Waukesha VGF F18G Operating instructions

FORM 6243
Copyright 1989, 2001, 2002 Dresser, Inc. All rights
reserved
Waukesha Engine
Dresser, Inc.
Waukesha, Wisconsin 53188
Printed in U.S.A. 7/02
This document contains proprietary and trade secret information and
is given to the receiver in confidence. The receiver by reception and
retention of the document accepts the document in confidence and
agrees that, except as with the prior expressed written permission of
Waukesha Engine, Dresser, Inc., itwill; (1) not use thedocument or any
copy thereof or the confidential or trade secret information
therein; (2) not copy or reproduce the document in whole, or in part
without the prior written approval of Waukesha Engine, Dresser, Inc.;
and (3) not disclose to others either the document or the confidential or
trade secret information contained therein.
All sales and information herein supplied subject to Standard Terms of
Sale, including limitation of liability.
WAUKESHA, DRESSER, and WKI are registered trademarks of
Dresser, Inc. VGF and DRESSER logo are trademarks of Dresser, Inc.
All other trademarks, service marks, logos, slogans, and trade names
(collectively “marks”) are the properties of their respective owners.
Dresser, Inc. disclaims any proprietary interest in these marks owned
by others.
Serial No.
Specification No.
Printed on Recycled Paper
Third Edition
F18/H24 G/GL/GLD/GSID
Repair & Overhaul Manual
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ILLUSTRATIONS
xiFORM 6243 Third Edition
LIST OF ILLUSTRATIONS
Section 1.00 -- Warning Tag And Decal
Locations
Figure 1.00-1. Warning Tag And
Decal Locations 1.00 -- 2......................
Figure 1.00-2. Warning Tag And
Decal Locations 1.00 -- 3......................
Figure 1.00-3. Caution Label -- P/N 209107M --
To Service Heater 1.00 -- 4....................
Figure 1.00-4. Danger Label -- P/N 211900 --
Disconnect Power Source 1.00 -- 4.............
Figure 1.00-5. Warning Label -- P/N 211910K --
Safety Guard 1.00 -- 4........................
Figure 1.00-6. Warning Label -- P/N 211910L --
Safety Guard 1.00 -- 4........................
Figure 1.00-7. Warning Label -- P/N 211910N --
Maximum Gas Inlet Pressure 1.00 -- 4...........
Figure 1.00-8. Warning Label -- P/N 211910T --
Maximum Gas Inlet Pressure 1.00 -- 4...........
Figure 1.00-9. Warning Label -- P/N 211910W --
Vent Flammable Gas 1.00 -- 5..................
Figure 1.00-10. Warning Label -- P/N 211911B --
Built Without Engine Protection 1.00 -- 5.........
Figure 1.00-11. Warning Label -- P/N 211911J --
Barring Device 1.00 -- 5.......................
Figure 1.00-12. Caution Label -- P/N 211920B --
Eye/Ear Protection 1.00 -- 5....................
Figure 1.00-13. Caution Label -- P/N 211920E --
Hot Components 1.00 -- 6.....................
Figure 1.00-14. Safety Label -- P/N 211930A --
Lifting Instructions 1.00 -- 6....................
Figure 1.00-15. Caution Label -- P/N 211930C --
Lifting Instructions 1.00 -- 6....................
Section 1.10 -- Rigging And Lifting
Engines
Figure 1.10-1. Correct Method Of Lifting
Engine -- Rear View 1.10 -- 1...................
Figure 1.10-2. Correct Method Of Lifting
Engine -- Side Views 1.10 -- 2..................
Section 1.15 -- General Information
Figure 1.15-1. Previous Production Model
Plate 1.15 -- 1................................
Figure 1.15-2. VGF Specification Plate 1.15 -- 2......
Figure 1.15-3. Engine Nameplate 1.15 -- 2...........
Figure 1.15-4. Current Nameplate
Configuration 1.15 -- 2........................
Figure 1.15-5. Engine Serial Number 1.15 -- 3........
Figure 1.15-6. Left Side View -- F18GL 1.15 -- 4......
Figure 1.15-7. Left Side View -- H24G 1.15 -- 5.......
Figure 1.15-8. Right Side View -- H24GL 1.15 -- 6.....
Figure 1.15-9. Right Side View -- H24GLD,
Impco Carburetor 1.15 -- 7.....................
Figure 1.15-10. Right Side View -- F18GLD,
Deltec Carburetor And High Temperature
Application 1.15 -- 8..........................
Figure 1.15-11. Right Side View -- F18GSID 1.15 -- 9...
Figure 1.15-12. Front View -- F18G/H24G 1.15 -- 10...
Figure 1.15-13. Front View -- F18GL/
H24GL 1.15 -- 11.............................
Figure 1.15-14. Rear View -- F18GL/
H24GL 1.15 -- 12.............................
Figure 1.15-15. Rear View -- F18G 1.15 -- 13.........
Figure 1.15-16. Rear View -- F18G/H24G,
Dual Fuel 1.15 -- 14...........................
Figure 1.15-17. Instrument Panel 1.15 -- 15..........
Figure 1.15-18. Rear View F18GL/H24GL,
Impco 1.15 -- 19..............................
Figure 1.15-19. Right And Left Side Views --
F18GLD/H24GLD 1.15 -- 20...................
Figure 1.15-20. Front View F18GL/H24GL,
Impco 1.15 -- 21..............................
Section 2.00 -- Cylinder Head Removal
Figure 2.00-1. Exhaust Thermocouple 2.00 -- 1.......
Figure 2.00-2. Exhaust Thermocouple
Conduit 2.00 -- 1.............................
Figure 2.00-3. Turbocharger Discharge
Elbow 2.00 -- 1...............................
Figure 2.00-4. Turbocharger Discharge
Elbow 2.00 -- 2...............................
Figure 2.00-5. Heat Shield 2.00 -- 2.................
Figure 2.00-6. High Tension Coil Lead 2.00 -- 2.......
Figure 2.00-7. Spark Plug Tube Tool --
P/N 472065 2.00 -- 2..........................
Figure 2.00-8. Rocker Arm Cover --
Standard 2.00 -- 2............................
Figure 2.00-9. CSA High Tension Lead 2.00 -- 3......
Figure 2.00-10. CSA Flange Mounted Coil 2.00 -- 3...
Figure 2.00-11. Spark Plug Tube Tool --
P/N 472065 2.00 -- 3..........................
Figure 2.00-12. CSA Rocker Arm Cover 2.00 -- 3.....
Figure 2.00-13. Rocker Arm Cover Removal
Tool 2.00 -- 3................................
Figure 2.00-14. Rocker Arm Support
Installation 2.00 -- 4...........................
Figure 2.00-15. Rocker Arm Support
Wrench 2.00 -- 4.............................
Figure 2.00-16. Rocker Arm Support
Installation 2.00 -- 4...........................

ILLUSTRATIONS
xii FORM 6243 Third Edition
Figure 2.00-17. Cross Bar Installation 2.00 -- 4.......
Figure 2.00-18. Intake Manifold 2.00 -- 4.............
Figure 2.00-19. Intake Manifold 2.00 -- 5.............
Figure 2.00-20. Exhaust Manifold 2.00 -- 5...........
Figure 2.00-21. CSA Conduit 2.00 -- 5...............
Figure 2.00-22. Vortox Separator Bracket 2.00 -- 5....
Figure 2.00-23. Current—Water Elbow
Assembly 2.00 -- 5............................
