EE 9 RS ERA WX kdo d d d ARA 15 Connecting rods and PISIONS se ei manos oue i RADE Rom AAA 15 17 Crankshaft flywheel and camshaft inspection eee eer ors 17 18 Cylinder block and sleeves oros 14 15 Miscellaneous parts InspecllOH s s 404 092 ea AA RA ARA A AAA 18 ASSEMBLY OF ENGINE MCCESSOTIES 5 62464 etme SS OS ECO da a Ale Ls ce oe eee ee 8 24 25 Camshaft and gears CERA aseo Tr 21 GIUTEA 4 wo oe Oo a el ee ee eS 9 cw Hw oe NR rr 43 Connecting rods and PISOS 4 6 9 ec dE GE CO ERU LU EE CE ww Ow We ORO E EO 18 23 Crankcase
53. Cl ck Gasket B 4744 N S Relief valve Fig 77 Details of Deluxe Oil Filter Donated by John amp Susan Hansen For Personal Use Only ANAIA INTERNATIONAL SUPER BLUE DIAMOND ENGINE PRINTED IN UNITED STATES OF AMERICA L LINE MOTOR TRUCK SERVICE MANUAL A 23212 Super Blue Diamond Sectional view of Super Blue Diamond Engine Fig Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Blue Diamond Section B Page 2 DESCRIPTION General The Model BD Super Blue Diamond engine is a 4 cycle 6 cylinder in line overhead valve type engine Fig 1 The engine serial number is stamped on a pad at the front on the left side of the crankcase just below the cylin der head The block has dry type replaceable liners for the cylinders The detachable cyl inder head contains all valves valve guides and springs The cylinders are numbered from front fan and timing gear end to rear Engine crankshaft rotationis clockwiseas viewed from the front end of the vehicle The intake and exhaust manifolds carburetor starter and generator are located on the right side of the engine The distributor fuel pump and oil filler arelocated onthe left side The oil filler inlet is located in the valve cover on the top of engine The bayonet type oil level gauge is located on the left side The water pump is located at the front of engine Construction l The generator fan and water
54. Crankshaft rear oil seal lower 25 30 3 8 16 Gear case cover to crankcase o o 25 30 3 8 16 Cam shaft thrust flange 25 30 3 8 16 Starting moter s ss 24240 PETT 25 30 3 8 24 Carburetor to manifold UE 23 28 3 8 24 Gear case cover to plate oo 9 11 7 16 14 Oil pressure relief valve 13 15 7 16 20 Connecting rod bolt T i 60 70 7 16 20 Intake to exhaust manifold 55 65 7 16 20 Connecting rod boll 4 s wok oon 60 70 1 2 13 Flywheel housing ceo 75 85 1 2 13 Cylinder head cap screw T 75 85 1 2 20 Flywheel to crankshaft Tm 90 100 9 16 12 Crankshaft bearing capscrew 100 110 9 16 12 Crankshaft bearing CapscreW o 100 110 20 Camshaft lock nut TP T 110 120 7 8 18 Spark plug in cast iron TT 32 35 14 MM Spark plug in cast iron 25 28 14 MM Spark plug in aluminum TEET 21 25 18 MM Spark plug in cast iron 28 31 18 MM Spark plug in aluminum eses esses i 25 28 Donated by John amp Susan Hansen For Personal Use Only ENGINES L LINE MOTOR TRUCK SERVICE MANUAL B SUPER RED DIAMOND ENGINE RECOMMENDED Es NAME OF ASSEMBLY WRENCH TORQUE LOAD FT LB 5 16 18 Distributor bracket to cylinder head 18 22 5 16 18 Crankshaft rear oil seal upper 18 22 5 1
55. Disassembly l Remove piston pin retainers from each piston and remove piston rings from pis ton ring grooves 2 Heat pistonin boiling water or piston heat er Place piston in piston vise and using pin driving tool drive piston pin from piston and connecting rod Fig 34 After piston pinis removed lift piston from con necting rod in Ta Xy Connecting rod l Piston pin i SE Piston vise A 22205 vise to hold piston pin out with SE 1264 Piston Use soft hammer Fig 34 Use suitable piston and drive Pin Driver 3 Wash all parts in a cleaning solvent CAUTION Do not use a caustic solution for aluminum pistons Clean the carbon rom piston ring grooves with a broken ring or ring groove cleaner 4 Inspect connecting rods caps and bearing shells All connecting rod bearings and piston pin bushings should be replaced at every majoroverhaul Testrods foralign ment Rods only slightly misaligned can be straightened with proper equipment Badly twisted or bent connecting rods must be replaced 5 Inspect pistons for cracks breakage or scores Check piston ring grooves and ring lands for wear using a new piston ring ard feeler gauge If clearance be tween ring and ring land exceeds 005 Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Red Diamond Section C Page 16 total clearance replace piston see spec ifications Pistons which are scored or damaged
56. Donated by John amp Susan Hansen For Personal Use Only ENGINES L LINE MOTOR TRUCK SERVICE MANUAL E ENGINE GROUP SPECIFICATIONS Page ENGINE SPECIFICATIONS o rasa ET ae eee PD 1 7 WRENCH TORQUE LOAD CHART Recommended DEENEN E SECTION A SILVER DIAMOND ENGINE MODELS iez L 120 LM 120 L 130 L 150 L 153 LM 150 SD 220 Engine LB 140 L 160 L 163 L 164 L 165 LC 160 SD 240 Engine DESCRIPTION 28 eee 85 9 5043 408 e QUE SO RHEE Oe ee eS E X 3 4 ENGINE REMOVAL 0 2 a TEE EE E he Se og we d pase ET Tn 4 ENGINE DISASSEMBLY Connec unsp rods and pistons errar AAA AAA 11 Cylinder head and Valves Ae ANEN a Aaa 6 9 Poly WCC 4 54 3 5 ko x9 x 3 X WR ES AAA Ew Wok Rok x3 3 11 Moin DEATINGS ssa 9 5 4 TETERA cia E 2a ee ee as 11 Manifolds e spss a CERAS oe coh 16 a ee GO ENEE EE e 14 15 Oil pump overhaul 4 ow we asserere sosio e Leia AAA E os 15 16 Rocker Armes sssr Gt od AAA CEDAR IAEA 4 5 6 Timing gears and camshaft a 5 su 3k 4 dete EE e 3 aua dere iae 10 Water pump OVerPhaUuL 2406 eb EOS RC ROREM we e F9 do X 9 PR AAA REESE OS 12 14 REPAIR OF SUB ASSEMBLIES AND ASSEMBLING Camshaft bushings wg s c 99 ns sa ea UE E x R4 asa ois Na AA 17 Connecting rods and PIStONS 4 RR E Eu AAA AA 17 19 Crankshaft flywheel and camshaft inspection o ooooo ooo oo oo oo ooo 19 20 Gylinder DIOCK 2hSpeCLLODh e eins EN EE AAA 17 Miscellaneous paris 1nsSp6CllO ech
57. Fig 22 Fig 25 Camshaft and cover plate removal Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL Crankshaft timing gear A 21936 Fig 26 Crankshaft gear puller SE 1715 is installed with puller plates in position shown Lubricate puller screw thoroughly Rings Piston Sa A 21925 Fig 27 Remove piston and rod from top of cylinder block Connecting rod cap as Wi LI ra 4 li 1 Groove A GS A EB 4 21924 Fig 28 Connecting rod caps are aligned by means of tongue and groove construction 5 The crankshaft bearing caps are numbered to identify their position and they must be reinstalled in their respective positions Remove self locking capscrews from each bearing cap Remove all crankshaft main bearing caps NOTE To removethe rear or No 4 main bearing cap a puller is re quired Fig 29 After all caps have been removed lift crankshaft straight up and out of cylinder block and place in a vise equipped with soft jaws PRINTED IN UNITED STATES OF AMERICA ENGINES Silver Diamond Section A Page 11 A A 21945 Fig 29 Use SE I719 Bearing cap puller to remove rear main bearing cap 6 With crankshaft securely clamped in vise remove the six self locking capscrews holding flywheel to crankshaft Fig 30 Tap flywheel with a soft hammer to loosen it from crankshaft remove flywheel with ring gear assembly Self lo
58. H Install clutch driven disc against flywheel so that the long por tion of the hub is toward the rear Place clutch in position on flywheel over clutch driven disc Locate clutch so that arrow or inspection mark usually a dab of white paint on flange of clutch backing plate or cover is as near as possible to the letter L on the flywheel and installtwo or three mounting capscrews and lockwashers loosely Insert a clutch aligning arbor if available or a transmission main drive gear shaft through clutch driven disc hub Spline and into clutch pilot bearings Hold clutch driven disc in position while com pleting installation of six mounting cap Screws and lockwashersin flange of clutch backing plate or cover Tighten all six capscrews securely Remove three retain ing capscrews and flat washers which were installed to hold clutch compressed NOTE clutch will not operate properly unless these retaining capscrews are removed INSTALL VALVE TAPPETS Coat each of twelve valve tappets with heavy engine oil and drop each flat side down through recess in side of cylinder block into sock ets in block INSTALL VALVE LIFTER ROD COVER Install new gasket over opening at left hand side of engine block Install valve lifter rod covers and slotted screws Install Cylinder Head E INSTALL HEAD Place gasketon cylinder block and align bolt holes Place cylinder head on crankcase being careful not to damage or shift gasket positi
59. ICE MANUAL Pf on e I Page 21 Plastigage flattened Pm A 21932 zeg BR Fig 46 Checking Behring Clearance e To determine the bearing clearance Main bearing bor compare the width of the flattened plastigage at its widest point with the Fig 47 graduations on the envelope Fig 46 The number within the graduation on bearing End clearance should be from the envelope indicates the clearance 004 to 012 in thousandths of an inch NOTE Do 6 INSTALL FLYWHEEL HOUSING Place B emu A 22464 not turn crankshaft during the above flywheel housing in position over two fly procedure wheel housing to cylinder block dowels and TN tap into place with soft hammer Install 4 ns AO the Bs in lead method use six capscrews and Iockwashers in flywheel the following procedure housing If either block or flywheel hous TE ing is replaced the flywheel housing will a Mapa i vbi iq bi have to be aligned with a dial indicator 010 thickness is not available mud When correctly aligned run out of bore thicker wire must be used it must be ep Ot o NC ee soled bo eet 010 thick sible align flywheel housing while engine PP y is in overhaul stand and with engine in ness vertical position flywheel housing up 9 dopo ur in Mead ni 7 INSTALL ENGINE FLYWHEEL Place Pads eg EN Medis Wo SE engine flywheel and ring gear into position E Med on dowels in crankshaft flange Install six self locking capscrews in fly
60. John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Blue Diamond Section B Page 7 minimum and average specifications The intake seats may be narrower than the exhaust because they are usually larger in diameter thus providing a total seat area approximately equal to smaller exhaust valve with the wider seat Also the less severe heat conditions do not require as large a seat area for heat dis sipation purposes Fig ll illustrates recom mended valve seats to be obtained There are also objections toan excessive ly wide seat a few of which are as follows l In city or light delivery service a wide seat collects carbon and particles of dirt that will produce variations or loss of compression resulting in poor idle and possible a loss of general performance and economy 4 A wide seat in severe service operating in the presence ofdirt oran excess of carbon will produce a badly pitted seat which may be just as detrimental to valve life as a too narrow seat Under these conditions a seat width to the minimum limit would possibly be better however the source of trouble which is the dirt and excessive carbon should be eliminated making it possible to retain the wider seat Valve Seat Inserts Necessity for replacing valve seat inserts Should be very rare however if a replace mentis made itis important that new inserts be peened securely in place using either
61. OF SUB ASSEMBLIES Cleaning the Cylinder Block Remove all old gasket material from block clean both inside and outside of block with steam or cleaning solvent Remove all dirty oil sludge scale and carbon from cylinder block Cylinder Block Inspection l Inspect cylinder walls for cracks Weld cracks or replace block if necessary 2 Check top surface for trueness with a straight edge Test by attempting to in sert a 012 feeler gauge ribbon between the straight edge and the cylinder block If this is possible either surface grind or replace the cylinder block 3 Inspect camshaft bearings for damaged or scored condition and inspect for wear Replace if damaged or if worn beyond clearance limit of 0035 End play should be from 001 to 0035 Special tool equipment is available for installation of the prereamed camshaft bearings Fig 33 4 Measure cylinder walls with an inside reading micrometer to determine taper out of round or worn condition The meas urements must be made not only at top of the cylinder bore just below ring groove but at several places around the inside circumference of the bore Bore should be checked at the bottom below ring wear surface to determine the amount of taper Re sleeve if worn beyond 008 clearance Bushing arbors Adapter sleeve Draw bar A 22149 Camshaft bushings Fig 33 ADA Donated by John amp Susan Hansen For Personal Use On
62. Pump Assembly The following instructions are to be fol lowed for reassembly l Install new Woodruff key on body end of drive shaft Place in press and press body gear on drive shaft The end of the shaft can be from flush to 030 below the level of gear face 3 Insert oil pump drive shaft and body gear into oil pump body 4 Install new Woodruff key in spiral gear end of drive shaft and press on spiral drive gear Make sure that spiral gear hub is down Install new spiral gear pin in place 5 Installidler gear on idler gear shaft In stall gaskets oil pump body cover four capscrews and lockwashers 6 Check oil pump body gear end clearance by using a dial indicator Fig 50 If end clearance is less than 0025 add one gas ket that measures not more than 003 in thickness If end clearance is in excess of 0055 remove one gasket of not more than 003 in thickness Body gear end clearance should measure between 0025 and 0055 7 Insert oil pump float in oil pump line up cotter pin holes install new cotter pin and fasten securely Dial indicator Spiral gear Drive shaft A 21565 Fig 50 Checking end clearance of pump shaft and body gear Donated by John amp Susan Hansen For Personal Use Only DISASSEMBLY CLEANING INSPECTION REPAIR AND ASSEMBLY OF SUBASSEMBLIES Cleaning the Cylinder Block l Removeall old gasketmaterial from block Clean both inside and outside of block
63. R P M cc cc ccc e ae XR ira a SEN he oes 3200 Torauegnaximurn Ibssfi 9x0 dee ee wd Xo RON GELEU EE OES OER OSH RRS 246 3 ALRSIBLME 293 948x349 eee SS R54 5x x44 9 9 X RUE X KE GE IRURE RU ERREUR OP RON 1800 Torque net SH 6465465 oe eee de CAR EIA 238 2 REM iris o 5 4 4 40909 7 8 9 4 x 409 5 9 348 EE AO ES 1600 Maximum recommended speed R P M o oo oooooo nn ooo on mo on a 3400 Compression ratio aaa AREA TIT s 0 5 Firing Ordr 4 22493 0x amp ok 9 9o o3 o E oec Ee RO de EC AO CUR Id OE 1 5 3 6 2 4 Crankcase refill capacity qts URREA oa a pia ol Weight Dare bo 6 4 due ACE UR EER REESE EAE AAA ER ae Ee 742 Weight with standard accessories 1bs o o tns 831 CRANKSHAFT Main journal diameter seare ssa ERR ans 97 E XXE IURE AAA AAA 2 701 Crankpin diameter sioe dopo moe orar T 2 1 8 Bedring cleauadee rou os T RAPWERSPERESEEEUCTEREAT E Crankshatt end play 539995 3 30 o EES CR OS WI Wow SN EEG Pw s Pr 8 0055 0145 Trust taken DV is essa EOE 4 ow ow X x wo is TT PPP Rear Hardening method oo o o o 0 lt 0 Through CTS 12 MARCH 1953 Supplemental pages for CTS 11 PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only ENGINES R LINE MOTOR TRUCK SERVICE Specifications Page 2 CAMSHAFT Camshaft journal diameter PTOD da a s
64. RO dida AAA 20 ASSEMBLY OF ENGINE Accessories 443 33 a PEA e E AA 26 Camshatt and Sear seiga nprap 230 93 99 4 8 Xp AA AA 24 CIUUDC x x URED d x X GO TER REE EEK DEe AA AAA 24 Connecting rods and PISTONS ssa speram i te a hisini kaiek 21 24 Crankshaft ic isa asa COR DA AAA XU ROSCE SE EE S vo ON ds 21 23 Cylinder head TIT ROERUDROR SSS PH Ce ELA AAA 25 Flywheel and housing lt lt 0 AAA AAA 24 MIaBnilOld a 4a xo cv obo RO 09 4 9 RA A ARA SU A OR AA A Lo Oil iin nor AAA ARAS Arda a ee Sd ws 24 Rocker arm es 6H DiV s 9 ow oe e PAM ODE ORES ORO Ew ARAS AAA 25 Tappels esas tah EW ee OEE AA AAA AAA 2 Valve ad usUng o Gs be ea howe ded es ee ee ee Ax E EE ee pe ee 25 PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only ENGINES Pase 2 L LINE MOTOR TRUCK SERVICE MANUAL ENGINE GROUP Continued SECTION B SUPER BLUE DIAMOND ENGINE MODELS L 170 L 173 L 174 L 175 LF 170 L 180 L 183 L 184 LC 180 BD 269 Engine DESCRIPTION serorea DEENEN c cw 6 40 a ee ee Pee SESE EG EO ED eS M s ENGINE REMOVAL aus sonoras CABRA TERE ENGINE DISASSEMBLY Connecting rods and pISTODS ceas aaea 6 He dE ER Xo RR TED ROHR DES s Cylinder head and Valves 6444 64 RECO OCURRE RS SEED DRAM OM CR Ow OC RS PLY WHEE a e ko we woo S LS RAR AAA AENA Main bearings and crankshaft aora aaa aaa AAA Manifold EMBA COW Gi EE EEN ow 9r ub A O
65. Red Diamond Section C Page 24 L LINE MOTOR TRUCK SERVICE MANUAL 3 ADJUSTING VALVES To adjust valve stem to valve rocker arm clearance cor rectly each cylinder must be on top dead center on its compression stroke at the time of adjustment of valves for that cyl inder To determine the correct position turnthe engine crankshaft until No 1 piston is attop dead center on compression stroke and the ignition timing mark on the crank Shaft pulley in line with the pointer on the timing gear case Adjust clearance on each valve of No l cylinder to 018 to 020 by using a feeler gauge between valve stem and valve rocker arm and turn rocker arm adjusting screw out of rocker arm until clearance is obtained Tighten adjusting screw lock nut and recheck clearance NOTE Valve clearance should be re checked with engine at normal operating temperature 4 Turn crankshaft one third revolution and adjust clearance on No 5 valves Working in firing order sequence continue to set valves of each of the remaining cylinders turning crankshaft one third turn after each valve adjustment 5 INSTALL WATER PUMP Place water pump gasket in position at water pump opening in front of cylinder head Fig 54 Install water pump and fan and installthree capscrews and lockwashers in pump and cylinder block Gasket Pulley men ee T ERE Ad S e x 3 CN X E a E d 3 gt e b e M gt HE 3 D T Lay pei gt i Pu E E H WE
66. Remove capscrews from shaft brackets Fig 6 Shaft brackets 3 4 3 Remove rocker arm assembly as a unit Fig 7 Rocker arm assembly Sleeve brackets HEC CMT Fig 7 PRINTED IN UNITED STATES OF AMERICA Rocker Arm and Valve Mechanism Disassembly The rocker arm assembly is composed of front and rear shafts joined at the center on which are mounted twelve rocker arms and six tension springs Fig 8 The shafts are mounted in seven brackets and are prevented from turning at the two end brackets by slots in the shaft into which the cylinder head bolts fit Joint in assembly Rocker arms Sleeve dowel Tension springs Brackets A 21909 Fig 8 Number two four and six rocker arm brackets have sleeve dowels which keep the rocker arm assembly aligned These sleeve dowels measure approxi mately 5 8 in diameter 1 long and 1 32 wall The three hold downbrackets are reamed from the bottom side Fig 9 so that the sleeve dowels willfit 0005 0035 tight in brackets About one half inch of dowel is in the bracket The remaining half of dowel is fitted 0025 0055 loose in the head When removing rocker arm assem bly the dowels will remain in hold down brackets Racker arm Rocker arm bracket gt Y r E 3 D kt p Ka Y A fo L D H i Sleeve dowel A 21938 Fig 9 Details of sleeve dowel located in bracket 5 Separate the shafts and slide rocker arms S