Figure 2.00-24. Previous—Water Elbow
Assembly 2.00 -- 6............................
Figure 2.00-25. Rocker Arm Cover Studs 2.00 -- 6....
Figure 2.00-26. Cylinder Head 2.00 -- 6.............
Figure 2.00-27. Lifting Eye 2.00 -- 6.................
Figure 2.00-28. Cylinder Head Gasket --
P/N 300000B 2.00 -- 7........................
Figure 2.00-29. Cylinder Head Gasket --
P/N 300000D 2.00 -- 7........................
Figure 2.00-30. Intake Manifold O--Rings 2.00 -- 7....
Section 2.05 -- Crankcase Removal
Figure 2.05-1. Connecting Rod Inspection
Cover 2.05 -- 1...............................
Figure 2.05-2. Piston Cooling Jet 2.05 -- 1...........
Figure 2.05-3. Connecting Rod Access 2.05 -- 2......
Figure 2.05-4. Match Cap And Rod
Numbers 2.05 -- 2............................
Figure 2.05-5. Carbon Removal 2.05 -- 2............
Figure 2.05-6. Piston Removal/Installation
Tool 2.05 -- 2................................
Figure 2.05-7. Piston Removal 2.05 -- 3.............
Figure 2.05-8. Cylinder Sleeve Removal 2.05 -- 3.....
Figure 2.05-9. Sleeve Removal Tool 2.05 -- 3........
Figure 2.05-10. Parallel Pins 2.05 -- 3...............
Figure 2.05-11. Upper Oil Separator Inlet
Tube 2.05 -- 4................................
Figure 2.05-12. Auxiliary And Jacket Water
Pumps 2.05 -- 4..............................
Figure 2.05-13. Water Pump Idler Oil Supply 2.05 -- 4..
Figure 2.05-14. PSG Governor 2.05 -- 4.............
Figure 2.05-15. Magneto 2.05 -- 4..................
Figure 2.05-16. Hall--effect Pickup Location 2.05 -- 5..
Figure 2.05-17. Vibration Damper Guard 2.05 -- 5.....
Figure 2.05-18. Vibration Damper 2.05 -- 5...........
Figure 2.05-19. Damper Driving Flange 2.05 -- 5......
Figure 2.05-20. Crankcase Seal Removal 2.05 -- 6....
Figure 2.05-21. Front Crankshaft Seal
Installation 2.05 -- 6...........................
Figure 2.05-22. Front Gear Cover Dowel
Locations 2.05 -- 6............................
Figure 2.05-23. Lifting The Gear Housing 2.05 -- 6....
Figure 2.05-24. Camshaft And Idler Gear
Removal 2.05 -- 7............................
Figure 2.05-25. Camshaft Thrust Flange 2.05 -- 7.....
Figure 2.05-26. Front Gear Housing 2.05 -- 7.........
Figure 2.05-27. Crankshaft Gear Removal 2.05 -- 7...
Figure 2.05-28. Oil Pump Idler Gear 2.05 -- 7.........
Figure 2.05-29. Rear Engine Support 2.05 -- 8........
Figure 2.05-30. Front Engine Support 2.05 -- 8.......
Figure 2.05-31. Electric Starter 2.05 -- 8.............
Figure 2.05-32. Barring Device 2.05 -- 8.............
Figure 2.05-33. Flywheel Removal 2.05 -- 9..........
Figure 2.05-34. Flywheel Housing Removal 2.05 -- 9..
Figure 2.05-35. Rear Seal Carrier 2.05 -- 9...........
Figure 2.05-36. Rear Crankshaft Seal
Carrier 2.05 -- 9..............................
Figure 2.05-37. Rear Seal Carrier
Installation 2.05 -- 10..........................
Figure 2.05-38. Cam Follower Holding Tool 2.05 -- 10..
Figure 2.05-39. Camshaft Thrust Flange 2.05 -- 10....
Figure 2.05-40. Lube Oil Filters 2.05 -- 10............
Figure 2.05-41. Regulator Support Bracket 2.05 -- 10..
Figure 2.05-42. Camshaft Access Doors 2.05 -- 11....
Figure 2.05-43. Camshaft Thrust Flange 2.05 -- 11....
Figure 2.05-44. Rear Camshaft Cover 2.05 -- 11......
Figure 2.05-45. Follower Shaft Retaining
Screws 2.05 -- 11.............................
Figure 2.05-46. Rocker Arm Shaft
Removal 2.05 -- 12...........................
Figure 2.05-47. Camshaft Follower
Removal 2.05 -- 12...........................
Figure 2.05-48. Camshaft Pilot Tool 2.05 -- 12........
Figure 2.05-49. Camshaft Removal 2.05 -- 12........
Figure 2.05-50. Lube Oil Leveler 2.05 -- 13...........
Figure 2.05-51. Lube Oil Leveler 2.05 -- 13...........
Figure 2.05-52. Breather System 2.05 -- 13..........
Figure 2.05-53. Fuel Regulator Support
Bracket 2.05 -- 13............................
Figure 2.05-54. Air/Gas Starter Motor
Connections 2.05 -- 13........................
Figure 2.05-55. Oil Pan Removal
Clearance 2.05 -- 14..........................
Figure 2.05-56. Oil Pump 2.05 -- 14.................
Figure 2.05-57. Crankcase Spreader Tool 2.05 -- 14...
Figure 2.05-58. Main Bearing Cap Thrust
Washer 2.05 -- 14............................
Figure 2.05-59. Bearing Cap CrossBolt 2.05 -- 15.....
Figure 2.05-60. Crankshaft Removal 2.05 -- 15.......
Figure 2.05-61. Oil Gallery Plug 2.05 -- 15...........
Figure 2.05-62. Oil Gallery Plug 2.05 -- 15...........
Figure 2.05-63. Crankcase Rear Dowels 2.05 -- 15....

ILLUSTRATIONS
xiii
FORM 6243 Third Edition
Section 3.00 -- Cylinder Head
Figure 3.00-1. Rocker Arm Support 3.00 -- 1.........
Figure 3.00-2. Rocker Arm Support Wrench 3.00 -- 1..
Figure 3.00-3. Rocker Arm Support 3.00 -- 1.........
Figure 3.00-4. Intake and Exhaust Rocker
Arms 3.00 -- 2................................
Figure 3.00-5. Cross Bars And Seats 3.00 -- 3........
Figure 3.00-6. Cross Bar Assembly 3.00 -- 3.........
Figure 3.00-7. Cross Bar Measurement 3.00 -- 3......
Figure 3.00-8. Cross Bar Guide And Seat 3.00 -- 3....
Figure 3.00-9. Rocker Arm Assembly 3.00 -- 4........
Figure 3.00-10. Rocker Arm Support 3.00 -- 5........
Figure 3.00-11. Spark Plug Tube 3.00 -- 5...........
Figure 3.00-12. Cylinder Head Face 3.00 -- 6........
Figure 3.00-13. Measure Head For
Warpage 3.00 -- 6............................
Figure 3.00-14. Measure Valve Recession 3.00 -- 6...
Figure 3.00-15. Remove Water Jet 3.00 -- 6..........
Figure 3.00-16. Valve Split Locks 3.00 -- 7...........
Figure 3.00-17. Remove Valve Springs 3.00 -- 7......
Figure 3.00-18. Valve Removal 3.00 -- 7.............
Figure 3.00-19. Valve Seat 3.00 -- 7.................