67. Under the glass the parting line surface of standard parts will show the manu facturing cutter tool marks and will not have a polished or extremely smooth appearance On the other hand reworked parts will have a polished surface and if a file was used will Show the even pattern of the file teeth Seri ousness ofthis condition is in direct proportion to the amount of reworking BEARING SPREAD Main and connecting rod bearings are designed with the spread width across the open ends slightly greater than the diameter of the crankcase bore orcon necting rod bore into which they are assembled For example the width across the open ends of the engine connecting rod bearing not in place is approximately 025 more than when the O D OF BEARING WHEN INSTALLED IS THE SAME AS THE DIA OF THE CRANKCASE OR CONN ROD BORE SPREAD OF BEARING BEFORE INSTALLATION JIA EA A 16088 Fig 44 Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Red Diamond Section C Page 20 L LINE MOTOR TRUCK SERVICE MANUAL bearing is in position in the rod This condi tion causes the bearing to fit snugly in the rod bore and the bearing must be snapped or lightly forced into its seat Fig 44 Rough handling in shipment storage or normal results of use in an engine may cause the bearing spreadtobe increased ordecreased from the specified width Bearing spread should therefore be caref
68. a A PE i e DEE E AAA 1 8130 1 8145 SECON AAA AAA 1 7248 1 7263 THT 6 sk oe ee Por Wo aos ee ee ee ee Se ee eee ee ee UN OR 9 ee 2 d 1 7098 1 7113 CR d anal e X 905 MO ee Pp eR VOR ARA AAA A 1 5010 1 5025 Camshaft bearing clearance EG WU NUR RR UN RR aaa dieses 0010 0035 Ccamshalt end play 4 2 E ER ox de 3 ow Re de Wo 9 Kw REE OH A TP 0020 0100 Thrust tak n DY 4 cx Sleek 603 A IEEE CLP Thrust flange Camshaft gear backlash o Torr 0015 desired CONNECTING RODS 0070 0130 Connecting rod bearing end clearance eee eee eee err ht n Connecting rod bearing clearance 44 e e 949 ue So Oe e ox HS dC WU ec a 0007 0032 PISTONS Material aser AAA EEDA E E HERERO RARA Aluminum alloy Recommended piston clearance o ee eee ee eee eee here sh mnn 003 PISTON PINS ENDOSO AAA ARO A 3 201 Diameter x 3 aos ro ERA AER AAA 9193 Pin fit at room temperature 709 Recommended clearance in rod ooo o ooo ooo eee eer nnns 0003 0005 0001 tight Recommended clearance in piston ooo oooo ooo t rot on 2003 loose FEELER GAUGE RIBBON CHECKING EE ORO EE Eee apo AA 1 2 TRIGKNESS a CC EE EE EE EE Ad 4 003 Tension on scales lbs ETT TT 6 18 12 Desired tension Ib5 e 4224 xa aii te HESS iei ee gs eg ARA AAA AA Donated by John amp Susan Hansen For Personal Use Only ENGINE R LINE MOTOR TRUCK SERVICE Specifications Page 3 PISTON
69. ace between the grooves provides a load bearing surface If the scratches are too deep and too close together the surface is referred to as rough and will not provide adequate ring and piston contact area which results infast wear Should the finishbe highly polished or too smooth the scratches or grooves are shallow and will have insufficient oil retaining capacity to provide adequate lu brication for the adjacent contact or load bearing area and will result in scuffing or scoring It is therefore advantageous to strike a happy medium by removing only the sharp peaks of these microscopic ridges and in this way still reap the benefits of the oil retaining grooves This type of cylinder wall surface is obtained through exercise of care in finishing operation and through proper use of equipment The following procedure will produce the best results when fitting pistons to sleeves l Using 150 grithone stones and having both Sleeve and stones coated with one of the vegetable shortenings Crisco Spry Dexo or equivalent work hone up and down in cylinder approximately 20 strokes This should bring the bore diameter to within 0003 of the desired size Hone should PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Blue Diamond Section B Page 13 be moved up and down ata speed rate of approximately one stroke per second
70. ace new gasket between the intake and exhaust manifolds and installfour bolts and four nuts Mount manifolds together loosely before installing on engine This will assure proper alignment of the units with each other and with the engine cylinder head NOTE Do not elim inate the intake manifold aligning pilot rings lighten both manifolds to head Tighten ex haust manifold expansion clamp bolts Fig 30 and replace with new seals if needed and tighten intake to exhaust manifold bolts Adjusting clamp bolt 77 DAS Fig 30 Oil Pump Overhaul Complete illustrated procedure for Oil Pump Overhaul is given in Shop Talk No 28 Special tool equipment is available for oil pump overhaul under SE 1499 Use of these tools will speed up the job and assure accurate work Oil Pump Disassembly See Sectional view of model RD engine oil pump Fig 31 l Remove cotter pin holding float to oil pump Remove float from pump 2 Remove six capscrews and lockwashers from oil pump body cover and lift cover and gaskets from oil pump body 3 Lift out oil pump idler gear from idler gear shaft After removing oil pump drive gear shaft guide from top of shaft use small punch to drive out spiral gear pin from oilpump spiralgear Using anadapt er collar which fits underneath the spiral gear and an adapter with a tang which will fit down into the slot of the oil pump drive PRINTED IN UNITED STATES OF AMERICA PIN SPIRAL
71. ace shaft Check crankshaft for ful not to damage camshaft bearings Be end play which is taken up by No 4 main fore completely entering camshaft rotate PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Red Diamond Section C Page 22 11 l2 n A 2246 Fig 48 shaft until marked teeth on crankshaft gear and camshaft gear index Fig 48 Install two capscrews and lockwashers in camshaft thrust flange working through large holes in camshaft gear Rotate crankshaft and camshaft to determine that gears do not bind or interfere Back lash must be from 000 to 002 0015 pre ferred INSTALL GEAR COVER CASE Place gasket in position on case cover Place crankshaft oil slinger over end of crank shaftand install Woodruff key for fan drive pulley in crankshaft Place gear case cover in position Install capscrews new lockwashers and nuts NOTE Do not tighten gear case capscrews and bolts at this point INSTALL FAN DRIVE PULLEY AND VIBRATION DAMPER Heat crankshaft fan drive pulley and vibration damper assembly in boiling water When heated quickly install assembly on crankshaft and install washer and fan drive pulley nut Tighten nut with wrenchof about 36 lever age Tighten gear case capscrews and bolts By tightening the gear case cover to the engine block after the drive pulley had been installed the pulley has served to align the gear c
72. ach bearing cap Remove all crankshaft main bearing caps Fig 21 After all caps have been removed lift crankshaft straight up and out of cylinder block and place ina vise equipped with soft jaws 6 With crankshaft securely clamped in vise remove the six self locking capscrews holding flywheel to crankshaft Tap fly wheel witha soft hammer to loosen itfrom PRINTED IN UNITED STATES OF AMERICA L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Blue Diamond Section B Page 9 crankshaft remove flywheel withring gear assembly 7 Remove capscrews and lockwashers from engine flywheel housing Drive out the two engine block dowels remove flywheel housing Fig 22 8 Remove fuel pump starter oil pressure regulator valve assembly distributor gen erator oil gauge and coil Bell housing dowel pin TAN Rear main bearing cap xy pu Oil pump to oil B a A gallery connection A A 22144 Fig 21 Flywheel housing Dowel pin holes EA x E 4 D 22146 Fig 22 Water Pump Removal and Overhaul See sectional view of BD Engine water pump Fig 23 The water pump assembly is composed ofa body andcover plate which house a ball bearing mounted pump shaft and impeller The rear and front bearings are pressed onto the shaft and are separated by a spacer A slinger is held in place by two half lock rings The shaft assembly with its two bearings is held in place in the housing by a retaining snap
73. al and Overhaul See sectional view of RD Engine water pump Fig 26 The water pump assembly is composed ofa body andcover plate which house a ball bearing mounted pump shaft and impel ler The rear and front bearings are pressed onto the shaft and are separated by a spacer A slingeris heldin place by two halflock rings The shaft assembly with its two bearings is held in place in the housing by a retaining snap ring The fan pulley is pressed onto the shaft press fit 0007 to 0018 and held in place by a nut and plain washer The impeller seal assembly consists of a seal spring seal clamp ring flexible seal seal ate supp 2 Retainer Wa Een Impeller ring SS T E e LAS CN SN Seal SL _ ie M Fan 24 belts ar Fig 26 PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Red Diamond Section C Page 11 spring guide and a seal carbon washer The parts are held in place in the impeller by a snap ring The impeller and seal assembly is pressed onto the pump shaft press fit of 002 to 0035 Water Pump Disassembly Complete illustrated procedure for Water Pump Servicing is given in Shop Talk No 14 l Remove four capscrews and lockwashers holding fan to pulley Remove fan blade assembly from pulley Remove water pump from front end of cylinder head 2 Remove nut and flat washer holding pulley to wa
74. ase cover Installing Connecting Rods and Pistons La Install one connecting rod and piston as sembly down through top of cylinder block having slotin pistontowards camshaft side of engine Pistons are also marked with an arrow indicating front of engine Usea piston ring compressor sleeve tocompress piston rings and thus avoid possible ring damage Fig 49 Wipe bore of connecting rod free of oil and dirt Place bearing shell upper half in con L LINE MOTOR TRUCK SERVICE MANUAL INTERNATIONAL Y Connecting S rod cap e J g5 Ze ws at Pet A 22462 necting rod bore being sure that oil hole aligns with oil hole in connecting rod and that locking tangs of bearing shell fit into recess Clean connecting rod cap bearing bore and clean back of bearing Fig 50 Place bearing shell lower half in connect ing rod cap Fig 51 making sure that tang of bearing fits into recess in cap NOTE See instructions under Main Bear ing and Connecting Rod Bearing Installa tion Coat bearing surfaces with oil Pull con necting rod into position on crankshaft journal and install connecting rod cap and bearing NOTE Bearing cap must only be installed on connecting rod one way with both con necting rod number and bearing cap number to camshaft side Install two self locking capscrews and tighten to 80 foot pounds use tension wrench 4 rod cap Bearing Bearing tang Re
75. ate the shafts and slide rocker arms springs and brackets from shafts 3j Clean all parts in a solvent cleaning fluid being careful to clean all accumulated sludge and carbon deposits from oil holes and slots Rocker Arm Inspection Carefully inspect all parts for defects and wear l Inspect rocker arm shaft expansion plugs Check on a surface plate for signs ofbend ing check for wear from rocker arms If a shaft is bent or shows perceptible wear it must be replaced 2 Inspect rocker arm adjusting screws for wear atcontactsurfaceandforthread wear Replace worn screws Check rocker arm bushings Inspect valve stem contact pad Press ram Bushing removing tool Press plate Rocker arm E 4 21595 Fig 7 Use SE i036 Bushing Removing Tool when removing the rocker arm bushing Support the rocker arm on the SE 033 support block support block to properly at the same time permit the bushing to clear the support block when being removed Use the support block when Ins stalling and burnishing the new bushing Select a hole in the support the rocker arm surface of rocker arm and resur ace if wear is perceptible Do not remove more than 010 of material when resurfacing rocker arm pads 3 Inspect tension springs for breakage or loss oftension Replace defective springs Remove valve lifter rods from engine Press ram Bushing installing tool Rocker arm Press
76. b merge vibration damper assembly in hot cleaning solvents 6 Inspect crankshaft fan drive pulley for wear in hub bore If inner diameter of bore is worn scored or Woodruff key way damaged replace pulley 7 Inspect engine gear case cover and re place if cracked or broken Remove old cover seal Fig 62 and with specialdriver install new seal Fig 63 E e TJ erit E Ee nd XA i aP Punch RM medii Cover seal Timing gear ca E cover Gear cover E ous A 21896 Fig 63 Use SE 1718 Seal Installing tool with the SE 1581 B Handle 8 Check each of 12 engine valve tappets for irregular wear chipping cracking Or scores Replace defective tappets A d IN 9 Inspect engine flywheel housing for cracks or breakage and replace if damaged In spect flywheel housing to crankcase pilot dowel holes for wear If wear is evident drill or ream the holes and install over size dowels Also inspect dowels for wear and replace if wear is evident 10 Inspect all capscrews and nuts for thread wear or breakage and replace as neces sary Use new lockwashers when reas sembling engine 11 All gaskets and oil seals must be replaced at each overhaul or major repair ASSEMBLY OF ENGINE When all parts have been cleaned in spected and repaired and necessary replace ment parts have been procured install engine cylinder block in engine overhaul stand for re assembly
77. cess Connecting BE A rn A 22465 Fig 5l To check connecting rod bearingto crank shaft clearance follow procedure given for plastigage or virgin lead test Speci fied connecting rod bearing to crankshaft clearance is from 0012 to 0037 Do not attempt to file connecting rods or bearing caps Follow procedure outlined in steps above for remaining connecting rods and pistons INSTALL CLUTCH Install clutch driven disc against flywheel so that the long por tion of the hub is toward the rear Place clutch in position on flywheel over clutch driven disc Locate clutch so that arrow or inspection mark usually a dab of white paint on flange of clutch backing plate or Cover is as near as possible to the letter UL on the flywheel and install two or three mounting capscrews and lockwashers loosely Inserta clutch aligning arbor if available or a transmission main drive gear shaft through clutch driven disc hub spline and into clutch pilot bearings Hold clutch driven disc in position while com pleting installation of twelve mounting cap screws and lockwashers in flange of clutch backing plate or cover Tighten all twelve capscrews alternately evenly and securely Remove threeretaining capscrews and flat washers which wereinstalled to hold clutch compressed Fig 52 NOTE Clutch will not operate properly unless these retain ing capscrews are removed INSTALL VALVE LIFTER ROD COVER Install new gasket ov
78. circuit wiring This includes coil wire starter cable engine ground strap and instrument sender unit wires 4 Disconnect fuel line at fuel pump Discon nect throttle control linkage and remove choke at carburetor 5 Disconnect clutch linkage at bell housing 6 Remove engine rear mounting bolts from both sides of engine support pads 7 Remove engine front mounting bolts from support bracket these are the bolts at the front crossmember 8 Remove radiator mounting bolts and lift out radiator support and core assembly 9 Disconnect engine exhaust pipe at mani fold 10 Attach engine sling to front and rear right side cylinder head bolts and remove en gine Fig 4 TTE Ge E my Dr inia H Eo o M ur ELLA iting sling E EDS V 162 Chain Fig 4 Removing engine from chassis sling attached to front and rear right sidecyl inder head bolts PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Blue Diamond Section B Page 3 ENGINE DISASSEMBLY Install the engine ina suitable rotating en gine overhaul stand NOTE Many of the dis assembly operations can be performed with the engine in the chassis However the following disassembly outline is performed with the en gine removed from thechassis to clearlyillus trate eachof the units Except where indicated no attempt has been made to pr
79. cker arm shaft Rocker arm cover Sleeve dowel F lt Cover gasket Jd Valve guide Valve Valve seat Push rod Piston Connecting rod A 21930 Fig 3 Sectional view through engine showing details of valve mechanism PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond Section A Page 4 L LINE MOTOR TRUCK SERVICE MANUAL MA A AN N INTERNATIONAL V 4 The cylinder block and crankcase are cast in one piece and carry the crankshaft main bearings Water circulation pas sages completely surround the cylinders in the crankcase and also provide coolant to the cylinder head 5 Oilis supplied under pressure by the oil pump to the engine lubrication system Oil spray from the revolving cranksahft is distributed to the cylinder walls pistons and other moving parts inside the engine 6 Exhaust valve seats are of alloy and are pressed into place Fig 3 These valve seats lengthen the period between valve reconditioning operations Valves and valve seats are cooled by continuous cir culation of water through the cylinder head 7 The detachable cylinder head is bolted to the crankcase anda gastight and water tight seal is maintained by means ofa gasket 8 The crankshaft is a drop forging of heat treated steel Itis counterweighted bal anced both statically and dynamically and ground to clos
80. cking E an s bots WF A 21946 Fig 30 Remove self locking capscrews to re move flywheel 7 Remove six capscrews and lockwashers from engine flywheel housing Drive out the two engine block dowels remove fly wheel housing 8 Remove fuel pump starter oil pressure regulator valve assembly distributor generator oil gauge coil and all freeze plugs in block NOTE Removal of the freeze plugs or core hole plugs is only necessary when itis determined that the condition of the water passages in the block warrant a thorough cleaning or the plugs appear to be leaking Clean inside and outside of block with a solvent cleaner or steam Install core plugs using SE 1725 Adapter and SE 1581 1B Handle Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond Section A Page 12 L LINE MOTOR TRUCK SERVICE MANUAL Water Pump Removal and Overhaul The water pump isof the centrifugal pack less type Fig 31 It is bolted to the front end of the engine and is driven by the fan pulley It requires no external adjustment The bear ing is of the sealed lubricated type and does not require added lubrication at any time The water pump is driven by a V belt on the fan pulley The pump by means of centrifugal force developed by the impeller rotation draws water up from the lower part of the radiator into the water passages in the cylinder block and cylinder head The water circulates thr