Figure 3.00-20. Valve Seat Removal Tool 3.00 -- 7....
Figure 3.00-21. Valve Guide Removal Tool 3.00 -- 8...
Figure 3.00-22. Valve Rework Dimensions 3.00 -- 9...
Figure 3.00-23. Valve Guide Installation 3.00 -- 12....
Figure 3.00-24. Valve Seat Installation Tool --
P/N 472004 3.00 -- 13.........................
Figure 3.00-25. Measure Valve Recession 3.00 -- 13..
Figure 3.00-26. Valve Recession 3.00 -- 13..........
Figure 3.00-27. Measure Valve Seat
Concentricity 3.00 -- 14........................
Figure 3.00-28. Valve Seat Dimensions 3.00 -- 14.....
Figure 3.00-29. Expander Plug Location 3.00 -- 17....
Figure 3.00-30. Expander Plug Installation 3.00 -- 17..
Figure 3.00-31. Water Jet Installation 3.00 -- 17.......
Figure 3.00-32. Spark Plug Holder
P/N 305003J 3.00 -- 17........................
Figure 3.00-33. Spark Plug Holder Seal
Washer 3.00 -- 18............................
Figure 3.00-34. Spark Plug Holder Tool 3.00 -- 18.....
Figure 3.00-35. P/N AE300302C Cylinder
Head 3.00 -- 18..............................
Figure 3.00-36. Valve Stem Seal Installation
Tool 3.00 -- 19...............................
Figure 3.00-37. Valve Seat 3.00 -- 19................
Figure 3.00-38. Install Valve Springs 3.00 -- 19.......
Figure 3.00-39. Valve Spring Compressor 3.00 -- 20...
Figure 3.00-40. Valve Springs 3.00 -- 20.............
Figure 3.00-41. Cross Bars And Seats 3.00 -- 20......
Figure 3.00-42. Rocker Cover Head Studs 3.00 -- 20..
Section 3.05 -- Crankcase Disassembly
Figure 3.05-1. Crankshaft Set Screws 3.05 -- 2.......
Figure 3.05-2. 12 Cylinder Crankshaft 3.05 -- 3.......
Figure 3.05-3. Crankshaft 3.05 -- 5..................
Figure 3.05-4. Inspect Cam Followers 3.05 -- 6.......
Figure 3.05-5. Camshaft Follower
Disassembly 3.05 -- 7.........................
Figure 3.05-6. Camshaft Follower 3.05 -- 7...........
Figure 3.05-7. Piston Pin 3.05 -- 8..................
Figure 3.05-8. Piston Ring Removal 3.05 -- 8.........
Figure 3.05-9. Piston Oil Drain Holes 3.05 -- 9........
Figure 3.05-10. Check Piston Ring Groove
Clearance 3.05 -- 11..........................
Figure 3.05-11. Piston Pin 3.05 -- 12................
Figure 3.05-12. Connecting Rod 3.05 -- 13...........
Figure 3.05-13. Connecting Rod, Bushing
And Bearing 3.05 -- 13........................
Figure 3.05-14. Connecting Rod Bushing
Press Removal 3.05 -- 14......................
Figure 3.05-15. Connecting Rod Bushing
Press 3.05 -- 15..............................
Figure 3.05-16. Connecting Rod Small End 3.05 -- 15..
Figure 3.05-17. Connecting Rod Bushing
Press Installation 3.05 -- 15....................
Figure 3.05-18. Flexible Hone 3.05 -- 16.............
Figure 3.05-19. Cylinder Sleeve Deglazing
Cross Hatch Pattern 3.05 -- 16.................
Figure 3.05-20. Lower Cylinder Liner 3.05 -- 18.......
Figure 3.05-21. Flywheel Ring Gear 3.05 -- 19........
Figure 3.05-22. Timing Tape Installation 3.05 -- 19....
Figure 3.05-23. Dual Dowel Pin Crankcase 3.05 -- 20..
Figure 3.05-24. Crankshaft Spreader Tool 3.05 -- 21...
Figure 3.05-25. Crossbolt Oil Passage 3.05 -- 21.....
Figure 3.05-26. Main Bearing Cap
Installation 3.05 -- 22..........................
Figure 3.05-27. Crossbolt Oil Passage 3.05 -- 22.....
Figure 3.05-28. Measure Main Bearing
Bores 3.05 -- 22..............................
Figure 3.05-29. Crankshaft Main Bearing
Journal 3.05 -- 23.............................
Figure 3.05-30. Main Bearing Running
Clearance 3.05 -- 23..........................
Figure 3.05-31. Bearing Thickness Formula 3.05 -- 24...
Figure 3.05-32. Measure Camshaft Bearing
Bores 3.05 -- 25..............................
Figure 3.05-33. Cam Thrust Bushing
Removal 3.05 -- 25...........................
Figure 3.05-34. Camshaft Bushing Press 3.05 -- 25...

ILLUSTRATIONS
xiv FORM 6243 Third Edition
Section 4.00 -- Crankcase Assembly
Figure 4.00-1. Crankcase Dowel Pin 4.00 -- 1........
Figure 4.00-2. Dual Dowel Pin Crankcase 4.00 -- 1....
Figure 4.00-3. Crankshaft Counterweights 4.00 -- 2...
Figure 4.00-4. Crankshaft Plugs 4.00 -- 2............
Figure 4.00-5. Upper Main Bearing 4.00 -- 2..........
Figure 4.00-6. Crankshaft Rigging 4.00 -- 2..........
Figure 4.00-7. Dual Dowel Pin Crankcase 4.00 -- 3....
Figure 4.00-8. Crankcase Spreader Tool 4.00 -- 3.....
Figure 4.00-9. Main Bearing Cap Installation 4.00 -- 3..
Figure 4.00-10. Main Bearing Cap Thrust
Washer 4.00 -- 4.............................
Figure 4.00-11. Crossbolt Oil Passage 4.00 -- 4.......
Figure 4.00-12. Crankshaft Gear Installation 4.00 -- 4..
Figure 4.00-13. Main Bearing Cap
Installation 4.00 -- 4...........................
Figure 4.00-14. Main Bearing Cap Thrust
Washer 4.00 -- 5.............................
Figure 4.00-15. Bearing Cap CrossBolt 4.00 -- 5......
Figure 4.00-16. Crossbolt Oil Passage 4.00 -- 5......
Figure 4.00-17. Crankshaft Gear Installation 4.00 -- 5..
Figure 4.00-18. Cylinder liner Assembly 4.00 -- 6.....
Figure 4.00-19. Cylinder Liner Installation
Tool 4.00 -- 6................................
Figure 4.00-20. Camshaft Bushing Press
Installation 4.00 -- 7...........................
Figure 4.00-21. Cam Bearing Installation 4.00 -- 7....
Figure 4.00-22. Front Camshaft Bushing 4.00 -- 7.....
Figure 4.00-23. Cylinder Head Stud
Installation 4.00 -- 8...........................
Figure 4.00-24. Crankcase Parallel Pin 4.00 -- 8......
Figure 4.00-25. Piston -- Connecting Rod 4.00 -- 8....
Figure 4.00-26. Connecting Rod Bushing
Press 4.00 -- 9...............................
Figure 4.00-27. Middle Compression Rings 4.00 -- 9..
Figure 4.00-28. Oil Control Ring Expander
Spring 4.00 -- 10.............................
Figure 4.00-29. Oil Control Ring Teflon
Tube 4.00 -- 10...............................
Figure 4.00-30. Middle Compression Rings 4.00 -- 10..
Figure 4.00-31. Piston Ring Installation 4.00 -- 11.....
Figure 4.00-32. Piston Installation Tool 4.00 -- 11.....
Figure 4.00-33. Piston Ring Compressor
P/N 472076 4.00 -- 11.........................
Figure 4.00-34. Rod End 4.00 -- 11.................
Figure 4.00-35. Piston Installation 4.00 -- 12.........
Figure 4.00-36. Connecting Rod Cap 4.00 -- 12.......
Figure 4.00-37. Offset Adapter On
Connecting Rod 4.00 -- 12.....................
Figure 4.00-38. Offset Adapter Dimension 4.00 -- 13..
Figure 4.00-39. Adapter Installed Inline With
Wrench 4.00 -- 13............................
Figure 4.00-40. Adapter Install 90_To
Wrench 4.00 -- 13............................
Figure 4.00-41. Adapter Installed At Angle
To Wrench 4.00 -- 14..........................
Figure 4.00-42. Piston Cooling Jet 4.00 -- 14.........
Figure 4.00-43. Piston Cooling Jet
Clearance 4.00 -- 14..........................
Figure 4.00-44. Oil Galley Plug Detail 4.00 -- 15......
Figure 4.00-45. Oil Gallery Plug Installation 4.00 -- 15..
Figure 4.00-46. Oil Gallery Plug Installation 4.00 -- 15..
Figure 4.00-47. Crankcase Set Screw
Installation 4.00 -- 15..........................
Figure 4.00-48. Oil Gallery Plug 4.00 -- 15...........
Figure 4.00-49. Pipe Adapter Installation 4.00 -- 16...
Figure 4.00-50. Stud Adapter 4.00 -- 16.............
Figure 4.00-51. Turbo Oil Drain Plugged --
G Models 4.00 -- 16...........................
Figure 4.00-52. Prelube Connection 4.00 -- 16........
Figure 4.00-53. Rear Lifting Eye
F18/H24GSID/GL/GLD 4.00 -- 17...............
Figure 4.00-54. Rear Lifting Eye Brace 4.00 -- 17.....
Figure 4.00-55. Idler Gear Oil Supply 4.00 -- 17.......
Figure 4.00-56. Water Pump Idler
Assembly 4.00 -- 17...........................
Figure 4.00-57. Water Pump Idler Housing 4.00 -- 18..
Figure 4.00-58. Front Lifting Eye 4.00 -- 18...........
Figure 4.00-59. Gear Housing Guide Pins 4.00 -- 18...
Figure 4.00-60. Gear Housing Gasket
Surface 4.00 -- 19............................
Figure 4.00-61. Gear Housing Installation 4.00 -- 19...
Figure 4.00-62. Oil Supply Tube 4.00 -- 19...........
Figure 4.00-63. Magneto Drive Studs
Installation 4.00 -- 19..........................
Figure 4.00-64. CEC Cover Studs
Installation 4.00 -- 20..........................
Figure 4.00-65. Remove Excess RTV In
Bore 4.00 -- 20...............................
Figure 4.00-66. Camshaft Installation 4.00 -- 20......
Figure 4.00-67. Camshaft Thrust Bushing
Installation 4.00 -- 20..........................
Figure 4.00-68. Front Cam Follower
Installation 4.00 -- 21..........................
Figure 4.00-69. Rear Cam Follower
Installation 4.00 -- 21..........................
Figure 4.00-70. Camshaft Follower
Installation 4.00 -- 21..........................
Figure 4.00-71. Camshaft Followers 4.00 -- 21........
Figure 4.00-72. Auxiliary Rocker Arm Shaft 4.00 -- 22..
Figure 4.00-73. Rear Camshaft Cover 4.00 -- 22......

ILLUSTRATIONS
xv
FORM 6243 Third Edition
Figure 4.00-74. Intermediate Gear Hub 4.00 -- 22.....
Figure 4.00-75. Intermediate Gear Hub 4.00 -- 22.....
Figure 4.00-76. Intermediate Gear
Assembly 4.00 -- 23...........................
Figure 4.00-77. Camshaft Installation 4.00 -- 23......
Figure 4.00-78. Timing Disc Installation 4.00 -- 23.....
Figure 4.00-79. Timing Disc Installation 4.00 -- 23.....
Figure 4.00-80. Idler Gear Location 4.00 -- 24........
Figure 4.00-81. Oil Pump Idler Gear
Assembly 4.00 -- 24...........................
Figure 4.00-82. Oil Pump Idler Gear 4.00 -- 24........
Figure 4.00-83. Oil Pump Idler Gear
Assembly 4.00 -- 24...........................
Figure 4.00-84. Gear Train Timing Marks 4.00 -- 25...
Figure 4.00-85. Gear Train 4.00 -- 25................
Figure 4.00-86. Gear Train Backlash
Locations 4.00 -- 25...........................
Figure 4.00-87. Crankshaft Oil Seals 4.00 -- 26.......
Figure 4.00-88. Gear Housing To Cover
Gasket Surface 4.00 -- 26.....................
Figure 4.00-89. Lifting The Gear Housing 4.00 -- 26...
Figure 4.00-90. Front Gear Cover
Installation 4.00 -- 27..........................
Figure 4.00-91. Alternator Mounting
Bracket 4.00 -- 27............................
Figure 4.00-92. Vibration Damper Driving
Flange 4.00 -- 27.............................
Figure 4.00-93. Vibration Damper 4.00 -- 27..........
Figure 4.00-94. Vibration Damper Guard 4.00 -- 28....
Figure 4.00-95. Camshaft Covers 4.00 -- 28..........
Figure 4.00-96. First Camshaft Cover --
P/N 304700F 4.00 -- 28.......................
Figure 4.00-97. Camshaft Cover --
P/N 304700J 4.00 -- 28........................
Figure 4.00-98. Breather Baffle Box 4.00 -- 29........
Figure 4.00-99. KDM Bracket/Baffle Box 4.00 -- 29....
Figure 4.00-100. KDM Mounting Bracket 4.00 -- 29....
Figure 4.00-101. Camshaft Cover
P/N 304700E 4.00 -- 29.......................
Figure 4.00-102. Jacket Water Drain Cock 4.00 -- 29..
Figure 4.00-103. Oil Pressure Tap 4.00 -- 30.........
Figure 4.00-104. Crankshaft Seal Surface 4.00 -- 30..
Figure 4.00-105. F18/H24 Crankshaft
Oil Seals 4.00 -- 30...........................
Figure 4.00-106. Rear Seal Installation 4.00 -- 30.....
Figure 4.00-107. Rear Seal Installation 4.00 -- 31.....
Figure 4.00-108. Oil Pressure Tap 4.00 -- 31.........
Figure 4.00-109. Flywheel Housing Guide
Pins 4.00 -- 31...............................
Figure 4.00-110. Flywheel Housing Dowels 4.00 -- 31..
Figure 4.00-111. Flywheel Housing
Installation 4.00 -- 32..........................
Figure 4.00-112. Flywheel Offset Mark 4.00 -- 32.....
Figure 4.00-113. Flywheel Installation 4.00 -- 32......
Figure 4.00-114. Barring Device 4.00 -- 32...........
Figure 4.00-115. Lubrication System 4.00 -- 33.......
Figure 4.00-116. Oil Pan Gasket
Installation 4.00 -- 33..........................
Figure 4.00-117. Rear Engine Supports 4.00 -- 34.....