81. ct all parts for defects and wear l Inspect rocker arm shaft and expansion plugs Check on a surface plate for signs of bending check for wear from rocker arms Ifa shaft is bent or shows percep tible wear it must be replaced Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Red Diamond Section C Page 4 L LINE MOTOR TRUCK SERVICE MANUAL 2 Inspect rocker arm adjusting screws for wear at contact surface and for thread wear Replace worn screws Check rocker arm bushings Inspect valve stem contact pad surface of rocker arm and resurface if wear is perceptible Do not remove more than 010 of material when resurfacing rocker arm pads 3 Inspect tension springs for breakage or loss of tension Replace defective springs Re Bushing Rocker Arms With properly fitting adapter of special tool equipment provided Figs 5 6 and 7 press old rocker arm bushing from rocker arm Place new rocker arm bushing in posi tion Align oil hole in bushing with oil hole in rocker arm which is located approximately 30 from top of rocker arm toward rocker arm adjusting nut Using installing tool press new bushing into rocker arm Burnish bushing into place in the rocker arm them ream rocker arm bushing to provide 0015 to 004 clear ance Ream dimension is 8745 8760 Press ram Bushing removing tool Rocker arm cota LE A o0 M A 21895 Fig 5 Use SE 1036 2 Bushing Removing
82. d Section C Page 5 2 Invert cylinder head their original location 3 Scrapeall carbon from cylinder head com bustion chamber and clean any gasket Clean the headusing steam cleaning or other suitable material from surface o head cleaning equipment 4 Clean allcarbon deposits from valve heads Wash allvalve springs and retainers in cleaning and valve stems with wire brush solvent Inspection of Cylinder Head l Inspect cylinder head visually for signs of x d e AS AR 2s M32 Minimum seat Preferred Preferred l g Maximum seat A 22610 Fig 9 Valve Seat Widths Exhaust PRINTED IN UNITED STATES OF AMERICA Remove all valves from their valve guides and from the head keeping each valve ina suitable rack which will assure replacement of the valves in cracks or sand holes and if found defec tive weld or replace head Inspect exhaust valveseat rings for loose ness and inspect for excessive width of valve seat surface Fig 9 If insert rings are loose replace If a seat has been pre viously ground to such extent thatit cannot be narrowed from top to bring to proper position near center of valve face the ring must be replaced Inspection of Valve Guides Valve Springs and ls Valves Clean valve guides with a suitable cleaning tool Fig 10 Check each valve guide with a Go and No Go gauge Fig 11 if avail able otherwise u
83. des Press ram Valve guide replacer Valve guide T head o NN A 20 A 21926 Fig 18 Using SE 1723 Guide replacer Push guide down until tool bottoms on head Donated by John amp Susan Hansen For Personal Use Only DADA sa BHO L LINE MOTOR TRUCK SERVICE MANUAL Bi er VW V Page 9 Valve Seat Widths In general the width of exhaust seat should range between the average and maximum spec ifications and the intake seats between the minimum and average specifications The in take seats may be narrower than the exhaust because they are usually larger in diameter thus providing a total seat area approximately equal to smaller exhaust valve with the wider seat Also the less severe heat conditions do not require as large a seat area for heat dissi pation purposes There are also objections to an excessive ly wide seat a few of which are as follows 1 In city or light delivery service a wide seat collects carbon and particles of dirt that will produce variations or loss of compression resulting in poor idle and possibly a loss of general performance and economy 2 A wide seat in severe service operating in the presence of dirt or an excess of car bon will produce a badly pitted seat which may be just as detrimental to valve life as a too narrow seat Under these conditions a seat width to the minimum limit would possible be better however the source of trouble which is the dirt and excessive ca
84. e cartridge When the cartridge is changed the cartridge and sump quickly and easily lift out as a single unit Change filter cartridge and clean sump at regularly es tablished periods according to operating conditions 3 When reassembling filter unit after com plete disassembly tighten center tube nut securely using wrench SE 1728 CRANKCASE VENTILA TION The BD engine has a crankcase ventilator metering valve installed at the rear left side of engine on the tappet cover To remove valve disconnect the vacuum line and unscrew unit from tappet cover plate To service separate the two halves of the unit and remove weight Clean all parts thoroughly When reinstalling the valve make sure the arrow on the housing is pointed up Fig 44 Large section of metering 72 pin in orifice 4 restricts flow of air Upper Metering orifice Small section of metering pin in orifice Lower housing Position of weight with high manifold vacuum above 3 to 442 inches mercury 23449 Fig 44 Position of weight with low manifold vacuum below 3 to 4 inches mercury Gasket Handle Sump bail Center tube Return channel d SESS 4 SS SS SS SS SN AY Sump handle id A Connection Y A hn A i Ny Ye vi A Metering inlet e tN Y ISS Yl EN Y NM D A Y BE SP E uei Eeer Relief valve spring Plug ee ZZ LA CA MT So d Ge KA Stu
85. e bore lo accomplish this the bearing manufacturer makes the diameterat right angles to the part ing line slightlylarger than the actual diameter of the bore into which they are assembled When the assembly is drawn up tight the bear ing is compressed assuring a good contact PRINTED IN UNITED STATES OF AMERICA L LINE MOIOR TRUCK SERVICE MANUAL Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Blue Diamond Section B Page 17 between the bearing back and the bore This increased diameter is referred to as bearing crush Fig 35 Difference between diameters and B is bearing crush C With bearing cap drawn up tight diameters and B are equal Diameter at right angles to parting lines greater than diameter B A 22550 Fig 35 To obtain proper bearing assembly with the correct crush care must be taken when tightening the clamping bolts to make sure they are drawn down alternately and evenly using a tension wrench and tightening as specified As a result of excessive bearing crush due to reworking the caps the rod or main bearing bore will possible become distorted because more force is required to draw the cap and housing together Rods caps or blocks must not be filed lapped or in any other manner reworked in order to reduce clearance While suchpractice will make a tighter fit at top and bottom it will result in an out of round bore and bearing s
86. e limits The shaft is mounted in four precision type replace able shell bearings the number three bearing taking up the thrust 9 The pistons are made of an aluminum al loy are cam ground and are fitted with three compression rings and one oil con trol ring The full floating type piston pins are held in place in the pistons at the ends of the pins by snap rings 10 The camshaft is machined from a solid drop forging and mounted in four special replaceable bearings 1l The flywheel is bolted and doweled to the crankshaft flange The timing mark is lo cated on the flywheel ENGINE REMOVAL The engine with transmission removed can be lifted from chassis without disturbing the fender and grille assembly by using a suit able chain sling and a floor crane Fig 4 Dis connect the following electrical circuits hose connections and various units as outlined l Drain engine oil pan Drain all coolant from engine cooling system by opening the drain cock on side of engine as well as the radiator drain cock A 21888 Fig Y Removing Silver Diamond Engine 2 Disconnect upper and lower radiator hose connections 3 Disconnect engine circuit wiring This includes coil wire starter cable engine ground strap and instrument sender unit wires 4 Disconnect fuel line at fuel pump Discon nect throttle control linkage at left side of engine and remove choke at carburetor 5 Disconnect clutch linkage at
87. e pilot dowel holes for wear If wear is evident drill or ream the holes and install over size dowels Also inspect dowels for wear and replace if wear is evident Inspect all capscrews and nuts for thread wear or breakage and replace as neces sary Use newlockwashers when reassem bling engine All gaskets and oil sales must be replaced at each overhaul or major repair ASSEMBLY OF ENGINE Whenall parts have been cleaned inspected and repaired and necessary replacement parts have been procured install engine cylinder block in engine overhaul stand for reassembly Main Bearing and Connecting Rod Bearing alignment with the crankshaft journals Installation It is essential that main bearings be in The model BD engines do not have the bearing caps piloted in the crankcase When no means of piloting the bearing caps has been provided misalignment is possible due to a slight shift ing of the bearing caps when the bearing cap bolts are tightened If a bearing cap bolt is not straight or if the threads are not concentric with the body of the bolt this condition will be aggravated therefore all bolts should be care fully examined before installation to avoid such a condition The following method has proved success ful in holding the caps and bearings in align ment with the crankshaft After bearings have been fitted to specified clearances remove the caps and apply a coating of petrolatum or white
88. e that valve springs can be installed with either end toward the cylinder head Remove all valve springs as outlined and remove valve spring damper rom each spring Fig 15 0 n ae A 21907 Retainer Damper A 21939 Fig 15 Dampers are used at all the valves Assemble damper spring and retainer as shown 2 Invert cylinder head Remove all valves from their valve guides and from the head 3 Scrape all carbon from cylinder head combustion chamber and clean any gasket material from surface of head Clean the head using steam cleaning or other suit able cleaning equipment 4 Clean all carbon deposits from valve heads and valve stems witha wire brush Wash all valve springs and retainers in clean ing solvent Inspection of Cylinder Head 1 Inspect cylinder head visually for signs of cracks or sand holes If found defective weld or replace head PRINTEO IN UNITED STATES OF AMERICA ness and inspect for excessive width of valve seat surface If rings are loose re place If a seat has been previously ground to such extent that it cannot be narrowed from top to bring to proper position near center of valve face the ring must be re places Inspection of Valve Guides Valve Springs and Valves l Clean valve guides with a suitable clean ing tool Check each valve guide with a Go and No Go gauge if available other wise use a new valve to check fit If No Go portion of gauge enters t
89. ect camshaft gear and replace if wear is evident or gear teeth are nicked or otherwise damaged 7 To reassemble install thrust flange over end of camshaft Install Woodruff key in slot in shaft Place camshaft gear in boil ing Water or piston heater and install over Woodruff key Install camshaft nut and tighten to approximately 120 foot pounds tension Cleaning and Inspecting Miscellaneous Parts l Cleaning miscellaneous engine parts in cludes brackets oil pan engine case cover flywheel housing and other parts that were removed during disassembly of en gine and were not covered by procedure Wash in cleaning solvent or steam clean preliminary to inspection 2 Check all twelve valve lifter or push rods for straightness by rolling on flat surface Replace any that are bent or have loose ends Fig 61 Bent push rod em ier zm A o n ae Flat surface A 21892 Fig 6l 3 Inspect oil pan for cracks or deep bends and straighten or weld 4 Inspect oil pan drain plug and drain plug boss for fit and thread wear If plug is loose or threads are damaged replace plug If threads in oil pan boss are worn or damaged repair threads or replace oil pan 5 Inspect crankshaft vibration damper for evidence of rubber coming loose from steel plates SD 240 engines only and in spect for wear Replace damper if either condition is encountered Do not su
90. ed that oil holes inbearing shells line up with oil holes in cylinderblock and that locking tongs on bearings fit into re cesses Follow same procedure place bearing shell cap halves in bearing caps Place a film of engine oil on bearing shell surfaces and lift crankshaft to align itself in the bearings and also provide lubrica tion Place bearing caps andbearing lower halves over crankshaft journals Be sure bearing caps are properly installed with numbers to camshaft L LINE MOTOR TRUCK SERVICE MANUAL Vd O D OF BEARING WHEN INSTALLED IS THE SAME AS THE DIA OF THE CRANKCASE OR CONN ROD BORE SPREAD OF BEARING BEFORE INSTALLATION di fi A 16088 Fig 36 SOFT MALLET STRIKE LIGHTLY AND SQUARELY BEARING WOOD BLOCK Fe EL D XXX OMT dee ie Lie LT OP s ene s ES LOLLES SOFT MALLET STRIKE LIGHTLY AND SQUARELY BEARING WOOD BLOCK TARO VILA OSS TERR Y ARA y INCREASING SPREAD A 16095 Fig 37 4 INTERNATIONAL Ni N In order thatan accurate measurement can be made to check allbearing clearances a material similar to plastigage or virgin lead can be used Use the following instructions when using plastigage A Remove oil from bearing cap insert and exposed halt of crankshaft journal B Place a piece of plastigage the full width of the bearing insert C Reinstall the
91. en up by number three main bearing End clearance should be from 0055 to 0135 Rear main bearing seal compressing tool EE AME A 21567 Fig 68 Installing upper oil seal in crank case using SE 1720 Rear Main Bearing Oil seal compressor e 5 Before installing rear main bearing cap after all bearing clearances have been checked install upper seal in block Use special tool to press or roll seal in place Fig 68 After seal has been seated in PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL 9 INSTALL CAMSHAFT AND GEAR ENGINES Silver Diamond Section A Page 23 block trim ends of seal that project above cap surface level Repeat the same oper ation with main bearing cap Install wick ing on each side of rear main bearing cap Fig 69 Tighten all main bearing cap bolts to 80 foot pounds Hammer E Punch Wicking gt y ZA ZE Fig 69 Pack wicking securely using punch to work wicking into holes provided 6 INSTALL FLYWHEEL HOUSING Place flywheel housing in position over two fly wheel housing to cylinder block dowels and tap into place with soft hammer In stall six capscrews and lockwashers in flywheel housing If either block or fly wheel housing is replaced the flywheel housing will have to be aligned with a dial indicator When correctly aligned run out of bore should
92. engine the timing should be 6 Ifnew engine oildiscolors toorapidly after checked with a timing light and the timing the filter element has been replaced it mark and pointer should be in register as may indicate that the pressure valve in indicated for the best engine performance the center tube is not functioning and the Two marks are located on the crankshaft pul oilis not going through the element Re ley One marked with an O indicates top move the complete filter unit from the en dead center T D C and the other mark shows gine and wash the parts with cleaning 5 before top dead center T D C solvent 7 Avoid using a wrench on the filter cover handle If the cover cannot be drawn down by hand tight enough to prevent oil leakage it is necessary to replace the gasket CRANKCASE VENTILATION 1 The RD engine has a crankcase ventilator metering valve installed at the oil filler pipe The purpose of the crankcase venti lator metering valve which is connected to the intake manifold by a vacuum line is to control the amount of fumes and vapors drawn from the crankcase by the intake manifold vacuum The operation of the crankcase ventilation system consists of drawing cleaned air into the engine and withdrawing the fumes fromthe crankcase 2 CRANKCASE VENTILATOR METERING VALVE To remove the ventilator meter ing valve disconnectthe vacuum line lead ing to the intake manifold Unscrew the ventilator metering valve unit from
93. eplacement is neces Sary remove and install new bushings with special camshaft bearing installation tool Fig 52 No reaming is required Bushing arbors Adapter sleeve Draw bar A 2 2149 Camshaft bushings Fig 52 SE 1724 Camshaft bushing installation Showing tool in position Connecting Rod and Piston 1 Remove piston pin retainers from each piston and remove piston rings from pis ton ring grooves 2 Heat pistonin boiling wateror piston heat er Place piston in piston vise and using pin driving tool drive piston pin from piston and connecting rod Fig 53 After piston pin is removed lift piston from connecting rod LG hin ts driver Piston Soft hammer Piston pin Piston vise M A 22205 Fig 53 Use suitable piston vise to hold pis ton and drive piston pin out using SE 1263 Use soft bronze or brass hammer when driving to prevent damage to tools Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond Section A Page 18 L LINE MOTOR TRUCK SERVICE MANUAL AL 3 Wash allparts ina cleaning solvent CAU TION Do not use a caustic solution for aluminum pistons Clean the carbon from piston ring grooves with a broken ring or ring groove cleaner 4 Inspect connecting rods caps and bearing shells All connecting rod bearings and piston pin bushings should be replaced at every major overhaul Test rods for align ment Rods only slight
94. er opening at left hand side of engine block Install valve lifter rod cover and six capscrews and copper washers PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL l ENGINES Super Red Diamond Section C Page 23 Cover plate 3 3 Ki For assembly only Cover retainer capscrews A 21578 Fig 52 Install Cylinder Head INSTALL HEAD Place gasket on cylinder block and align bolt holes Place cylinder head on crankcase being careful not to damage or shift gasket position Loosely install all cylinder head bolts and flat washers omitting rocker arm oil feeding bolt Tighten alternately and evenly in sequence to 105 foot pounds INSTALL VALVE ROCKER ARM ASSEM BLY Insert twelve valve lifter rods in cylinder head make sure they enter the valve tappet Lift the valve rocker arm assembly into position on cylinder head Install rocker arm oil feeding bolt six 3 8 SAE nuts on hole down bracket studs and six hold down bracket capscrews Be sure to place stud with the oil hole in the left third from rear cylinder head bolt hole and tighten to 105 foot pounds Re tighten cylinder headafter engine has been operated fora short period Install oil pan making sure all gasket joints are leak proof See Fig 53 OIL PAN SIDE Fig 53 Donated by John amp Susan Hansen For Personal Use Only ENGINES Super
95. erweighted bal anced both statically and dynamically and ground to close limits The shaft is mounted in seven precision type replace able shell bearings the number seven rear bearing taking up the thrust The rear main bearing is made up of two shell halves together with four thrust flanges The two lower thrust flanges are held in position by dowels inthe main bearing cap 9 The pistons are made of an aluminum al loy are cam ground and are fitted with three compression rings and one oil con trol ring The full floating type piston pins are held in place in the pistons at the ends of the pins by snap rings 10 The camshaft is machined from a solid drop forging and mounted in four special replaceable bearings 11 The flywheel is bolted and doweled to the crankshaft flange The timing mark is located on the front crankshaft pulley ENGINE REMOVAL Disconnect the following electrical cir cuits hose connections and various units as outlined l Drain engine oil pan Drain all coolant from engine cooling system by opening the drain cock on side of engine as well as the radiator drain cock Remove radiator filler cap when draining cooling system 2 Disconnect upper and lower radiator hose connections Disconnect engineair cleaner and remove air cleaner Disconnect vac uum line at manifold Air line at com pressor when vehicle is equipped with air brakes l 3 Disconnect engine circuit wiring This includ
96. es which actas oil reservoirs or retainers of oil while the surface betweenthe grooves provides a load bearing surface If the scratches are too deep and too close together the surface is referred to as rough and will not provide adequate ring and piston contact area which results in fast wear Should the finish be high ly polished or too smooth the scratches or grooves are shallow and will have insufficient oil retaining capacity to provide adequate lu brication for the adjacent contact or load bearing area and will result in scuffing or scoring Itis therefore advantageous to strike a happy medium by removing only the sharp peaks of these microscopic ridges and in this way still reap the benefits of the oil retaining grooves This type of cylinder wall surface is obtained through exercise of care in finish ing operation and through proper use of equip ment CAUTION Extreme care must be taken to assure that no abrasive remains in the engine after the finish honing operation After engine has been reassembled it should be allowed to run in for two or three hours ata fastidle approximately 1200 r p m PRINTED IN UNITED STATES OF AMERICA Replacing Camshaft Bushings If camshaft bearing replacement is neces sary remove and install new bushings with special camshaft bearing installation tool No reaming is required Fig 33 illustrates the use of camshaft bearing installing tool Connecting Rod and Piston
97. es coil wire starter cable engine ground strap and instrument sender unit wires 4 Disconnect fuel line at fuel pump Discon nect throttle control linkage and remove choke wire at carburetor 5 Remove hood and floor boards Remove fenders and radiator grille as a unit 6 Remove radiator mounting bolts and lift out radiator support and core assembly 7 Remove ending front mounting bolts from support bracket These are the bolts at the front crossmember 8 Support transmission using floor jack or suitable blocking Remove capscrews from around bell housing 9 Disconnectengine exhaust pipe at manifold 10 Attach engine sling to front and rear right side cylinder head bolts and remove en gine ENGINE DISASSEMBLY Install the engine ina suitable rotating en gine overhaul stand NOTE Many of the dis assembly operations canbe performed with the engine in the chassis However the following disassembly outline is performed with the en gine removed from the chassis to clearly illus trate each ofthe units Except where indicated no attempt has been made to prescribe a par ticular sequence for removing the various units since some can be readily removed with the engine in the chassis The extent of the service required on a particular unit will gov ern the necessity for its removal Removing Rocker Arms The following steps are to be followed when removing the rocker arm cover and rocker arm assembly Carb
98. escribe a par ticular sequence for removing the various units since some can be readily removed with the engine in the chassis The extent of the serv ice required on a particular unit will govern the necessity for its removal Removing Rocker Arms The following steps areto befollowed when removing the rocker arm cover and rocker arm assembly Carburetor and air cleaner previously removed l Remove three nuts from rocker arm cover Remove air cleaner line and remove cover 2 Remove bolts from shaft brackets Fig 5 NOTE Left front head bolt supplies oil to rocker arms Rocker arm bracket ME A 22220 Fig 5 3 Remove rocker arm assembly as a unit Rocker Arm and Valve Mechanism Disassambly l The rocker arm assembly is composed of front and rear shafts joined at the center on which are mounted twelve rocker arms and six tension springs The shafts are mounted in seven brackets and are pre vented from turning at the two end brack ets by slots in the shaft into which the cylinder head bolts fit Fig 6 Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Blue Diamond Section B Page 4 L LINE MOTOR TRUCK SERVICE MANUAL Exhaust valve rocker arm Front rocker arm shaft Shaft bracket Oil connection bracket Rocker arm adjusting nuts A 22207 Intake valve rocker arm Spacers End bracket Fig 6 Details of rocker arm assembly 2 Separ
99. experienced in reconditioning valves is obtaining nearly identical angles on the valve seat and valve face The importance of these angles in the grinding operation cannot be overemphasized because itis impossible to produce a flat or square seat by lapping The grinding stones on both the valve re facing machine and valve seat grinder should be dressed before starting a reconditioning job You will be unable to determine how closely the angle of the seat will match the valve face until the valve and seat have been ground and a check made with a very light tint of Prussian blue If a full seat width contact around the entire circle of seated valve is not shown the angles do not match It will then be necessary to redress the valve seat grinding stones changing the angle sufficiently to correct the error The correction should be made on the valve seat and not on the valve No more material should be removed from the valve face than is necessary to true it up and remove the burned or pitted portion New valves should not be refaced but should be checked for true ness When a satisfactory match of valve seat and valve face angles has been obtained the adjustment of both the valve refacer and the seat grinder should be locked in position in order to eliminate this trial by error method on additional valves having the same angle Valve Seats The primary purpose of a valve seatis to seal the combustion chamber against pressure los
100. gasket in place on cylinder block Install four capscrews and lockwashers in oil filter base NOTE Be sure filter assembly is thoroughly cleaned and a new cartridge is installed before replacement on engine Tighten center tube nut using wrench SE 1728 INSTALL ACCESSORIES Install carbu retor generator distributor and connect ing wires starter fuel pump ignition coil oil gauge and thermostat FILL ENGINE WITH OIL After making certain that oil drain plug is securely in stalled fill crankcase with oil After en gine has been installed and placed in oper ation again recheck oil level and if neces sary add sufficient oil to bring level up to full mark on gauge INSTALL CYLINDER HEAD COVER If engine is not to be installed at this time install new cylinder head cover gasket and install cylinder head cover Install three flat copper washers and three capscrews on cover Gasket Handle Gasket a 7 m aC A 4 NND 7 GEN A F a Dz 9 y Y i d Cartridge s y Sump bail H n KA CG A Center tube Return channel de f SSS 1 lt Shell Sum handle Connection 4 SONNE EER A PS K eb S E TQ NE AA e Mf v7 SESSA NENA gt 7 E i d Y Mile ADS XN 277 A ZLI SZZ v N ELA TILA Base SS 277 Relief valve spring Plug uw SU o X k SS
101. gearif teeth are worn or damaged NOTE Replace timing gear on camshaft when replacing crankshaft gear These gears are provided in matched sets Install Woodruff key in groove in crank Shaft Heatcrankshaftgearin boiling water orpiston heater This willexpand the gear enough to allow it to be tapped onto the crankshaft without the danger of damaging the gear A special crankshaft gear in stalling tool is available Flywheel and Ring Gear Inspection l Clean flywheel and ring gear with a clean ing solvent remove all traces of oil and grease Inspectthe flywheel ring gear If any teeth are damaged or if ring gear is loose on flywheel the ring gear must be replaced Checkthe flywheel dowel holes and mount ing bolt holes for wear also check for fly wheel having been loose Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Red Diamond Section C Page 18 4 To replace flywheel ring gear heat gear with torch and remove from flywheel with a hammer and drift Heat new ring gear with torch heating evenly all the way around While the ring gear is hot install gear on flywheel and allow it to cool 5 Check pilot bearing in flywheel for wear or damage and replace if needed 6 Install flywheel on crankshaft Install six self locking capscrews drive dowel pins through flywheel to cranksha t Tighten to 155 foot pounds Camshaft Cleaning and Inspection l Wash camshaft in cleaning solve
102. haft one third revolution and adjust clearance on No 5 valves Working in firing order sequence continue to set valves of each of the remaining cylinders turning crankshaft one third turn after each valve adjustment 222005 EL ids 5 INSTALL INTAKE AND EXHAUST MAN IFOLDS To facilitate installing the mani folds after manifold gaskets and pilot rings are installed start capscrews at each end of intake manifold This will permit the Donated by John amp Susan Hansen For Personal Use Only ENGINES ea Howe L LINE MOTOR TRUCK SERVICE MANUAL ES Page 26 A AV 10 manifold to slide straight up between the engine head and capscrews and flat wash ers When manifold is lined up with pilot rings and gasket tilt bottom of manifold toward engine block This will force man ifold out at top enough to bind against the two capscrews and hold manifold in posi tion until the front and rearcapscrews can be installed Fig 76 no EISE en SCH gt m E v D 4 Syd bien TEE A a TR ERE E 3 tma n4 gt ed et ER a d CIL Tr i Mounting capscrew jle Jk Mounting capscrew VNDE EST XXE o E ERA RAS Exhaust manifold bh mE A 22209 Fig 76 INSTALL WATER PUMP Place water pump gasket in position at water pump opening in front of cylinder head Install water pump and fan and installfour cap screws and lockwashers in pump and cyl inder block INSTALL OIL FILTER Place oil filter and new
103. he guide must be replaced Recommended valve stem to valve guide clearance is from 0015 to 0035 for intake valves and from 002 to 004 for exhaust valves Clearance in excess of 006 for intake valves or 008 for exhaust valves require guide replace ment Valve guides are reamed to 3743 3758 after assembly in cylinder head 2 Test valve springs with damper in posi tion Test tension of each valve spring at valve open length with a valve spring test er Fig 16 Check valve springs at 1 11 16 length and replace if pressure is less than 149 lbs Scale inches Valve spring vb bd AU M REN H s aly stas O cmm ctm ya m ate Scale pounds aum A 21890 Fig 16 Use SE 1565 Valve spring testing tool or similar tool to check spring tension 3 Inspect eachvalve for warpage for severe ly burned condition and for excessive grinding on the valve head Inspect valve stem for scuff marks or perceptible wear Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond Section A Page 8 Inspect valve stem end for wear at contact surface with valve rocker arm If valve is warped excessively burned or has been previously ground to extent that valve head is thin at edge replace valve otherwise valve can be reconditioned and reinstalled Repair of Cylinder Head l If cylinder head has to be resurfaced re move only enough material to true up surface 2
104. heel ring gear If any teeth are damaged or if ring gear is loose on flywheel the ring gear must be replaced 3 Check the flywheel dowel holes and mount ing bolt holes for wear also check for flywheel having been loose 4 To replace flywheel ring gear heat gear with torch and remove from flywheel with a hammer and drift Heatnew ring gear with torch heating evenly all the way around While the ring gear is hot install gear on flywheel and allow it to cool 5 Check pilot bearing in flywheel for wear or damage and replace if needed 6 Install fly wheel on crankshaft Install six self locking capscrews drive dowel pins through flywheel to crankshaft Camshaft Cleaning and Inspection 1 Remove nut from front of camshaft gear Attach gear puller and remove camshaft gear from camshaft and remove cam shaft thrust flange Remove Woodruff key Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond Section A Page 20 L LINE MOTOR TRUCK SERVICE MANUAL AMM INTERNATIONAL 2 Wash parts in cleaning solvent brushing to facilitate removal of all sludge or car bon deposits 3 Inspect camshaft journals for signs of wear or out of round 4 Inspect oil pump drive gear in center of shaft If teeth are worn or damaged the camshaft must be replaced as the gear is integral with shaft 5 Inspect camshaft lobes If worn chipped or scored replace the camshaft 6 Insp
105. hell distortion New bearing shells will have to be installed eventually and thatis when addi tional trouble starts In general a visual inspection of the part ing faces of the rod or caps under a magnifying glass will provide sufficient proof of any attempt at reworking Under the glass the parting line surface of standard parts will show the manufacturing cutter tool marks and will not have a polished or extremely smooth appear ance On the other hand reworked parts will have a polished surface and if a file was used will show the even pattern of the file teeth Seriousness of this condition is in direct pro portion to the amount of reworking BEARING SPREAD Main and connecting rod bearings are designed with the spread width across the open ends slightly greater than the diameter of the crankcase bore or con necting rod bore into which they are assemblied For example the width across the open ends of the BD engine connecting rod bearing not in Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Blue Diamond Section B Page 18 place is approximately 025 more than when the bearing is in position in the rod This condi tion causes the bearing to fit snugly in the rod bore and the bearing must be snapped or lightly forced into its seat Fig 36 Rough handling in shipment storage or normal results of use in an engine may cause the bearing spread tobe increased or decreased from the
106. hould be 016 to 026 Fig 40 Piston Ring Installation l Before installing rings in glazed cylinder bores a surface hone should be passed through the bores to remove the glaze and minor irregularities This should only be done provided a thorough job of cleaning the grit and abrasives from the engine is performed after the honing operation IMPORTANT if the engine is not thor oughly cleaned after surface honing the benefits are more than offset by damage caused by the remaining gritandabrasives When installing piston rings in piston grooves be careful not to distort rings If possible use a suitable piston ring ex pander tool Fig 41 Also check new piston rings in piston ring grooves for clearance between ring and ring lands The correct ring clearance is shown in specifications Crankshaft Cleaning and Inspection m 2 Wash and clean crankshaft with cleaning solvent or steam Inspect main bearing and connecting rod journals for wear If journals show wear or out of round in excess of 003 the shaft should be either reground and under size bearings installed or replaced Use micrometers for checking PRINTED N UNITED STATES OF AMERICA Piston ring expander A 21566 Fig 41 installing piston ring using SE 1149 6 Ring Installing Tool 3 Check crankshaft and flywheel dowels for damage and fit and replace if worn or damaged Examine crankshaft timing gear teeth and replace
107. iameter Bearing clearance Crankshaft end play Thrust taken by Hardening method Main bearing bolt ten sion ft lbs CAMSHAF T Camshaft journal dia meter SD 220 6 3 9 16 3 11 16 220 50 30 4 100 0 3600 90 3600 173 5 2000 167 1200 3600 6 8 153624 7 607 673 2 148 2 749 2 3713 2 374 0010 0040 005 013 rear interm through 75 85 2 109 2 110 2 089 2 090 Donated by John amp Susan Hansen For Personal Use Only ENGINE SPECIFICATIONS SD 240 6 3 9 16 4 1 64 240 30 30 4 108 3600 93 3400 191 9 1400 186 1100 3400 6 5 153624 D 607 673 2 148 2 149 2 313 2 374 0010 0040 005 013 rear interm through 75 85 2 109 2 110 2 089 2 090 BD 269 6 3 9 16 4 1 2 269 10 30 4 100 5 3000 88 6 2800 222 0 1600 216 5 1000 3000 6 3 153624 7 781 874 2 7005 2 1015 2 122 2 163 0013 0043 0055 0135 rear through 100 110 1 81 1 812 1 577 1 578 RD 372 6 4 3 8 4 1 8 372 06 45 9 143 8 3200 128 2850 282 5 1600 280 0 1000 2850 6 3 153624 9 937 1047 3 2495 3 2505 2 151 Ls AA 0013 0043 004 2 012 rear tocco 100 110 2 109 s110 2 089 2 090 6 4 3 8 4 1 2 405 89 45 9 154 2 3200 138 2750 319 0 1200 313
108. il pamp overhaul i4 4 x Hw wx 3 8 Y ox ac ME ROCKET BETIS as AA TP MT TT che Timing gears and camshaft Ke amp ee ee EIER E eee ee ee TEVE x9 Water pump overhaul ss sss o 6 bs 3 35 Tr TULIT REPAIR OF SUB ASSEMBLIES AND ASSEMBLING Camshaft bushings ee ee eee ee ee ee KON WR ov FW S ER S P Connecting rods and PISOS e xx x Uc dedo de o AER Crankshaft flywheel and camshaft inspection 0 Gylinder block INSPECTION ss sss ae eo ue o 6o ko ow kataa CREDO Ge AAA Gyimnmder sleeve LS x9 BES o v rm Be cee im SOR KSEE EERE AAA 5 Miscellaneous parts inspection ewe eS AAA TT ee ke e ASSEMBLY OF ENGINE ACCESSOTIES 4 4 44 6 5 PRREPS EERE GES EES EES Oe 8 eS TIT Camshartand Gear dodge E doe EMSS OOS ESS OK E UXOR DEC 0e ER TT e ntur DEET EECH AAA A AAA Connecting rods and pistons 49 se ne s ESOS OS nara ARA UranESHalb 4 5 R3 9d wo 1309 4 ee TCU EE Cylinder head TT iN IOAUR Pom AAA A Engine mounting Wow wok s r1 EEN e Flywheel and housing 1 e 0 22 KE s CRESS REESE Manifold NARA feet ee eg ha amp oe E EE 4E vede A Rocker arm assembly TP A AAA ETT jio lo c PPL rrrrrrrrrrT T Valve AdJusbing ue go EHR XE 4 XE AAA TEETE EEE EEEE A Donated by John amp Susan Hansen For Personal Use Only i MIA ENGINES INTERNATIONAL L LINE MOTOR TRUCK SERVICE MANUAL EL A age ENGINE GROUP Continued SECTION
109. in and rim of cap just contacts top of gauge Read gauge Readings to right of Zero indicate positive clearance see B in Fig 18 and readings to left indicate negative clearance No clearance Clearance Gauge shows 002 no clearance Gauge shows psy 003 clearance HST see A in Fig 18 To check cap clearance with valve removed from engine install keys and valve spring retainer under shoulder of valve stem Position clearance gauge on valve stem Place cap on plunger pin pressing down firmly Turn spindle of gauge and check read ing as outlined in foregoing Fig 19 gt AS UNS Retainer and locks x A 23202 Fig I9 Checking cap clearance with valve removed Repair of Cylinder Head l If cylinder head has to be resurfaced re move only enough material to true up surface 2 If any valve guide shows excessive clear ance or out of round condition press guide from head Install new guide and press into head until approximately 1 1 16 remains above the top surface of the head Check valve guides after installation to 002 to 004 for exhaust and 0015 to 0035 onintake with Go and No Go gauge Ream valve guides to 437 after assembly in cylinder head Fig 12 3 If inspection indicates necessity replace valve seat 4 Grind valve seats in cylinder head to 45 for exhaust and 15 for intakes Reconditioning Valves and Seats One ofthe principaldifficulties