Figure 4.00-118. Rear Supports Brace 4.00 -- 34......
Figure 4.00-119. Front Support Brace 4.00 -- 34......
Section 4.05 -- Cylinder Head Installation
Figure 4.05-1. Cylinder Head Gasket --
P/N 300000D 4.05 -- 1........................
Figure 4.05-2. Cylinder Head Gasket --
P/N 300000B 4.05 -- 1........................
Figure 4.05-3. Cylinder Head Installation 4.05 -- 2....
Figure 4.05-4. Cylinder Head Installation 4.05 -- 2....
Figure 4.05-5. Rear Lifting Eye Brace 4.05 -- 2.......
Figure 4.05-6. Cylinder Head Bolt Tightening
Sequence -- Top View 4.05 -- 2.................
Figure 4.05-7. Spark Plug Holder 4.05 -- 3...........
Figure 4.05-8. Cylinder Head O--Rings 4.05 -- 3......
Figure 4.05-9. Cross Bar Assembly 4.05 -- 3.........
Figure 4.05-10. Cross Bar Installation 4.05 -- 3.......
Figure 4.05-11. Pushrod Installation 4.05 -- 3.........
Figure 4.05-12. Rocker Arm Components 4.05 -- 4....
Figure 4.05-13. Rocker Arm Support
Installation 4.05 -- 4...........................
Figure 4.05-14. Rocker Arm Support
Installation 4.05 -- 4...........................
Figure 4.05-15. Rocker Arm Support
Wrench 4.05 -- 4.............................
Figure 4.05-16. Cylinder Head Exhaust
Ports 4.05 -- 5...............................
Figure 4.05-17. VGF Exhaust Manifold
Drain Hole 4.05 -- 5...........................
Figure 4.05-18. F18GL Exhaust Manifold 4.05 -- 5....
Figure 4.05-19. Water Elbow Assembly 4.05 -- 6......
Figure 4.05-20. Previous—Water Elbow
Assembly 4.05 -- 6............................
Figure 4.05-21. Cylinder Head O--Rings 4.05 -- 6.....
Figure 4.05-22. Intake Manifold Installation 4.05 -- 6..
Figure 4.05-23. Rocker Arm Cover Recess
Tube 4.05 -- 7................................
Figure 4.05-24. Rocker Arm Cover Recess
Tube 4.05 -- 7................................
Figure 4.05-25. Rocker Cover Installation 4.05 -- 7....
Figure 4.05-26. CSA Valve Cover 4.05 -- 7...........
Figure 4.05-27. Ignition Coil (Non CSA) 4.05 -- 8......

ILLUSTRATIONS
xvi FORM 6243 Third Edition
Figure 4.05-28. CSA Flange Mounted Coil 4.05 -- 8...
Figure 4.05-29. CSA High Tension Coil Lead 4.05 -- 8..
Figure 4.05-30. High Tension Coil Lead 4.05 -- 8......
Section 4.10 -- Valve Adjustment
Figure 4.10-1. High Tension Coil Lead 4.10 -- 1.......
Figure 4.10-2. Rocker Arm Cover --
Standard 4.10 -- 1............................
Figure 4.10-3. Rocker Cover Removal Tool
P/N 472074 4.10 -- 1..........................
Figure 4.10-4. CSA High Tension Coil Lead 4.10 -- 1..
Figure 4.10-5. CSA Flange Mounted Coil 4.10 -- 2....
Figure 4.10-6. CSA Rocker Arm Cover 4.10 -- 2......
Figure 4.10-7. Rocker Arm Cover Removal
Tool 4.10 -- 2................................
Figure 4.10-8. Rocker Arm Adjusting
Screws 4.10 -- 3..............................
Figure 4.10-9. Rocker Arm Adjustments 4.10 -- 3.....
Figure 4.10-10. CSA Valve Cover 4.10 -- 4...........
Figure 4.10-11. CSA Flange Mounted Coil 4.10 -- 4...
Figure 4.10-12. CSA High Tension Coil Lead 4.10 -- 4..
Figure 4.10-13. High Tension Coil Lead 4.10 -- 4......
Section 5.00 -- Engine Speed Governing
System
Figure 5.00-1. 4024 EPG Governor 5.00 -- 1.........
Figure 5.00-2. EG3P Governor Actuator 5.00 -- 1.....
Figure 5.00-3. PSG Governor 5.00 -- 2..............
Figure 5.00-4. Governor Rod 5.00 -- 2...............
Figure 5.00-5. 4024 Governor And Linkage 5.00 -- 2..
Figure 5.00-6. Governor Rod And Lever
Installation 5.00 -- 2...........................
Figure 5.00-7. PSG And EG3P Governor Rod
Length 5.00 -- 3..............................
Figure 5.00-8. 4024 Governor And Linkage 5.00 -- 3..
Figure 5.00-9. 4024 Governor Rod Length 5.00 -- 3...
Figure 5.00-10. Governor Air Actuator 5.00 -- 3.......
Figure 5.00-11. Air Actuator 5.00 -- 4................
Figure 5.00-12. PSG Governor Linkage
Adjustment 5.00 -- 5..........................
Figure 5.00-13. EG3P Governor Linkage
Adjustment 5.00 -- 6..........................
Figure 5.00-14. 4024 Governor Linkage
Adjustment 5.00 -- 7..........................
Figure 5.00-15. Governor Speed Sensor
Hole 5.00 -- 7................................
Figure 5.00-16. Alternate Speed Sensor
Location 5.00 -- 7.............................
Figure 5.00-17. Ring Gear Tooth Alignment 5.00 -- 8..
Figure 5.00-18. Magnetic Pickup Sensor 5.00 -- 8.....
Figure 5.00-19. Valve Adjustment (PSG) 5.00 -- 8.....
Figure 5.00-20. Governor Rod 5.00 -- 9..............
Figure 5.00-21. Governor Oil Drain Tube 5.00 -- 9.....
Figure 5.00-22. Governor Drive 5.00 -- 9.............
Figure 5.00-23. Governor Drive Location 5.00 -- 9.....
Figure 5.00-24. Governor Drive 5.00 -- 9.............
Figure 5.00-25. Governor Drive
Disassembly 5.00 -- 10........................
Figure 5.00-26. Governor Drive
Disassembly 5.00 -- 10........................
Figure 5.00-27. Governor Drive Gear,
Shaft And Coupling 5.00 -- 10..................
Figure 5.00-28. Governor Drive Bearings 5.00 -- 10...
Figure 5.00-29. Governor Drive
Disassembly 5.00 -- 11........................
Figure 5.00-30. Governor Drive 5.00 -- 11............
Figure 5.00-31. Governor Drive Assembly 5.00 -- 11..
Figure 5.00-32. Governor Drive Location 5.00 -- 12....
Figure 5.00-33. Governor Drive Installation 5.00 -- 12..
Figure 5.00-34. 4024 Actuator Mounting 5.00 -- 12....
Figure 5.00-35. 4024 Governor And
Linkage 5.00 -- 12............................
Figure 5.00-36. EG3P Gasket 5.00 -- 13.............
Figure 5.00-37. EG3P Governor --
Bottom View 5.00 -- 13........................
Figure 5.00-38. Gasket Located On EG3P
Governor Base 5.00 -- 13......................
Figure 5.00-39. Magneto Drive Oil Supply
Adapters 5.00 -- 13...........................
Figure 5.00-40. Camshaft Cover --
P/N 304700F 5.00 -- 14.......................