110. ing shaft and using a small punch drive out spiral gear pin from oil pump spiral gear Fig 47 Pl ce two support plates under spiral gear in press and press oil pump drive shaft out of pump spiral gear Fig 48 Remove Woodruff key Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond Section A Page 16 L LINE MOTOR TRUCK SERVICE MANUAL AAA VV Ze Press ram Spiral gear d Drive shaft BE A 2 937 Fig 48 Use SE 1499 Oil pump support plate or other suitable support when pressing shaft from gear Drive shaft A 21935 Fig 49 6 Remove body gearand drive shaft from oil pump body Fig 49 7 Press pump body gear from shaft and re move Woodruff key 8 Wash all parts ina cleaning solvent Oil Pump Inspection Check the following parts carefully l Check oil pump drive shaft for wear at points of contact with body If shaft is worn or bent it should be replaced 2 The standard measurement of oil pump shaft is 4885 4890 The shaft should be concentric and straight through its en tire length within 004 indicator reading 3 Check oil pump body for warpage damage and wear Replace if body is warped or cracked or if shaft bore is worn so that clearance between shaft and bore is in ex cess of 005 The oil pump body shaft bore measures 490 4 Inspect oil pump gears and replace if wear is perceptible Oil
111. ings are designed with the spread width across the open ends slightly greater than the diameter of the crankcase bore or connecting rod bore into which they are as sembled Fig 65 For example the width across the open ends of the Silver Diamond engine connecting rod bearing not in place is approximately 025 more than when the bearing is in position in the rod This condition causes the bearing to fit snugly in the rod bore and the bearing must be snapped or lightly forced into its seat Rough handling in shipment storage or normal results of use in an engine may cause the bearing spreadto beincreased ordecreased from the specified width Bearing spread Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond Section A Page 22 L LINE MOTOR TRUCK SERVICE MANUAL INTERNATIONAL O D OF BEARING WHEN INSTALLED IS THE SAME AS THE DIA OF THE CRANKCASE OR CONN ROD BORE SPREAD OF BEARING o A BEFORE INSTALLATION A 16088 Fig 65 should therefore be carefully measured and corrected as necessary before installation in an engine Bearing spread can be safely adjusted as follows although care and judgment should be exercised in the process l Excessive spread If measurement of spread Fig 65 indicates that distance A is excessive see chart for specifica tions place bearing on a wood block Fig 66 and strike the side lightly and sq
112. insert peening tool ora dull pointed chisel 1 4 wide to peen cylinder head metal over outer edge of valve seat insert Valve available seat insert installing tools are Valve seat inserts supplied for service are standard size and 0301 oversize which permits a tight fit in cylinder head Repair of Valves l True up the ends of valve stem against face of grinder Remove only enough material to true the surface 2 Reface exhaust valves to 45 The valve face and valve seat angle mustbe identical 3 Reface intake valves to 45 with valve seat being the same 4 Place valves in cylinder head Place a thin coat of Prussian blue on each valve face and tap valve lightly to its seat NOTE This is merely for test and proof of results of refacing and reseating oper ations A poor grinding job cannot be cor rected by valve lapping PRINTED IN UNITEO STATES OF AMERICA 5 Inspect each valve coated with blue for seat position The seat should be at the approximate center of valve face 7 64 5 64 wide for exhaust and 5 64 7 64 wide for intake Valve Assembly l Wipe valve faces and valve seats with a cleaning solvent to remove all dirt or for eign material Coat valve stems and valve faces with oil and install valves in same seats to which they were checked 4 Install valve springs with dampers Com press valve springs with a valve spring compressor and install valve spring re tainers and retainer loc
113. ioned and reinstalled Rotating Exhaust Valve Mechanism Slo Roto Valves Valve burning is commonly caused by deposits accumulating on valve seat thus hold ing valves open to be burned to escaping ex haust gases Carbon deposits collecting under valve head hold valves open further causing blow by With the valve slowly rotating these accumulations are kept from forming to a great degree thus improving valve life All rotator parts are interchangeable but should be checked after assembly to insure proper clearance re quired for rotation Care should be taken not to damage or nick valve stem ends or tips as this will alter the clearance The parts involved in the rotating valve mechanism are special spring seat retainer a pair of flat half moon keys a close fitting cap located on the valve stem and a specially constructed valve stem In order to accommodate valve expansion the tappet lash valve tappet clearance must be maintained When camshaft rotation causes this lash or tappet clearance to be taken up the cap onthe valve stemcauses the valve keys to lower the spring retainer removing the load of the valve springs from the valve before the valve is raised from its seat A clearance of 002 to 006 should be maintained between the end face of the valve stem and cap Fig 14 S Key wear Key wear f Right installation Valve tappet clearance lash 018 to 020 engine m gt Spring retainer Geck
114. ire circle of seated valve is not shown the angles do not match It will then be necessary to redress the valve seat grinding stones changing the angle sufficiently to correct the error The correction should be made on the valve seat and not on the valve No more material should be removed from the valve face than is necessary to true it up and remove the burned or pitted portion New valves should not be refaced but should be checked for true ness When a satisfactory match of valve seat and valve face angles has been obtained the adjustment of both the valve refacer and the seat grinder should be locked in position in order to eliminate this trial by error method on additional valves having the same angle Valve Seats The primary purpose of a valve seat is to seal the combustion chamber against pressure losses and to provide a path to dissipate the heat accumulated in the valve head so as to prevent burning of the seat and warping of the valve head The location of the valve seat on the valve face and its width controls the amount of valve head that protrudes into the combustion cham ber It is obvious that the greater the expo sure withinthe combustion chamber the higher the valve temperature or in other words the more heat it will collect High valve tempera tures and poor heat dissipation also produce excessive valve stem temperatures and hasten the accumulation of carbon on the stem caus ing them to stick in the gui
115. iscellaneous Parts l includes brackets Cleaning miscellaneous engine parts This oil pan engine case L LINE MOTOR TRUCK SERVICE MANUAL 10 cover flywheel housing and other parts that were removed during disassembly of engine and were not covered by procedure Wash in cleaning solvent or steam clean preliminary to inspection Check all twelve valve lifter or push rods for straightness by rolling on flat surface Replace any that are bent or have loose ends Inspect oil pan for cracks or deep bends and straighten or weld Inspect oil pan drain plug and drain plug boss for fit and thread wear If plug is loose or threads are damaged repair threads or replace oil pan Inspect crankshaft pulley and vibration damper assembly for evidence of rubber coming loose from pulley and inspect for wear Replace damper assembly if either condition is encountered Do notsubmerge vibration damper assembly in hot cleaning solvents Inspect crankshaftfan drive pul leyfor wear inhub bore If inner diameter of bore is worn scored or Woodruff key way damaged replace pulley Inspect engine gear case cover and re place if cracked or broken Remove old cover seal and install new seal Check each of twelve engine valve tappets for irregular wear chipping cracking or scores Replace defective tappets Inspect engine flywheel housing for cracks or breakage and replace if damaged In spect flywheel housing to crankcas
116. istons inthe cylinder sleeves use a 003 feeler ribbon 1 2 wide between the piston and cylinder 90 from the piston pin hole and inline withthe thrust face of the piston Fig 32 Apply a tension pull on scale to the feeler ribbon and check clearance to specifica tions as outlined in the chart Feeler Gauge Ribbon Checking Thickness Tension on Scale Lb Desired Tension Lb Tension scale Thrust face of piston Fig 32 Checking pistonfit using feeler gauge ribbon SE 1007 Gauge Set is available for this operation Connecting Rod and Piston Assembly l With piston heated to approximately 200 F support connecting rod in vise push piston pin into piston bosses while piston is hot When assembling piston on rod the slot in the piston skirt must be toward the camshaft side of the engine which is the numbered side of the connecting rod Install piston pin retainerin piston ateach end of pin making sure that retainers seat ful and with tension in grooves connecting rod and piston assembly on a connecting rod aligner and correct any misalignment 2 Place piston and connecting rod in vise Test each piston ring for proper gap by placing in cylinder and measuring gap with feeler gauge Gap should be 016 to 026 Fig 33 PRINTED iN UNITED STATES OF AMERICA Test a Feeler gauge Piston ring au Piston ring expander Piston E A 21566 XC Fig 34 Installing pistonring u
117. ked at the bottom below ring wear surface to determine the amount of taper Re sleeve if worn beyond 008 clearance Cylinder Sleeve Fits The fit ofthe cylinder sleeve in the crank case should be 100 to 200 lbs hand push fit or approximately 0005 to 001 loose fit This fit can be obtained by honing the cylinder bore sufficiently in the crankcase until the cylinder sleeve can be pushed all the way in by hand Before installation of cylinder sleeve the crankcase bores should be cleaned of all car bon and foreign matter Installation of cylinder sleeves inthe fore going manner will preclude to a large extent the necessity of excessive honing when fitting pistons to the cylinder sleeves NOTE If cylinder water jacket shows an excesSive amount of lime deposits the cooling system cannot provide effective heat dissipa tion Whenever the top of the sleeve flange goes below the top of the crankcase a thin tag wire should be placed under the sleeve flange to raise it flush with the crankcase or not to ex ceed 006 above the crankcase face Cylinder wall surface finish is of utmost importance in piston and piston ring life and in oil consumption control The best type surface is one having characteristics midway between smooth and highly polished The resulting surface ofa boring or honing operation consists of numerous microscopic scratches or grooves which act as oil reservoirs or retainers of oil while the surf
118. ks Be sure that retainers and locks are correctly seated Engine Disassembly Continued When overhauling engine with head and pan removed the following procedures are recom mended l Remove fan drive pulley nut and washer from end of crankshaft Install puller and remove crankshaft fan drive pulley and damper assembly from crankshaft 2 Remove nuts and capscrews from engine gear case cover Fig 12 remove gear case cover Fig 13 Remove crankshaft oil slinger from end of shaft Fig 14 Re move side cover plate and remove valve tappets Fig 15 Remove nut from end of camshaft and remove camshaft gear with puller Fig 16 NOTE Camshaft may be removed without removing timing gear by removing thrust plate retainer screws Fig I2 Removing timing gear case cover Donated by John amp Susan Hansen For Personal Use Only ENGINES on p L LINE MOTOR TRUCK SERVICE MANUAL Section B Page 8 Gear puller e RK di ia L A 22158 H Fig 16 Pulling camshaft gear Fig 13 Showing details of timing gears Cover removed 3 Remove capscrews from camshaft retainer thrust lange plate Fig 17 Remove cam shaft Fig 18 Remove capscrew holding the gear case cover plate to block remove plate and gasket Remove crankshaft tim ing gear using a gear puller Fig 19 NOTE Lubricate puller screw to pre vent damage to screw threads Camshaft timing gear mt Mag cvs oe
119. lock rings from under the slinger 6 Remove snap ring from groove inthe front of impeller and lift out the sealparts from the impeller Water Pump Cleaning and Inspection l Following disassembly wash all except rubber parts in cleaning solvent L LINE MOTOR TRUCK SERVICE MANUAL 2 Examine seal parts for wear corrosion or damage and replace with new parts as necessary Examine the pump body seal seat surface If face of surface is scored it must be resurfaced to prevent leakage Inspect pump shaft bearing for wear or corrosion If worn or corroded replace bearings Examine shaft for wear at ends or for damaged threads at front end Water Pump Repair If water pump body seal seat is scored pitted or rough it must be resurfaced Use Special water pump housing seat finishing tool and adapter Water Pump Assembly l Install rear bearing spacer and front bearing onto water pump shaft Place slinger in position behind rear bearing Place two half moon lock rings in groove in shaft and press shaft into bearing and Spacer from rear until rear bearing rests firmly against slinger and ring locks 2 Place seal clamp ring seal spring seal spring guide flexible seal and retainer and carbon sealthrust washer into position in impeller Hold them in position while installing snap ring in impeller groove 3 Install water pump shaftand bearing assem bly into body and hold in place by inserting snap ring in gro
120. ly L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Red Diamond Section C Page 15 Cylinder Sleeve Fits The fit ofthe cylinder sleeve in the crank case should be 100 to 200 lbs hand push fit or approximately 0005 to 001 loose fit This fit can be obtained by honing the cylinder bore sufficiently in the crankcase until the cylinder sleeve can be pushed all the way in by hand Before installation of cylinder sleeve the crankcase bores should be cleaned ofall carbon and foreign matter Installation of cylinder sleeves inthe fore going manner will preclude to a large extent the necessity of excessive honing when fitting pistons to the cylinder sleeves NOTE New cylinder sleeves are rough honed and must be finish honed to size in the crankcase NOTE If cylinder water jacket shows an excessive amount of lime deposits the cooling system cannot provide effective heat dissipation Whenever the top of the sleeve flange goes below the top of the crankcase a thin tag wire should be placed under the sleeve lange to raise it flush with the crankcase or not to ex ceed 006 above the crankcase face Cylinder wall surface finish is of utmost importance in piston and piston ring life and in oil consumption control The best type sur ace is one having characteristics midway between smooth and highly polished The resulting surface ofa boring or honing operation consists of numerous microscopic scratches or groov
121. ly See sectional view of the model BD engine oil pump Fig 26 l Remove cotter pin holding float to oil pump Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Blue Diamond Section B Page 12 Remove float from pump Loosen oil out let coupling and remove oil line from pump Remove four capscrews and lockwashers from oil pump body cover and lift cover and gaskets from oil pump body Lift out oil pump idler gear from idler gear Shaft After removing oil pump drive gear shaft guide from top of shaft use small punch to drive out spiral gear pin from oil pump spiral gear Using an adapter collar which fits underneath the Spiral gear and an adapter with a tang which will fit down into the slot of the oil pump drive shaft so as to apply pressure of press at bottom of slot press oil pump drive shaft out of oil pump spiral gear Remove Woodruff key from shaft Remove oil pump body gear and oil pump drive shatt from oil pump body Press oil pump gear onto oil pump drive shaft far enough to reveal retainer ring Remove ring from oil pump shaft Press oil pump body gear from shaft and remove Woodruff key from shaft Wash all parts in cleaning solvent Oil Pump Inspection Check the following parts carefully Check the oil pump drive shaft for wear at points of contact with body If wear is perceptible the shaft must be replaced Diameter of shaft is from 4985 to 4992 inches Check the oil
122. ly In serta clutch aligning arbor if available ora transmission main drive gear shaft through clutch driven disc hub spline and into clutch pilot bearings Hold clutch driven disc in position while completing installation of six mounting capscrews and lockwashers in flange of clutch backing plate or cover Tighten all six capscrews securely Remove three retaining cap screws and flat washers which were in stalled to hold clutch compressed NOTE Clutch will not operate properly unless these retaining capscrews are removed 8 INSTALL VALVE TAPPETS Coat each of 12 valve tappets with heavy engine oil and drop each flat side down through re Cess in side of cylinder block into sockets in block Fig 73 Valve tappet a a MEO A 21568 Fig 73 9 INSTALL VALVE LIFTER ROD COVER Install new gasket over opening at left hand side of engine block Install valve lifter rod covers and slotted screws Install Cylinder Head l INSTALL HEAD Place gasketon cylinder block and align bolt holes Place cylinder head on crankcase being careful not to damage of shift gasket position Loosely install all cylinder head bolts and flat washers omitting bolts in holes for rock er arm assembly 2 INSTALL VALVE ROCKER ARM ASSEM BLY Insert 12 valve lifter rods in cylin der head make sure they enter the valve tappet Lift the valve rocker arm assem bly into position on cylinder head with the drilled oil bracket placed third fro
123. ly mis aligned can be straightened with proper equipment Badly twisted or bent connecting rods must be replaced 5 Inspect pistons for cracks breakage or scores Check piston ring grooves and ring lands for wear using a new piston ring and feeler gauge If clearance be tween ring and ring land exceeds 005 total clearance replace piston see spec ifications for data covering piston fit in cylinder block 6 Inspect piston pins for wear and if wear is perceptible replace pins Replace pis ton pins which show signs of corrosion or etching 7 With properly fitting adapter press old piston pin bushing from connecting rod Fig 54 Place new piston pin bushing in position align oil hole in bushing with oil hole in connecting rod install bushing with a 0055 to 0035 press fit Fig 55 Bur nish bushing into place in the connecting rod Fig 56 8 With reamer ream piston pin bosses in piston to provide a tight fit of from 0000 to 0002 with piston pin NOTE When fitting piston pins the pins should be at room temperature 70 F and the pistons should be heated to approximately 200 F in boiling water or piston heater The pin should be a palm push fit under these conditions Adapter gt E g Press ram Support plate Connecting rod UN A 22159 Fig 54 Press bushing from rod using SE 1036 U Bushing adapter and SE 1033 support plate Adapter Support
124. m front Make sure number 2 4 and 6 bracket Sleeve dowels are in place Fig 74 In stall the remainder of cylinder head bolts and tighten alternately and evenly in se quence to 90 foot pounds PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR IRUCK SERVICE MANUAL ENGINES Silver Diamond Section A Page 25 Rocker arm bracket i Rocker arm l Ma ER llana E im imi UR E i Sleeve dowel A 21938 Fig 74 3 ADJUSTING VALVES To adjust valve stem to valve rocker arm clearance cor rectly each cylinder must be on top dead center on its compression stroke at the time of adjustment of valves for that cyl inder To determine the correct position turn the engine crankshaft until No 1 piston is at top dead center on compression siroke and the ignition timing dot on the flywheel is in line with the pointer on the flywheel housing Fig 75 Adjust clear ance on each valve of No 1 cylinder to 018 to 020 by using a feeler gauge be tween valve stem and valve rocker arm and turn rocker arm adjusting screw out of rocker arm until clearance is obtained Tighten adjusting screw lock nut and re check clearance NOTE Valve clearance should be rechecked with engine at normal operating temperature Ignition timing pointer housing AT GER D NS v e Ignition timi SG ark on flywheel Sic I y Fig 75 4 Turn cranks
125. nd check the clearancebetweenthe straight edge and impeller There should be about 025 clearance Fig 40 A 21947 Pump housing BN A 21906 Fig 39 Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond Section A Page 14 L LINE MOTOR TRUCK SERVICE MANUAL Feeler gauge Scale 3 Water pump housing NN A 21903 Fig 40 5 Install cover plate with new gasket and mount fan blades Intake and Exhaust Manifolds When disassembling and assembling the manifolds the following procedures are used l After removing the eight capscrews from head and three bolts from exhaust flange remove both intake and exhaust manifolds as a unit Fig 41 NOTE Let manifolds cool before starting above operations 2 To separate the two manifolds remove the two outside capscrews and two inside nuts from the center of manifolds Fig 42 3 The intake and exhaust manifolds are each of one piece construction requiring no disassembly after separation Carburetor Re Intake Manifold l The intake manifold consists of three out lets each supplying fuel to two cylinders Two studs are located on the top for car buretor mounting Heat control counterweight Fig 42 2 If vacuum is needed to operate any unit within the truck a threaded inlet is pro vided in the manifold for such purposes Exhaust Manifold l1 The exhaust manifold c
126. nder ROTATING EXHAUST VALVE MECHANISM Remove only enough material to true the surface 2 Reface exhaust valves to 45 The valve face and valve seatangle must be identical 3 Reface intake valves to 15 with valve seat being the same PRINTED IN UNITED STATES OF AMERICA 4 Place valves in cylinder head Place a thin coat of Prussian blue on each valve face and tap valve lightly to its seat NOTE This is merely for test and proof of results of refacing and reseating opera tions A poor grinding job cannot be cor rected by valve lapping 5 Inspect each valve coated with blue for seat position The seat should be at the approximate center of the valve face 3 32 1 8 exhaust with the widest seat prefer able Intake seat should be 5 64 7 64 Valve Assembly l Wipe valve faces and valve seats with a cleaning solvent to remove all dirt or for eign material Coat valve stems and valve faces with oil and install valves in same seats to which they were checked NOTE Check exhaust valve rotating mechanism to assure proper clearance between valve Stem and cap before installing valves 2 Install inner and outer valve springs In stall retainers Compress valve springs with a valve spring compressor and install valve spring retainer locks Be sure that retainers and locks are correctly seated Recheck exhaust valve cap clearance Engine Disassembly Continued When overhauling engine with head and pan
127. nder tool Fig 59 Also check new piston rings in piston ring grooves for clearance between ring and ring lands The correct ring clearance is shown in specifications Piston ring expander A 21566 Fig 59 installing piston ring using SE 149 8 piston ring installing tool Crankshaft Cleaning and Inspection l Wash and clean crankshaft with cleaning solvent or steam 2 Inspect main bearing and connecting rod journals for wear If journals show wear or out of round in excess of 003 the Shaft should be either reground and under size bearings installed or replaced Use micrometers for checking PRINTED IN UNITED STATES OF AMERICA 3 Check crankshaft and flywheel dowels for damage and fit and replace if worn or damaged 4 Examine crankshaft timing gear teeth and replace gear if teeth are wornor damaged 5 Install Woodruff key in groove in crank shaft Heat crankshaft gear in boiling water or piston heater This will expand the gear enough to let it be tapped on the crankshaft without the danger of damaging the gear Use gear driver to insure align ment when starting gear Fig 60 Crankshaft timing gear ERs A x Sy la We Gear driver Soft hammer A 21887 Fig 60 Installing crankshaft timing gear using SE 1716 Installing tool Flywheel and Ring Gear Inspection l Clean flywheel and ring gear with a clean ing solvent remove all traces of oil and grease 2 Inspect theflyw
128. not exceed 005 7 INSTALL ENGINE FLYWHEEL Place engine flywheel and ring gear into position on dowels in crankshaft flange Install six self locking capscrews in flywheel and crankshaft flange and tighten to a tension of approximately 60 foot pounds using a tension wrench 8 INSTALL GEAR CASE COVER PLATE Place plate and gasket at front end of en gine cylinder block Install two capscrews and lockwashers Coat camshaft with engine oil Insert camshaft into front end of engine block being care ful not to damage camshaft bearings Be fore completely entering camshaft rotate shaft until marked teeth oncrankshaft gear and camshaft gear index Fig 70 Install two capscrews and lockwashers in cam shaft thrust flange working through large holes in camshaft gear Rotate crankshaft and camshaft to establish that gears do not bind or interfere Backlash must be from 000 to 007 0015 preferred Place Place 10 INSTALL GEAR COVER CASE gasket in position on case cover Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond Section A Page 24 L LINE MOTOR TRUCK SERVICE MANUAL NAL WV Camsh re aft ge a S Crank E d A 21943 Fig 70 crankshaft oil slinger over end of crank shaft andinstall Woodru f key for fan drive pulley in crankshaft Place gear case cover in position and install gear case cover aligning tool Fig 71 Install cap screws
129. nstalled on the shaft in the proper location 6 Remove seal from housing through back side of pump Use a drift and carefully drive seal from the pump body Water Pump Cleaning and Inspection Before reassembling water pump the fol lowing should be checked l Clean all parts by steam or cleaning sol vent 2 Examine seal for wear or damage and re place partsas necessary Use special tool when installing seal Use a new seal when rebuilding the pump since the old seal may have been damaged upon removal 3 Examine pump impeller seat seal surface if face of surface is scored it must be re surfaced or replaced to prevent leakage amen Press ram Adapter gt UE er NEL v wA 21904 Press ram Small hub end Fan hub Large hub end Water pump shaft gt Water pump bearing A 22492 Fig 37 PRINTED IN UNITED STATES OF AMERICA 4 Inspect pump shaft bearing for wear If worn replace bearing 5 Examine shaft for wear and replace if needed Water Pump Assembly l Press fan hub on shaft with the smaller diameter of the hub to the front Fig 37 2 Install shaft in housing from front end by pressing shaft bearing slinger and fan hub in as one unit Fig 38 3 Install snap ring in place behind fan hub Fig 39 4 Mountassembly in press Press impeller on rear end of shaft Place a straight edge across the back of the water pump housing a
130. nt brush ing to facilitate removal of all sludge or carbon deposits 2 Inspect camshaft journals for signs of wear or out of round 3 Inspect oil pump drive gear in center of shaft If teeth are worn or damaged the camshaft must be replaced as the gear is integral with shaft 4 Inspect camshaft lobes If worn chipped or scored replace the camshaft 5 Inspect camshaft gear and replace if wear is evident or gear teeth are nicked or otherwise damaged NOTE Timing gears are factory matched and are furnished in sets The gears should be replaced in sets 6 To reassemble install thrust flange over end of camshaft Install Woodruff key in slot in shaft Place camshaft gear in boil ing water or piston heater and install over Woodruff key Install camshaft nut and tighten to approximately 120 foot pounds tension Cleaning and Inspecting Miscellaneous Parts l Cleaning miscellaneous engine parts This includes brackets oil pan engine case cover flywheel housing and other parts that were removed during disassembly of engine and were not covered by procedure Wash in cleaning solvent or steam clean preliminary to inspection 2 Check all twelve valve lifter or push rods for straightness by rolling on flat sur ace Replace any that are bent or have loose ends 3 Inspect oil pan for cracks or deep bends and straighten or weld 4 Inspect oil pan drain plug and drain plug L LINE MOTOR TRUCK SERVICE MANUAL
131. om top of cylinder block Replace cap on connecting rod Remove the remaining pistons fol lowing the same procedure b Rear main bearing cap T Rear main Em bearing gt exe WE E AO SERE 3 aAA enl e 3E 4 22232 Fig 23 lli A 22230 Fig 21 5 The crankshaft bearing caps are numbered to identify their position and they must be reinstalled in their respective positions Remove rear oil seal retainer Fig 22 Remove all crankshaft main bearing caps Fig 23 Remove twelve capscrews from clutch and remove clutch Remove six self locking bolts from flywheel Install two 1 2 N C bolts 2 long in threaded holes in flywheel and force flywheel from crankshaftflange dowels Fig 24 Remove flywheel from housing Remove six bolts from engine flywheel housing Fig 25 Tap housing with a soft hammer to knock S D A it from dowels Remove housing from do Tue SI crankcase Lift crankshaft straight up and an out of cylinder blockand place in vise with INTERNATIONAL 1 d y V Crankshaft dowels Flywheel housing dowel A 22226 NOTE be used instead of bolts requiring locking wires The self locking bolts identifiable by the depression in their heads require no locking wires soft jaws Self locking bolts may 6 Remove fuel pump starter oil pressure regulator valve assembly distributor generator oil gauge and ignition coil Water Pump Remov
132. on Loosely es install all cylinder head bolts and flat washers omitting bolts in holesfor rocker arm assembly INSTALL VALVE ROCKER ARM ASSEM BLY Insert twelve valve lifter rods in cylinder head make sure they enter the valve tappet Lift the valve rocker arm assembly into position on cylinder head with the drilled oil bracket on the front end Install the remainder of cylinder head bolts and tighten alternately and evenly in sequence to 80 foot pounds Fig 40 Be sure to place stud with oil hole in the left front cylinder head bolt hole Retighten cylinder head after engine has been oper ated for a short period 3s 4 5 Fig 40 ADJUSTING VALVES To adjust valve stem to valve rocker arm clearance cor rectly each cylinder must be on top dead center on its compression stroke at the time of adjustment of valves for that cyl inder To determine the correct position turn the engine crankshaft until No 1 piston is at top dead ceiiter on compression stroke and the ignition timing mark on the crankshaft pulley in line with the pointer on the timing gear case Adjust clearance on each valve o No 1 cylinder to 018 to 020 by using a feeler gauge between valve stem and valve rocker armand turn rocker arm adjusting screw out of rocker arm until clearance is obtained Tighten ad justing screw lock nut and recheck clear ance NOTE Valve clearance should be rechecked with engine at normal operating tem
133. onsists of four out lets The two end outlets remove burned gases from the No 1 and No 6 cylinders while the two center outlets remove burned gases from Nos 2 3 4 and 5 cylinders 2 Located in the exhaust manifold in the center is the manifold heat control unit Fig 43 Exhaust pipe flange e Heat control counterweight Heat control valve q KS Thermostatic spring xhaus manifold CA 222i3 Fig 43 3 The purpose of the heat control unit is to keep the intake manifold warm enough to vaporize the fuel mixture as completely as possible The heat control is automatic in operation being controlled by a coiled thermostatic spring A counterweight under spring tension is mounted on the heat control valve shaft and this counter weight operates with the spring to close and operate the heat control valve 4 Should the valve hold too much heat the engine is likely to detonate or ping when engine is accelerated If valve opens too early not enough heat is retained in the manifold resulting in a slow warm up If the thermostatic spring becomes discon nected the whole heat control system will be upset 5 Should the shaftof the heat control become stuck tapping it with a hammer and work ing the valve back and forthby handusually frees it An application of penetrating oil will help the process of freeing a sticking heat valve Manifold Inspection Inspect intake and exhaust
134. ops arsan 2 950 8748 D Ol ars i iameter 8750 Pin fit room tempera ture 70 F Recommended clear 1 0002 ance in rods 0004 Recommended clear 0000 ance in piston 0002 FEELER GAUGE RIBBON CHECKING Width See A ANE 1 2 Thickness 003 Tension on scales lbs 6 18 Desired tension lbs 12 SD 240 2 069 2 070 1 4995 1 5005 Seeeeeeeee desired 0070 013 0011 0032 45 55 aluminum alloy 003 2 950 8748 8750 0002 0004 0000 0002 1 2 003 6 18 12 BD 269 1 562 1 563 1 499 1 500 01100 0 desired 0070 0130 0007 0032 60 70 aluminum alloy 003 2 950 9192 42194 0003 0004 0000 0002 1 2 003 6 18 12 RD 372 2 069 2 010 1 4995 1 5005 60 9 goe 0010 00351 0020 0080 Thrust Flange 0015 desired 0070 0130 0012 s0057 75 85 aluminum alloy 003 3 796 1 1089 1 1091 0005 0006 0000 0002 1 2 003 6 18 12 2 069 2 070 1 4993 1 5005 60 9 90 ge 0010 0035 0020 0080 Thrust Flange 0015 desired 0070 0130 0012 o0037 75 85 aluminum alloy 003 3 796 1 1089 1 1091 0005 0006 0000 UO002 2 003 6 18 12 RD 406 RD 450 2 069 2 070 1 4995
135. ough the cylinder block and then out through the thermostat housing into the radiator upper tank Fan _ Seal tesche S Fan mounting capscrew RAMA a Water pump Fan hub P housing Water pump shalt Back bs U ia Fan belt 7 Fig 31 Sectional view of water pump Fan pulley mu Water Pump Disassembly l Remove four capscrews and lockwashers holding fan to hub Remove fan blade as sembly from hub 2 Remove four mounting capscrews from water pump Fig 32 Remove water pump from front end of cylinder head Generator adjusting gen bracket EE 3 Water pump assembly UNS Capscrews MT TS Engine front eee RBA mounting support ET nnl e Fig 32 A 21927 Pump housing SN a Q ilo 3 Remove three screws from back cover plate Remove plate and gasket from pump body Fig 33 Fan hub Cover plate Pump housing A 21928 Fig 33 4 Remove snap ring from front of water pump shaft bearing Fig 34 Support the water pump on an arbor press and push shaft and bearing out as one assembly Fig 35 Pump housing A 21906 Impeller Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Silver Diamond Section A Page 13 5 Place shaft assembly in press and press fan hub from shaft Fig 36 Do not attempt to remove bearing or slinger as they are factory i
136. ove in front of front bear ing 4 Support water pump shaft at front end press impeller and seal assembly onto rear end of water pump shaft Press im peller only flush with end of shaft 5 Placenew gasketin position on water pump body and install cover plate and four cap screws 6 Place fan assembly in position on front of pulley and install six capscrews and lock washers Fill pump housing with wheel bearing grease Use low pressure gun Intake and Exhaust Manifolds When disassembling and assembling the manifolds the following procedures are used l After removing the eight capscrews from head and three bolts from exhaust flange remove both intake and exhaust manifolds asa unit Fig 24 Remove three manifold pilot rings Fig 25 NOTE Let mani folds cool before starting above operations this will help to prevent manifold warpage Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Blue Diamond Section B Page 11 v ow LS A 22148 are to hold the in Fig 25 Pilot m s take manifold in alignment and should always be reinstalled 2 To separate the two manifolds remove the two outside bolts and nuts and two inside bolts and nuts from the center of mani folds 3 The intake and exhaust manifolds are each of one piece construction requiring no disassembly after separation Intake Manifold l The intake manifold consists of
137. page Rocker arm assembly O inih wf A 22236 Pilot ring Sha S Fig 28 2 To separate the two manifolds remove the two outside bolts and nuts and two inside bolts and nuts from the center of mani folds 3 The intake manifold is of one piece con struction The exhaust manifold is of three piece construction Fig 29 Carburetor mounting studs 5 Gasket Intake manifold Three section exhaust manifold A 22467 Fig 29 Intake Manifold l The intake manifold consists of three out lets each supplying fuel to two cylinders Two studs are located on the top for car buretor mounting 2 If vacuum is needed to operate any unit within the truck a threaded inlet is pro vided in the manifold for such purposes Exhaust Manifold The exhaust manifold consists of three parts and four outlets The two end outlets re move burned gases from the No 1 and No 6 cylinders while the two center outlets remove burned gases from Nos 2 3 4 and 5 cylin ders Manifold Inspection Inspect intake and exhaust manifolds visu ally for cracks or breakage Place manifolds Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Red Diamond Section C Page 13 on surface plate and check for warpage If cracked or broken replace or weld If slightly warped true up on surface grinder but replace if warpage is extreme Manifold Assembly Pl
138. perature Turn crankshaft one third revolution and adjust clearance on No 5 valves Work ing in firing order sequence continue to set valves of each of the remaining cyl inders turning crankshaft one third turn after each valve adjustment INSTALL INTAKE AND EXHAUST MANI FOLDS To facilitate installing the mani folds after manifold gaskets and pilot rings are installed start capscrews at end of intake manifold This will permit the manifold to slide straight up between the engine head and capscrews and flat washers When manifold is lined up with PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL 10 ENGINES Super Blue Diamond Section B Page 21 pilot rings and gasket tilt bottom of mani fold toward engine block This will force manifold out at top enough to bind against the two capscrews and hold manifold in position until the front and rear cap5crews can be installed INSTALL WATER PUMP Place water pump gasket in position at water pump opening in front of cylinder head Install water pump and fan and install three cap screws and lockwashers in pump and cyl inder block INSTALL OIL FILTER Place oil filter and new gasket in place on cylinder block Install four capscrews and lockwashers in oil filter base NOTE Be sure filter assembly is thoroughly cleaned and a new cartridge is installed before replacement on engine