Figure 5.00-41. Governor Oil Drain Tube 5.00 -- 14....
Figure 5.00-42. Governor Linkage 5.00 -- 15.........
Figure 5.00-43. Governor Regulator Shaft 5.00 -- 16..
Figure 5.00-44. Support Bracket 5.00 -- 16...........
Figure 5.00-45. Governor Shaft Support
Bracket 5.00 -- 16............................
Figure 5.00-46. Universal Joints 5.00 -- 16...........
Figure 5.00-47. Quick Start Oil Supply 5.00 -- 17......
Figure 5.00-48. Oil Fill Location 5.00 -- 17...........
Figure 5.00-49. Governor Quick Start
Oil Supply 5.00 -- 18..........................
Figure 5.00-50. Air Actuator Installation 5.00 -- 19.....
Figure 5.00-51. Governor Throttle Control 5.00 -- 20...
Figure 5.00-52. Governor Throttle Control 5.00 -- 20...
Section 5.05 -- Fuel System
Figure 5.05-1. Impco 200 Carburetor 5.05 -- 1........
Figure 5.05-2. H24G Impco 600 Carburetor 5.05 -- 1..
Figure 5.05-3. F18/H24 GLD IMPCO 600D
Carburetor 5.05 -- 2...........................
Figure 5.05-4. Impco 400 Carburetor 5.05 -- 2........

ILLUSTRATIONS
xvii
FORM 6243 Third Edition
Figure 5.05-5. F18/H24 GLD Deltec
Fuel System 5.05 -- 2.........................
Figure 5.05-6. F18/H24 GLD Deltec
Fuel System 5.05 -- 2.........................
Figure 5.05-7. Fuel Pressure Regulator --
S211 Shown 5.05 -- 2.........................
Figure 5.05-8. Shutoff Valve 5.05 -- 3................
Figure 5.05-9. F18G Carburetor 5.05 -- 3............
Figure 5.05-10. Impco 200 Fuel Piping 5.05 -- 3......
Figure 5.05-11. Impco 200 Balance Tube 5.05 -- 4....
Figure 5.05-12. Butterfly Valve 5.05 -- 4.............
Figure 5.05-13. 4024 Actuator Linkage 5.05 -- 4......
Figure 5.05-14. Butterfly Valve 5.05 -- 4.............
Figure 5.05-15. Carburetor -- Impco 200 5.05 -- 5.....
Figure 5.05-16. Proper Gas Valve Assembly 5.05 -- 6..
Figure 5.05-17. Balance Line 5.05 -- 6...............
Figure 5.05-18. Governor Linkage 5.05 -- 6..........
Figure 5.05-19. GL Impco 400 Carburetor 5.05 -- 7....
Figure 5.05-20. Intercooler To Carburetor
Connection 5.05 -- 7..........................
Figure 5.05-21. Butterfly Valve Housing 5.05 -- 7......
Figure 5.05-22. Impco 400 VF Carburetor 5.05 -- 8....
Figure 5.05-23. Offset Connection 5.05 -- 8..........
Figure 5.05-24. Intercooler To Carburetor
Connection 5.05 -- 8..........................
Figure 5.05-25. Butterfly Valve Housing 5.05 -- 8......
Figure 5.05-26. Governor Linkage 5.05 -- 9..........
Figure 5.05-27. 4024 Actuator Linkage 5.05 -- 9......
Figure 5.05-28. Balance Line 5.05 -- 9...............
Figure 5.05-29. F18/H24G Impco Carburetor 5.05 -- 9...
Figure 5.05-30. H24G Impco 600
Carburetor 5.05 -- 10..........................
Figure 5.05-31. H24G Impco 600
Carburetor 5.05 -- 10..........................
Figure 5.05-32. H24G Impco 600
Carburetor 5.05 -- 10..........................
Figure 5.05-33. F18/H24G IMPCO
Carburetor 5.05 -- 10..........................
Figure 5.05-34. Impco GLD Fuel Piping 5.05 -- 11.....
Figure 5.05-35. F18/H24 GLD IMPCO 600D
Carburetor 5.05 -- 11..........................
Figure 5.05-36. Carburetor -- GSID 5.05 -- 11.........
Figure 5.05-37. Impco GLD Carburetor 5.05 -- 11.....
Figure 5.05-38. Carburetor Fuel
Connection 5.05 -- 12.........................
Figure 5.05-39. Impco GLD Fuel Piping 5.05 -- 12.....
Figure 5.05-40. Impco 600D Carburetor 5.05 -- 12....
Figure 5.05-41. F18/H24GLD Impco 600D
Carburetor 5.05 -- 12..........................
Figure 5.05-42. Impco 600D Carburetor 5.05 -- 13....
Figure 5.05-43. GLD/GSID Turbo Air Inlet
Connection 5.05 -- 13.........................
Figure 5.05-44. Carburetor Fuel
Connection 5.05 -- 13.........................
Figure 5.05-45. Typical Impco 400
Carburetor 5.05 -- 14..........................
Figure 5.05-46. Typical Impco 600
Carburetor 5.05 -- 15..........................
Figure 5.05-47. Impco 400 VF Carburetor 5.05 -- 16...
Figure 5.05-48. Air/Gas Valve Assembly 5.05 -- 17....
Figure 5.05-49. Air/Gas Valve 5.05 -- 17.............
Figure 5.05-50. Air/Gas Valve Base And
O--ring 5.05 -- 17.............................
Figure 5.05-51. Carburetor Jet And O--ring 5.05 -- 17..
Figure 5.05-52. GLD Impco Carburetor
Assembly 5.05 -- 18...........................
Figure 5.05-53. IMPCO GLD Sleeve 5.05 -- 19.......
Figure 5.05-54. Air/Gas Valve Assembly 5.05 -- 19....
Figure 5.05-55. Valve Housing 5.05 -- 19............
Figure 5.05-56. Valve Housing Cover 5.05 -- 20.......
Figure 5.05-57. Carburetor Jet And O--ring 5.05 -- 20...
Figure 5.05-58. Air/Gas Valve Base And
O--ring 5.05 -- 20.............................
Figure 5.05-59. Air/Gas Valve 5.05 -- 20.............
Figure 5.05-60. Deltec MAS And
Carburetor 5.05 -- 21..........................
Figure 5.05-61. F18/H24 GLD Deltec
Fuel System 5.05 -- 21........................
Figure 5.05-62. F18/H24 GLD Deltec
Fuel System 5.05 -- 21........................
Figure 5.05-63. F18GLD Deltec Carburetor 5.05 -- 21..
Figure 5.05-64. Deltec 140 mm
Carburetor 5.05 -- 22..........................
Figure 5.05-65. Deltec 200 mm
Carburetor 5.05 -- 22..........................
Figure 5.05-66. Inspect O--ring -- Rear 5.05 -- 22......
Figure 5.05-67. Inspect O--ring -- Front 5.05 -- 22.....
Figure 5.05-68. Deltec Dual Fuel Insert 5.05 -- 22.....
Figure 5.05-69. F18GLD Deltec
Carburetor 5.05 -- 23..........................
Figure 5.05-70. H24 GLD Deltec Fuel
System 5.05 -- 23.............................
Figure 5.05-71. Deltec MAS And
Carburetor 5.05 -- 23..........................
Figure 5.05-72. Deltec MAS And
Carburetor 5.05 -- 23..........................
Figure 5.05-73. Deltec System Main
Adjustment Screw 5.05 -- 23...................