139. placement of the valves in their original location 3 Scrapeall carbon from cylinder head com bustion chamber and clean any gasket material from surface of head Clean the head using steam cleaning or other suit able cleaning equipment 4 Cleanall carbon deposits from valve heads and valve stems with wire brush all valve springs and retainers in cleaning solvent Inspection of Cylinder Head l Inspect cylinder head visually for signs of cracks or sand holes and if found de fective weld or replace head 2 Inspect exhaust valve seat rings for loose ness and inspect for excessive width of valve seat surface If insert rings are loose replace Ifa seat has been previ ously ground to such extent that it cannot be narrowed from top to bring to proper position near center of valve face the ring must be replaced PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL Wash ENGINES Super Blue Diamond Section B Page 5 Inspection of Valve Guides Valve Springs and Valves 1 Clean valve guides witha suitable cleaning tool Check each valve guide with a Go and No Go gauge if available otherwise use a new valve to check fit If No Go portion of gauge enters the guide must be replaced Recommended valve stem to valve guide clearanceis from 002 to 004 for exhaust valves and from 0015 to 0035 for intake valves Clearance in e
140. plate Connecting rod A 21586 Fig 55 Installing new bushing in rod ES i E d Press ram 8 r Genee et AH Support plate Connecting rod Pos A si Eee e o ABE P UN dx A 22161 Fig 56 Use SE 879 Burnishing tool Connecting Rod and Piston Assembly l With piston heated to approximately 2009 F support connecting rod in vise push piston pin into piston bosses while piston is hot Fig 57 When assembling piston on rod the slot in the piston skirt must be toward the camshaft side of the engine which is the numbered side of the connect ing rod Install piston pin retainer in pis ton at each end of pin making sure that Piston ec 4 21901 INTERNATIONAL AN Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Silver Diamond Section A Page 19 retainers seat fully and with tension in grooves Test connecting rod and piston assembly ona connecting rod aliner and correct any misalignment 2 Place piston and connecting rod in vise Test each piston ring for proper gap by placing in cylinder and measuring gap with feeler gauge Gap should be 016 to 026 Fig 58 DG IAM B Feeler gauge Piston ring ER 4 faa A De Fig 58 Checking ring gap 3 When installing piston rings in piston grooves be careful not to distort rings If possible use a suitable piston ring ex pa
141. pport bracket cap Support bracket Bell housing trunnion 1 H Rubber insulator PM ili sx CR a Rubber S N Rear support bracket Fig 56 A 15420 Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Red Diamond L LINE MOTOR TRUCK SERVICE MANUAL Secti n Page 25 Handle e hi E Gasket Snap NAS e AR D Gasket fe 4 Qum 7 Q 1 Pressure valve H LS 4 aS a Cap B j Lock pin f r Center tube e Cartridge ande d A Oil return E channel ll outlet shell gt M Cartridge spacer Plate Gasket CBU Gasket A 22636 Relief valve Fig 57 DeLuxe Oil Filter OIL FILTER DELUXE l The DeLuxe oil filter is used on the RD engines and incorporates a removable sump Fig 57 2 Water grit metal particles sludge and other contaminants that settle out of the oil are held in the sump away from the cartridge When the cartridge is changed the cartridge and sump quickly and easily lift out as a single unit Change filter cartridge and clean sump at regularly es tablished periods according to operating conditions OIL FILTER MICHIANA l The Michiana oil filter is used on the RD engines Fig 58 Oil from the engine is delivered by the oil pump into the filter PRINTED IN UNITED STATES OF AMERICA Center tube Oil outlet Shell NN gt gt j le Lal zm i lt A LL lt lt
142. prings and brackets from shafts Clean all parts in a solvent cleaning fluid being careful to clean all accumulated sludge and carbon deposits from oil holes and slots Donated by John amp Susan Hansen For Personal Use Only ENGINES Silver Diamond Section A Page 6 Rocker Arm Inspection Carefully inspect all parts for defects and wear l Inspect rocker arm shaft expansion plugs Check ona surface platefor signs of bend ing check for wear from rocker arms If a shaft is bent or shows perceptible wear it must be replaced 2 Inspect rocker arm adjusting screws for wear at contact surface and for thread wear Replace worn screws Check rock er arm bushings for wear If clearance on shaft exceeds 004 replace bushings Inspect valve stem contact pad surface of rocker arms and resurface if wear is perceptible 3 Inspect tension springs for breakage or loss of tension Replace defective springs Remove valve lifter rods Re bushing Rocker Arms With properly fitting adapter press old rocker arm bushing from rocker arm Fig 10 Place new rocker arm bushing in posi tion Align oil hole in bushing with oil hole in rocker arm which is located 23 from top of rocker arm toward rocker arm adjusting nut Use an installing tool and press new bushing into rocker arm Fig 11 Burnish bushing into place in the rocker arm Fig 12 then ream rocker arm bushing to provide 0015 004 clearance Press
143. pump are driven by a V type belt from a driven pul ley mounted on the front end of the crank shaft The distributor mounted at the left side of the engine is driven by the cam shaft through the oil pump 2 The exhaustand intake manifolds are bolted to each other and to the right side of the engine head The intake manifold and the exhaust manifold are each cast in one piece 3 A vibration damper is provided atthe front end of the crankshaft 4 The cylinder block and crankcase are cast in one piece and carry the crankshaft main bearings Water circulation passages completely surround the cylinders in the crankcase and also provide coolant to the cylinder head 5 Oilis supplied under pressure by the oil pump to the engine lubrication system Oil spray from the revolving crankshaft is distributed to the cylinder walls pistons and other moving parts inside the engine 6 Exhaust valve seats are of alloy and are pressed into place These valve seats lengthen the period between valve recon ditioning operations Valves and valve seats are cooled by continuous circulation of water through the cylinder head 7 The detachable cylinder head is bolted to the crankcase anda gastightand watertight seal is maintained by means of a gasket L LINE MOTOR TRUCK SERVICE MANUAL 8 The crankshaft is a drop forging of heat treated steel It is counterweighted bal anced both statically and dynamically and ground to close
144. pump body for warpage dam age and wear Replace if body is warped or cracked or if shaft bore is worn so that clearance between shaft and bore is in excess of 005 Inspectall oil pump gears and replace if wear is perceptible Oil Pump Assembly l Press body gear onto oil pump drive shaft after placing new Woodruff key in slot of shaft Press gear onto shaft far enough to permit installation of retainer ring in groove in oil pump Press oil pump body gear down against ring Insert oil pump drive shaft and body gear into oil pump body Install new Woodruff key in slot at top end of shaft Install oil pump spiral gear with gear hub down onto drive shaft Press spiral gear down onto shaft until 1 32 clearance remains be tween gear hub and pump body when oil pump body gear is up against pump body L LINE MOTOR TRUCK SERVICE MANUAL Using hole in spiral gear as guide drill 1255 holein shaft Drive new spiral gear pin into place Install a new guide on the end of the pump shaft use guide installing tool Install idler gear on idler gear shaft In stall gasket and oil pump body cover and install four capscrews and lockwashers Test oil pump body gear end play to cover by using a feeler gauge between oil pump spiral gear hub and oil pump body End play mustbefrom 0025 0055 Ifclear ance is in excess of 0055 remove one gasket from cover If clearance is less than 0025 add one gasket between cover and body
145. rbon should be eliminated making it possible to retain the wider seat Valve Seat Inserts Necessity for replacing valve seat inserts should be very rare however if a replace mentis made itis important that new inserts be peened securely in place using either in sert peening tool or a dull pointed chisel 1 4 wide to peen cylinder head metal over outer edge of valve seat insert insert installing tools are Valve seat available Valve seat inserts supplied for service are standard size and 030 oversize which permits a tight fit in cylinder head Repair of Valves 1 True up the ends of valve stem against face of grinder Remove only enough ma terial to true the surface 2 Reface exhaust valves to 309 The valve face and valve seat angle must be identi cal 3 Reface intake valves to 30 with valve seat being the same 4 Place valves in cylinder head Place a thin coat of Prussian blue on each valve PRINTED IN UNITED STATES OF AMERICA face and tap valve lightly to its seat NOTE This is merely for test and proof of results of refacing and reseating oper ations A poor grinding job cannot be cor rected by valve lapping 5 Inspect each valve coated with blue for seat position The seat should be at the approximate center of valve face 3 64 5 64 wide for exhaust and 1 64 3 64 wide for intake Fig 19 if a Ge y Valve guide S gt mae Intake valve KST T NS A
146. re damaged or if ring gear is loose on flywheel the ring gear must be replaced Check the flywheel dowelholes and mount ing bolt holes for wear also check for fly wheel having been loose To replace flywheel ring gear heat gear with torch and remove from flywheel with a hammer and drift Heat new ring gear with torch heating evenly all the way around While the ring gear is hot install gear on flywheel and allow it to cool Check pilot bearing in flywheel for wear or damage and replace if needed Install flywheel on crankshaft Install six self locking capscrews drive dowel pins through flywheel to crankshaft Camshaft Cleaning and Inspection l Wash camshaft in cleaning solvent brush ing to facilitate removal of all sludge or carbon deposits Inspect camshaft journals for signs of wear or out of round Inspect oil pump drive gear in center of shaft If teeth are worn or damaged the camshaft must be replaced as the gear is integral with shaft Inspect camshaft lobes If worn chipped or scored replace the camshaft Inspect camshaft gear and replace if wear is evident or gear teeth are nicked or otherwise damaged To reassemble install thrust flange over end of camshaft Install Woodruff key in slot in shaft Place camshaft gear in boil ing water or piston heater and install over Woodruff key Install camshaft nut and tighten to approximately 120 foot pounds tension Cleaning and Inspecting M
147. rew 85 95 1 2 13 Crankshaft bearing bolt 75 85 1 14 Starting crank nul 9 om es sis 90 100 l 20 Camshaft lock nut TEE 110 120 7 8 18 Spark plug in cast iron Lass aes 32 35 14 MM Spark plug in cast iron 25 28 14 MM Spark plug in aluminum 21 25 18 MM Spark plug in cast iron 28 3 18 MM Spark plug in aluminum 25 28 PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only ENGINES Specifications L LINE MOTOR TRUCK SERVICE MANUAL age SUPER BLUE DIAMOND ENGINE SIZE AND RECOMMENDED THREAD NAME OF ASSEMBLY WRENCH TORQUE LOAD FT LB 5 16 18 Air cleaner to cylinder head 18 22 5 16 18 Fuel pump to crankcase o M 8 10 5 16 18 Crankshaft rear oil seal upper o 14 16 5 16 18 Distributor bracket to cylinder head 14 16 5 16 18 Oil pump cover to body 14 16 5 16 24 Vibration damper to pulley 16 18 5 16 24 Gear case cover to plate T 8 10 5 16 24 Generator mounting o eee n 8 10 3 8 16 Manifold to cylinder head 25 30 3 8 16 Oil pan to crankcase rasa a 25 30 3 8 16 Generator bracket to crankcase o 25 30 3 8 16 Oil pump body to crankcase v 25 30 3 8 16 Water pump to cylinder head 25 30 3 8 16
148. ring The fan pulley is pressed onto the shaft press fit 0007 to 0018 and held in place by a nut and plain washer Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Blue Diamond Section B Page 10 Retainer wi ring L Thrust 7 washer H p Cover plate and gasket A 23187 Fig 23 The impeller seal assembly consists ofa seal spring seal clamp ring flexible seal seal spring guide and a seal carbon washer The parts are held in place in the impeller by a snap ring The impeller and seal assembly is pressed onto the pump shaft press fit of 002 to 0035 Water Pump Disassembly Complete illustrated procedure for water pump servicing is given in Shop Talk No 14 l Remove six capscrews and lockwashers holding fan to pulley Remove fan blade assemblyfrom pulley Remove water pump from front end of cylinder head 2 Remove nut and flat washer holding pulley to water pump shaft Remove pulley from water pump shaft with puller 3 Remove four capscrews from cover plate Remove plate and gasket from pump body 4 Remove snap ring from front of the water pump shaftfront bearing Supporting water pump on arbor press push shaft and bear ing as an assembly out of impeller from the rear 5 Support the shaft and bearing assembly on an arbor press force shaft out of bearing spacer and slinger pressing shaft toward rear bearing Be careful not to lose the two halfmoon
149. rod and piston assembly down through top of cylinder block having slot in piston towards cam shaft side of engine Pistons are also marked with an arrow indicating front of engine Use a piston ring compressor sleeve to compress piston rings and thus avoid possible ring damage Wipe bore of connecting rodfree of oil and dirt Place bearing shell upper half in connecting rod bore being sure that oilhole aligns with oil hole in connecting rod and that locking tangs of bearing shall fit into recess Clean connecting rod cap bearing bore and clean back of bearing Place bearing shell lower half in connecting rod cap making sure that tang of bearing fits tions under Main Bearing and Connecting Rod Bearing Installation Coat bearing surfaces with oil Pull con necting rod into position on crankshaft journal and install connecting rod cap and bearing NOTE Bearing cap must only be installed on connecting rod one way with both connecting rod number and bear ing cap number to camshaft side Install two self locking capscrews and tighten to 65 foot pounds use tension wrench lo check connecting rod bearing to crank shaft clearance follow procedure given for plastigage on virgin lead test Spec ified connecting rod bearing to crankshaft clearance is from 0007 0032 Do not attempt to file connecting rods or bearing caps Follow procedure outlined in steps above for remaining connecting rods and pistons INSTALL CLUTC
150. s perceptible replace pins Replace piston pins which show signs of corrosion or etching 7 With properly fitting adapter press old piston pin bushing from connecting rod Fig 29 Place new piston pin bushing in position align oil hole in bushing with oil hole in connecting rod Fig 30 install bushing with a 0035 to 0055 press fit Burnish bushing into place in the connect ing rod Fig 31 ry then ream pin bushing to provide a hand push fit 8 With reamer ream piston pin bosses in piston to provide a tight fit of from 0000 Press ram gt Adapter _ gt Support plate Connecting rod Ze Fig 29 Use SE 1036 4 to remove bushing Select proper hole in SE 1033 Support plate to permit clearance for bushing Press ram PE Adapter U y Support plate Connecting rod A n A 21586 Fig 30 Installing new bushing in rod Press ram JNi Er E 5s A 22161 Fig 3 Burnish bushing using SE 879 to 0002 with piston pin NOTE When fitting piston pins the pins should be at room temperature 709 F and the pistons should be heated to approximately 2009 F Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Blue Diamond Section B Page 15 in boiling water or piston heater The pin should be a palm push fit under these conditions Piston Fitting When fitting p
151. se a new valve to check fit If No Go portion of gauge enters the guide must be replaced Recommended valve stem to valve guide clearance is Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Red Diamond Section C Page 6 L LINE MOTOR TRUCK SERVICE MANUAL from 002 to 004 for exhaust valves and from 0015 to 0035 for intake valves Clearance in excess of 006 for intake valves or 008 for exhaust valves re quires guide replacement Valve guides are reamed to 437 after assembly Fig 12 Valve guide reamer l1 Valve guide Fig 12 Fig 13 Test ten sion of each valve spring at valve open length with a valve spring tester Check inner valve springs at 1 1 2 length re place if pressure is less than 86 pounds Test outer spring at 1 45 64 length and replaceif pressureis less than 136 pounds 2 Test valve springs Scale inches Valve spring Scale pounds woe A 21890 Fig I3 Testing valve springs in SE 1565 Valve Spring Testing Tool 3 Inspecteach valve for warpage for severe ly burned condition and for excessive grinding on the valve head Inspect valve stem for scuf marks or perceptible wear Inspect valve stem end for wear at contact surface with valve rocker arm l valve is warped excessively burned or has been previously ground to extent that valve head is thin at edge replace valve otherwise valve can be recondit
152. ses and to provide a path to dissipate the heat accumulated in the valve head so as to prevent burning of the seat and warping of the head The location of the valve seat on the valve face and its width controls the amount of valve head that protrudes into the combustion cham ber It is obvious that the greater the exposure within the combustion chamber the higher the valve temperature or in other words the more heat it will collect High valve temperatures and poor heat dissipation also produce exces sive valve stem temperatures and hasten the accumulation of carbon on the stem causing them to stick in the guides Valve Seat Widths In general the width of exhaust seat should range between the average and maximum spe cifications and the intake seats between the minimum and average specifications The in take seats may be narrower than the exhaust 3 d Ai INTERNATIONAL Y U Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Red Diamond Section C Page 9 because they are usually larger in diameter thus providing a total seat area approximately equal to smaller exhaust valve with the wider seat Also the less severe heat conditions do not require as large a seat area for heat dis sipation purposes Figure 9 illustrates re commended valve seats to be obtained There arealso objections to an excessively wide seat a few of which are as follows