Figure 5.05-74. Main Adjustment Screw 5.05 -- 24....
Figure 5.05-75. F18/H24 GLD Deltec
Fuel System 5.05 -- 24........................

ILLUSTRATIONS
xviii FORM 6243 Third Edition
Figure 5.05-76. Deltec Main Adjusting
Screw 5.05 -- 24..............................
Figure 5.05-77. Manifold Elbow And
Butterfly Valve 5.05 -- 24......................
Figure 5.05-78. Manifold Elbow
Butterfly Valve 5.05 -- 25......................
Figure 5.05-79. Manifold Elbow Assembly 5.05 -- 25..
Figure 5.05-80. Butterfly Valve Shaft 5.05 -- 26.......
Figure 5.05-81. Intake Manifold Elbow 5.05 -- 26......
Figure 5.05-82. Manifold Elbow And Butterfly
Valve 5.05 -- 26..............................
Figure 5.05-83. Impco 200 Carburetor 5.05 -- 26......
Figure 5.05-84. Butterfly Valve 5.05 -- 26............
Figure 5.05-85. Throttle Valve 5.05 -- 27.............
Figure 5.05-86. Butterfly Valve/Throttle Stop
Screw 5.05 -- 27..............................
Figure 5.05-87. Butterfly Valve Assembly 5.05 -- 28...
Figure 5.05-88. Regulator Bracket 5.05 -- 28.........
Figure 5.05-89. G/GL Fuel Regulator 5.05 -- 28.......
Figure 5.05-90. Regulator Support Brace 5.05 -- 29...
Figure 5.05-91. Fuel Line 5.05 -- 29.................
Figure 5.05-92. Regulator Balance Line 5.05 -- 29....
Figure 5.05-93. Fuel Orifice Assembly 5.05 -- 29......
Figure 5.05-94. F18G Carburetor 5.05 -- 30..........
Figure 5.05-95. F18/H24G Impco
Carburetor 5.05 -- 30..........................
Figure 5.05-96. Dresser Elbow Coupling 5.05 -- 30....
Figure 5.05-97. G, GL Fuel Regulator
System 5.05 -- 31.............................
Figure 5.05-98. Impco GLD Fuel Piping 5.05 -- 32.....
Figure 5.05-99. Regulator Support Bracket 5.05 -- 32..
Figure 5.05-100. Carburetor Fuel
Connection 5.05 -- 32.........................
Figure 5.05-101. Impco GLD Fuel Piping 5.05 -- 32...
Figure 5.05-102. Fuel System Installation 5.05 -- 33...
Figure 5.05-103. Mixture Valve 5.05 -- 33............
Figure 5.05-104. Impco GLD Fuel Piping 5.05 -- 33...
Figure 5.05-105. Impco GLD Fuel Piping 5.05 -- 33...
Figure 5.05-106. Maxitrol GLD Fuel
Regulator 5.05 -- 33...........................
Figure 5.05-107. Impco GLD Fuel Regulator
System 5.05 -- 34.............................
Section 5.10 -- Ignition System
Figure 5.10-1. Ignition Module Diagnostic
LEDs 5.10 -- 1...............................
Figure 5.10-2. Current Ignition Module 5.10 -- 2.......
Figure 5.10-3. Previous Ignition Module 5.10 -- 2.....
Figure 5.10-4. CEC Timing Disc 5.10 -- 2............
Figure 5.10-5. Hall--effect Pickup Location 5.10 -- 2...
Figure 5.10-6. F18/H24 Magneto 5.10 -- 3...........
Figure 5.10-7. Standard Ignition Coil 5.10 -- 3........
Figure 5.10-8. CSA Flange Mounted Ignition
Coil 5.10 -- 4.................................
Figure 5.10-9. CSA Ignition Coil Heat Shield 5.10 -- 4.
Figure 5.10-10. Standard Ignition Coil Heat
Shield 5.10 -- 4...............................
Figure 5.10-11. Shielded Ignition System 5.10 -- 4....
Figure 5.10-12. CSA Stop Switch 5.10 -- 4...........
Figure 5.10-13. Shielded Ignition System 5.10 -- 5....
Figure 5.10-14. #1 Cylinder Junction Box 5.10 -- 5....
Figure 5.10-15. Timing Marks 5.10 -- 5..............
Figure 5.10-16. Shielded Ignition Timing Light
Hookup 5.10 -- 5.............................
Figure 5.10-17. Shielded Ignition Switch 5.10 -- 6.....
Figure 5.10-18. Rocker Arm Cover 5.10 -- 7..........
Figure 5.10-19. Spark Plug Tube Retaining
Tool 5.10 -- 7................................
Figure 5.10-20. CSA Ignition Coil 5.10 -- 7...........
Figure 5.10-21. Spark Plug Tube Retaining
Tool 5.10 -- 7................................
Figure 5.10-22. CSA Ignition Assembly 5.10 -- 8......
Figure 5.10-23. Shielded Ignition Assembly 5.10 -- 8..
Figure 5.10-24. Spark Plug Extension 5.10 -- 9.......
Figure 5.10-25. Coil Installation 5.10 -- 9.............
Figure 5.10-26. CSA Ignition Coil 5.10 -- 11..........
Figure 5.10-27. Standard Ignition Coil 5.10 -- 11......
Figure 5.10-28. Ignition Module Ground
Wire 5.10 -- 12...............................
Figure 5.10-29. Standard Ignition Coil 5.10 -- 12......
Figure 5.10-30. Standard Ignition Coil 5.10 -- 12......
Figure 5.10-31. Standard Ignition Coil 5.10 -- 13......
Figure 5.10-32. CSA Ignition Coil 5.10 -- 13..........
Figure 5.10-33. CSA Ignition Coil 5.10 -- 13..........
Figure 5.10-34. Standard Ignition Coil 5.10 -- 13......
Figure 5.10-35. Conduit Box 5.10 -- 14..............
Figure 5.10-36. Standard Ignition Coil --
P/N 69694 5.10 -- 14..........................
Figure 5.10-37. CSA (Flange Mounted)
Coil 5.10 -- 14................................
Figure 5.10-38. CSA Flange Mounted Coil 5.10 -- 15..
Figure 5.10-39. Spark Plug Extension 5.10 -- 15......
Figure 5.10-40. Standard Ignition Coil 5.10 -- 15......
Figure 5.10-41. Coil Ground Wire
Attachment 5.10 -- 16.........................
Figure 5.10-42. Current Blue Coil 5.10 -- 16..........
Figure 5.10-43. Coil Installation 5.10 -- 17...........
Figure 5.10-44. CSA Ignition Coil 5.10 -- 17..........
Figure 5.10-45. Current Ignition Module 5.10 -- 17....

ILLUSTRATIONS
xix
FORM 6243 Third Edition
Figure 5.10-46. Harness Ground Wire --
Right Rear 5.10 -- 18..........................
Figure 5.10-47. Non CSA Ignition Harness
Clip 5.10 -- 18................................
Figure 5.10-48. Current Ignition Module 5.10 -- 18....
Figure 5.10-49. Conduit Box 5.10 -- 18..............
Figure 5.10-50. CSA Conduit U--Bolt 5.10 -- 18.......
Figure 5.10-51. Wiring Harness 5.10 -- 19...........
Figure 5.10-52. Current Ignition Module 5.10 -- 19....
Figure 5.10-53. Six Cylinder Ignition Module
Harness 5.10 -- 20............................