153. sing SE 149 8 Ring installing tool 3 When installing piston rings in piston grooves be careful not to distort rings If possible use a suitable piston ring ex pander tool Fig 34 Also check new piston rings in piston ring grooves for Clearance between ring and ring lands The correct ring clearance is shown in Specifications Crankshaft Cleaning and Inspection l Wash and clean crankshaft with cleaning solvent or steam 2 Inspect main bearing and connecting rod journals for wear If journals show wear or out of round in excess of 003 the shaft should be either reground and under size bearings installed or replaced Use micrometers for checking 3 Check cranksha t and flywheel dowels for damage and fit and replace if worn or damaged 4 Examine crankshaft timing gear teeth and replace gear if teeth are worn or damaged 5 Install Woodruff key in groove in crank shaft Heat crankshaft gear in boiling water Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Blue Diamond Section B Page 16 or piston heater This willexpand the gear enough to allow it to be tapped onto the crankshaft without the danger of damaging the gear A special crankshaft gear in stalling tool is available under SE 1088 Flywheel and Ring Gear Inspection i Clean flywheel and ring gear with a clean ing solvent remove all traces of oil and grease Inspect the flywheel ring gear If any teeth a
154. sing to crankcase 75 85 9 16 18 Crankshaft to flywheel 150 160 9 16 18 Crankshaft to flywheel 150 160 9 16 18 Crankshaft bearing CaP 100 110 9 16 18 Crankshaft bearing cap eec 100 110 l 20 Camshaft gear nul oo o oo o oo 110 120 7 8 18 Spark plug in cast iron o 32 35 14 MM Spark plug in cast iron 25 28 14 MM Spark plug in aluminum 2 25 18 MM Spark plug in cast iron TETT 28 31 18 MM Spark plug in aluminum 25 28 PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only ENGINES Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ee d Page 1 SILVER DIAMOND ENGINE Fig Silver Diamond Engine PRINTED IN UNITED STATES OF AMERICA ENGINES A SE L LINE MOTOR TRUCK SERVICE MANUAL Page 2 Donated by John amp Susan Hansen For Personal Use Only NMA o e A Zei b XL Fig 2 Sectional view of Silver Diamond Engine Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Silver Diamond Section A Page 3 DESCRIPTION General The Model SD engine is a4 cycle 6 cylin der in line overhead valve type engine Fig 1 and Fig 2 The engine serial number is stamped on a pad at the front on
155. specified width Bearing spread should therefore be carefully measured and corrected as necessary before installation in an engine Bearing spread can be safely adjusted as follows although care and judgment should be exercised in the process l Excessive spread If measurement of spread indicates that distance A is ex cessive see chart for specifications place bearing on a wood block and strike the side lightly and squarely with a soft mallet Fig 37 Recheck measurement and if necessary continue until correct width measurement A in chart is obtained 2 Insufficient spread If measurement of spread indicates insufficient spread place bearing on wood block and strike the back of the bearing lightly and squarely with a soft mallet Fig 37 Recheck measure ment and if necessary continue until cor rect width measurement A in chart is obtained Chart of Bearing Spread Dimentions BD Engine Minimum Connecting Rod Bearing 2 2951 d 025 HAN Main Bearing 2 875 025 MAIN 1l INSTALL CRANKSHAFT AND BEARINGS Clean all surfaces of crank shaft bearing Journals and wipe clean the bearing bores in the cylinder block Re move bearing cap self locking capscrews and bearing cap Wipe backs of cylinder block half of bearings making sure that dirt and oil is removed Place bearing shell halves in position in bore in cylinder block making sure that bearing shells are fully seat
156. st valve The ro tating feature is used on the exhaust valves anu Fig nd Make sure end of valve stem Intake valve No cap used E 1 23203 Fig 15 and gauge plunger pin are clean Place Clear ance Gauge on end of exhaust valve with gauge set at 0 marking Press the plunger pin of the gauge firmly against the valve stem and tighten clamp screw oie 16 Remove gauge Plunger pin ke d Pa m Clearance gauge E EE P s Clamp screw a E o 4 23200 Fig 16 ue use of SE 1726 Gauge from stem and place valve cap on plunger pin of gauge The clearance or lack of clearance that existed between the valve stem and cap are now transfered to the end of the gauge plunger pin and valve cap and shows in thousandths of an inch on the spindle barrel Fig 17 Press Y7 Clearance between er Valve cap valve stem and cap do is transferred to uM NS this point N i A A Gauge spindle gt A N NTE A Plunger pin xs Screw in contact with A 7 i end of valve stem Ba AY A i e 4 D x Valve key lock Spring retainer on e QUO RF E ong O Clos e Spring ZS Ot Exhaust valve A 23205 Fig 17 Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Red Diamond Section C Page 8 L LINE MOTOR TRUCK SERVICE MANUAL MIDA the cap firmly against the gauge Turn spindle of gauge to right or left until cap bottoms on gauge p
157. ston in piston vise and using pin driving tool drive piston pin from Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Blue Diamond Section B Page 14 L LINE MOTOR TRUCK SERVICE MANUAL A A ANA piston and connecting rod Fig 28 After piston pin is removed lift piston from connecting rod He tada Dr E a n AN PAG UE rise et n Am i F Iiston Soft hammer Piston pin SC Piston vise A 22205 Fig 28 Use suitable piston vise to hold pis ton and drive pin out with SE 1263 Piston Pin Driver Use soft hammer 3 Wash all parts in a cleaning solvent CAUTION Donotuseacaustic solution for aluminum pistons Clean the carbon from piston ring grooves with a broken ring or ring groove cleaner 4 Inspect connecting rods caps and bearing shells All connecting rod bearings and piston pin bushings should be replaced at every major overhaul Test rods for align ment Rods only slightly misaligned can be straightened with proper equipment Badly twisted or bent connecting rods must be replaced 5 Inspect pistons for cracks breakage or scores Check piston ring grooves and ring lands for wear using a new piston ring and feeler gauge If clearance be tween ring and ring land exceeds 005 total clearance replace piston see spec ifications Pistons which are scored or damaged must be replaced 6 Inspect piston pins for wear and if wear i
158. ter pump shaft Remove pulley from water pump shaft with puller 3 Remove five capscrews from cover plate Remove plate and gasket from pump body 4 Remove snap ring from in front of the water pump shaft frontbearing Supporting water pump on arbor press push shaft and bearing as an assembly out of impeller from the rear 5 Support the shaft and bearing assembly on an arbor press force shaft out of bearing Spacer and slinger pressing shaft toward rear bearing Be careful not to lose the two half moon lock rings from under the slinger 6 Remove snap ring from groove in the front of impeller and liftout the seal parts from the impeller Water Pump Cleaning and Inspection l Following disassembly wash all except rubber parts in cleaning solvent d Examine seal parts for wear corrosion or damage and replace with new parts as necessary Examine the pump body seal seat surface If face of surface is scored it must be resurfaced to prevent leakage Inspect pump shaft bearing for wear or corrosion If worn or corroded replace bearings Examine shaft for wear at ends or for damaged threads at front end Water Pump Repair If water pump body seal seat is scored pitted or rough it must be resurfaced Use special water pump housing seat finishing tool and adapter Water Pump Assembly and front Place l Install rear bearing bearing onto water spacer pump shaft Donated by John amp Susan Hansen
159. the right side of crankcase just below the cylinder head The block does not have replaceable liners for the cylinders The detachable cylinder head con tains all valves valve guides and springs The cylinders are numbered from front fan and timing gear end to rear Engine crank shaft rotation is clockwise as viewed from the front end of the vehicle The intake and ex baust manifolds carburetor starter and gen erator are located on the right side of engine The ignition coil distributor fuel pump oil pressure regulator and breather are located on the left side of engine The oil filler inlet is located in the valve cover on the top of en Exhaust aust Rocker arm manifold Retainer j lt Seal ring p Exhaust pipe gine The bayonnet type oil level gauge is located on the left side of engine The water pump is located at the front of engine Construction l The generator fan and water pump are driven by a V type belt from a driven pul ley mounted onthe front end of crankshaft The distributor mounted at the left side of engine is driven by the camshaft through the oil pump 2 The exhaustand intake manifolds are bolted to each other and to the right side of the engine head The intake manifold and the exhaust manifold are each cast in one piece 3 A vibration damperis providedat the front end of the crankshaft on the model SD 240 engine only Cover capscrew Ro
160. three out lets each supplying fuel to two cylinders Two studs are located on the top for car buretor mounting 2 If vacuum is needed to operate any unit within the truck a threaded inlet is pro vided in the manifold for such purposes Exhaust Manifold The exhaust manifold consists of four out lets The two end outlets remove burned gases from the No 1 and No 6 cylinders while the two center outlets remove burned gases from Nos 2 3 4 and 5 cylinders Manifold Inspection Inspect intake and exhaust manifolds visu ally for cracks or breakage Place manifolds on surface plate and check for warpage If PRINTED IN UNITED STATES OF AMERICA cracked or broken replace or weld If slightly warped true up on surface grinder but replace if warpage is extreme Manifold Assembly Place new gasket between the intake and exhaust manifolds and install two capscrews and two nuts Mount manifolds together loosely before installing on engine This will assure proper alignment of the units with each other and with the engine cylinder head NOTE Do not eliminate the intake manifold aligning pilot rings Oil Pump Overhaul Complete illustrated procedure for oil pump overhual is given in Shop Talk No 28 Special tool equipment is available for oil pump overhaul under SE 1499 Use of these tools will speed up the job and assure accurate work IDLER GEAR OUTLET PIPE OIL FLOAT Fig 26 Oil Pump Disassemb
161. uarely with a soft mallet Recheck measurement and if necessary continue until correct width measurement A in chart is ob tained 2 Insufficient spread If measurement of spread indicates insufficient spread place bearing on wood block Fig 66 and strike the back of the bearing lightly and square ly with a soft mallet Recheck measure ment and if necessary continue until cor rect width measurement A in chart is obtained Chart of Bearing Spread Dimensions Silver Diamond Engine Minimum Connecting Rod Bearing 29004 025 Main Bearing 2 942 F 025 l INSTALL CRANKSHAFT AND BEARINGS Clean all surfaces of crankshaft bearing journals and wipe clean the bearing bores in the cylinder block Remove bearing cap self locking capscrews and bearing cap Wipe backs of cylinder block half of bear ings making sure that dirt and oil are re moved Place bearing shell halves in position in bore in cylinder block making sure that bearing shells are fully seated that oil holes inbearing shells line up with SOFT MALLET STRIKE LIGHTLY AND SQUARELY BEARING WOOD BLOCK 4 TATI RL TS TAE tr ALA E 4 Ter ee AA DECREASING SPREAD SOFT MALLET STRIKE LIGHTLY AND SQUARELY BEARING WOOD BLOCK TELL RII RS F A SE p LLL ITE Ve ZRC ISS A 16095 INCREASING SPREAD Fig 66 oil holes in cylinder block and that lock ing tongs on bearings fit into
162. ully measured and corrected as necessary before installation in an engine Bearing spread can be safely adjusted as follows although care and judgment should be exercised in the process l Excessive spread If measurement of spread indicates that distance A is ex cessive seechartfor specifications place bearing ona wood block and strike the side lightly and squarely witha soft mallet Fig 45 Recheck measurement and if neces sary continue until correct width meas urement A in chart is obtained 2 Insufficient spread If measurement of spread indicates insufficient spread place bearing on wood block and strike the back of the bearing lightly and squarely with a soft mallet Fig 45 Recheck measure ment and if necessary continue until cor rect width measurement A1 in chart is obtained Chart of Bearing Spread Dimensions RD Engine Minimum Connecting Rod Bearing 2 8985 025 Main Bearing 3 424 025 l INSTALL CRANKSHAFT AND MAIN BEARINGS Clean all surfaces of crank shaft bearing journals and wipe clean the bearing bores in the cylinder block Re move main bearing cap self locking cap screws and main bearing cap Wipe backs of cylinder block half of bearings making sure that dirt and oilis removed Place bearing shell halves in position in bore in cylinder block making sure that bearing Shells are fully seated that oil holes in bearing shells line up with oil holes in cylinder
163. up 85 95 Donated by John amp Susan Hansen For Personal Use Only 1 683 141 149 0015 004 I9 469 480 go 023 0025 0055 1885 4890 005 15 20 idling 40 45 1200 up 85 95 0015 004 59 459 409 023 0025 0055 03125 04985 24992 005 15 20 idling 40 45 1200 up 75 85 1 595 1 706 83 88 133 141 0015 004 g9 520 550 159 023 0025 2 0055 03125 4985 04990 005 15 20 idling 40 45 1500 up 100 110 1 503 1 706 83 88 133 141 0015 004 go 529 559 4 063 0025 2 0055 03125 4985 4990 005 15 20 idling 40 45 1500 up 100 110 CONT R 6602 1 503 1 750 1 706 1 750 83 88 82 88 133 141 160 170 0015 0002 004 0014 89 129 529 629 559 549 159 209 023 020 0025 2 0055 03125 4985 005 15 20 idling 40 45 1500 up 100 110 100 110 yp 22e 4 suotjeotjrsedg Z mi lt O E Q 2 2 C O Fe UN m e lt O n gt Z C gt E SU NIONS Donated by John amp Susan Hansen For Personal Use Only ENGINES ANIMA L LINE MOTOR TRUCK SERVICE MANUAL Specifications VA UV Page 5 SILVER DIAMOND ENCINE RECOMMENDED piedi NAME OF ASSEMBLY WRENCH TORQUE LOAD FT LB 5 16 18 Generator strap to generator 14 16 5 16 18 Water outlet T
164. uretor and air cleaner previously removed 1 Remove four nuts from rocker arm cover Remove air cleaner lineand removecover 2 Remove nuts capscrews and oil bolts from shaft brackets NOTE Third bolt from the rear on the left side of the cylinder head supplies oil to rocker arms Fig 2 Fig 2 PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL ENGINES Super Red Diamond Section C Page 3 3 Remove rocker arm assembly as a unit Fig 3 Rocker arm assembly Oil stud bracket pi d e i gt m LAS E aa Fig 3 Removing Rocker Arm Assembly Rocker Arm and Valve Mechanism Disassembly 1l The rocker arm assembly is composed of front and rear shafts joined at the center on which are mounted twelve rocker arms and four tension springs The shafts are mounted in seven brackets and are pre vented from turning at the two center brackets which contain locking washers fitting into slots in the shaft Remove locking washers from two center brackets Fig 4 Rocker arm Shaft bracket Locking Slot Rocker arm 95555 Fig Y 2 Separate the shafts and slide rockerarms springs and brackets from shafts 3 Clean all parts ina solvent cleaning fluid being careful to clean all accumulated sludge and carbon deposits from oil holes and slots Rocker Arm Inspection Carefully inspe
165. ventll4lO X d 0x 2o EE EE EE E AAA TEET 26 Cylinder Nead 334 AREA AAA EA 23 Engine mounting 0 mues o DESIDIA 24 Flywheel and housing CAI AAA ICAA tee ee ee EE 21 Main Dearing s 4 06 40 Shee we dx Tr COT 18 21 Rocker arm assembly 4 e AAA EA AS 23 TAaDPets 6445464 9x 40x aes Eod os Oe X ode dod 9 ee eS eR 4 9 EEN m 21 jb iD AAA AAA ROO ORS SE GS 22 Valve adus BO 4 interior AAA Esa 24 PRINTED N UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only R LINE MOTOR TRUCK SERVICE neris Page l SUPER BLACK DIAMOND 282 SLEEVELESS ENGINE SPECIFICATIONS Engines used in R Line chassis are the same as used in L Line trucks except the new BD 282 Super Black Diamond Sleeveless Engine has been added for the RF 170 R 180 RC 180 as standard equipment The following chart lists specifications of this new engine LAPINE 66 wo 9 aos EE Ow ewe ow d Super Black Diamond 282 Sleeveless Engine Number Of Cylinders 4 bow oe ES m dO woe AAA s Es Pc wow wo ee 4 39 x3 6 DOR 4m nck AR EE EE ENEE TITLED 3 13 16 pn o 22 presos SAO ron ara AE Res 4 1 8 Displacement cu in ooo Terre eT SG e eae E ENS 282 546 Rated HP AMA PEE EIC 34 8 Brake HP Maita 4 4 scd dar AEREA Oe eee ee SR AER 130 2 AUICP M ke o Ne aparador ea ars Id 3400 Brake HP nel we dE E EC AAA oe ENEE ES owas E 117 5 At
166. wheel and c x cap and bearing shell ee In crankshaft flange and tighten to a tension ian paier pai bie and ighten to of approximately 155 foot pounds using a E SOL pesce tension wrench d Rock the crankshaft back and forth two 8 INSTALL VALVE TAPPETS Coat each or three times Further tighten bolts of twelve valve tappets with heavy engine to 60 to 70 foot pounds and n jade rock oil and install from crankcase side of en the crankshaft two or three times gine Fig 47 Tighten bolts to 105 foot pounds and EE bearmg cap 9 INSTALL GEAR CASE COVER PLATE o Place plate and gasket at front end of en e Thevirginlead willnowbe compressed gine cylinder block Install two capscrews exactly in accordance with the amount and lockwashers NOTE To be sure that of bearing to crankshaft clearance cover plate is in line with the gear case Peel off flattened piece of virgin lead mounting bolts which go through the cover wire and measure with micrometer plate install or start three or four gear Thickness of flattened piece of wire case bolts before tightening the two cover is exact amount of bearing clearance plate capscrews Remove gear case bolts present Repeat above operations on after tightening op ration all bearings 10 INSTALL CAMSHAFT AND GEAR Coat 5 If clearance is not within 0013 to 0043 camsha t with engine oil Insert camshaft either use undersize bearing regrind shaft into front end of engine block being care or repl
167. x cess of 006 for intake valves or 008 for exhaust valves require guide replacement Ream guides to 3435 3455 after assem bly in cylinder head 2 Test valve springs with damper in posi tion Test tension of each valve spring at valve open length witha valve spring test er Fig 10 Check valve springs at 1 43 64 length and replace if pressure is less than 111 lbs Scale inches Valve spring Scale pounds a A 21890 Fig IO Test valve springs in SE 1565 Valve spring testing tool 3 Inspect each valve for warpage for se verely burned condition and for exces sive grinding on the valve head Inspect valve stem for scuff marks or perceptible wear Inspect valve stem end for wear at contact surface with valve rocker arm If valve is warped excessively burned or has been previously ground to extent that valve head is thin at edge replace valve otherwise valve can be reconditioned and reinstalled Donated by John amp Susan Hansen For Personal Use Only ENGINES Super Blue Diamond Section B Page 6 L LINE MOTOR TRUCK SERVICE MANUAL Repair of Cylinder Head l If cylinder head has to be resurfaced re move only enough material to true up surface 4 If any valve guide shows excessive clear anceor out of round condition press guide from head with special removing tool In Stall new guide and press into head until approximately 1 1 16 remains above the topsurface

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