Figure 5.10-54. Eight Cylinder Ignition Module
Harness 5.10 -- 20............................
Figure 5.10-55. Eight Cylinder Magneto
Harness 5.10 -- 21............................
Figure 5.10-56. Six Cylinder Magneto
Harness 5.10 -- 21............................
Figure 5.10-57. Conduit Box 5.10 -- 21..............
Figure 5.10-58. CSA Conduit U--Bolt 5.10 -- 22.......
Figure 5.10-59. Wiring Harness Clip
Installation 5.10 -- 22..........................
Figure 5.10-60. Wiring Harness 5.10 -- 22...........
Figure 5.10-61. Coil Ground Wire 5.10 -- 22..........
Figure 5.10-62. Magneto Pin Connector
Cable 5.10 -- 22..............................
Figure 5.10-63. Previous Ignition Module
Position 5.10 -- 23............................
Figure 5.10-64. Current Ignition Module
Position 5.10 -- 23............................
Figure 5.10-65. H24 (Non--CSA) Junction
Box 5.10 -- 24................................
Figure 5.10-66. CEC Ignition Module/Junction
Box 5.10 -- 24................................
Figure 5.10-67. Junction Box And Bracket
Assembly 5.10 -- 24...........................
Figure 5.10-68. Ignition Module Bracket 5.10 -- 25....
Figure 5.10-69. H24 KDM 5.10 -- 25................
Figure 5.10-70. F18 Bracket And Brace 5.10 -- 25.....
Figure 5.10-71. H24 Bracket And Brace 5.10 -- 26....
Figure 5.10-72. CEC Ignition Module/Junction
Box 5.10 -- 26................................
Figure 5.10-73. CSA Ignition Harness
(Right Side) 5.10 -- 27.........................
Figure 5.10-74. F18 Standard Ignition 5.10 -- 27......
Figure 5.10-75. H24 KDM/CSA 5.10 -- 28............
Figure 5.10-76. F18 KDM/CSA 5.10 -- 28............
Figure 5.10-77. Ignition Timing Cover 5.10 -- 28......
Figure 5.10-78. Camshaft Gear 5.10 -- 28............
Figure 5.10-79. CEC Ignition Module Timing
Disc 5.10 -- 29...............................
Figure 5.10-80. CEC Ignition Timing Cover 5.10 -- 29..
Figure 5.10-81. Hall--effect Pickup
Installation 5.10 -- 29..........................
Figure 5.10-82. Previous Ignition Module
Selector Switch 5.10 -- 30.....................
Figure 5.10-83. Current Ignition Module
Selector Switch 5.10 -- 30.....................
Figure 5.10-84. CEC Ignition Module Selector
Switches 5.10 -- 30...........................
Figure 5.10-85. Ignition Module 16 Position
Switches 5.10 -- 31...........................
Figure 5.10-86. Conduit Box 5.10 -- 32..............
Figure 5.10-87. Flywheel Timing Marks 5.10 -- 32.....
Figure 5.10-88. Flywheel Timing Marks 5.10 -- 34.....
Figure 5.10-89. Shielded Ignition Switch 5.10 -- 34....
Figure 5.10-90. Magneto 5.10 -- 35.................
Figure 5.10-91. Flywheel Timing Marks 5.10 -- 35.....
Figure 5.10-92. Magneto Static Timing 5.10 -- 36.....
Figure 5.10-93. Magneto 5.10 -- 36.................
Figure 5.10-94. Magneto Oil Supply Tube 5.10 -- 36...
Figure 5.10-95. Splined Magneto Drive 5.10 -- 36.....
Figure 5.10-96. Magneto Mounting Housing 5.10 -- 37..
Figure 5.10-97. Magneto Drive Hub
Assembly 5.10 -- 37...........................
Figure 5.10-98. Magneto Adapter Housing 5.10 -- 37..
Figure 5.10-99. Magneto Drive Housing 5.10 -- 38....
Figure 5.10-100. Magneto Drive 5.10 -- 39...........
Figure 5.10-101. Magneto Drive Lube Oil
Supply Adapters 5.10 -- 39.....................
Figure 5.10-102. Magneto Drive Lube Oil
Supply Tube 5.10 -- 39........................
Figure 5.10-103. Magneto Installation 5.10 -- 40......
Figure 5.10-104. Magneto 5.10 -- 40................
Figure 5.10-105. CEC Ignition Module Power
Supply 5.10 -- 40.............................
Figure 5.10-106. CEC Ignition Module Wiring
Diagram (Without Murphy Gas Valves) --
VGF Six Cylinder 5.10 -- 41....................
Figure 5.10-107. CEC Ignition Module Wiring
Diagram (Without Murphy Gas Valves) --
VGF Eight Cylinder 5.10 -- 42..................
Figure 5.10-108. CEC Ignition Module
Harness -- Six Cylinder 5.10 -- 43...............
Figure 5.10-109. CEC Ignition Module
Harness -- Eight Cylinder 5.10 -- 43.............
Figure 5.10-110. Magneto Ignition System
Schematic -- Six Cylinder 5.10 -- 44.............
Figure 5.10-111. Magneto Ignition Harness --
Six Cylinder 5.10 -- 44.........................
Figure 5.10-112. Magneto Ignition System
Schematic -- Eight Cylinder 5.10 -- 45...........
Figure 5.10-113. Magneto Ignition Harness --
Eight Cylinder 5.10 -- 45.......................

ILLUSTRATIONS
xx FORM 6243 Third Edition
Section 5.15 -- Air Induction System
Figure 5.15-1. F18 Air Cleaner 5.15 -- 1.............
Figure 5.15-2. Turbocharger 5.15 -- 1...............
Figure 5.15-3. Intercooler 5.15 -- 1..................
Figure 5.15-4. Throttle Valve 5.15 -- 2...............
Figure 5.15-5. GL Carburetor 5.15 -- 2..............
Figure 5.15-6. H18G Carburetor 5.15 -- 2............
Figure 5.15-7. F18/H24GSID Carburetor 5.15 -- 2.....
Figure 5.15-8. F18/H24 GLD Deltec Fuel
System 5.15 -- 3..............................
Figure 5.15-9. F18/H24 GLD IMPCO
600D Carburetor 5.15 -- 3.....................
Figure 5.15-10. Air Filter Restriction Indicator 5.15 -- 3...
Figure 5.15-11. GL -- Filter Restriction
Indicator 5.15 -- 3............................
Figure 5.15-12. Restriction Filter 5.15 -- 4............
Figure 5.15-13. Typical Air Filter Components --
G, GL 5.15 -- 5...............................
Figure 5.15-14. F18/H24 GSID Air Cleaner
With Offset Studs 5.15 -- 6.....................
Figure 5.15-15. F18 Air Cleaner 5.15 -- 6............
Figure 5.15-16. H24G Air Duct Brace 5.15 -- 6........
Figure 5.15-17. Dual Fuel Air Duct Support 5.15 -- 7..
Figure 5.15-18. Closed Breather Connection 5.15 -- 7.
Figure 5.15-19. F18/H24G IMPCO
Carburetor 5.15 -- 7...........................
Figure 5.15-20. G Air Duct Support Bracket 5.15 -- 7..
Figure 5.15-21. F18 Air Cleaner 5.15 -- 7............
Figure 5.15-22. Turbocharger Air Elbow 5.15 -- 8.....
Figure 5.15-23. Closed Breather
Connection 5.15 -- 8..........................
Figure 5.15-24. Air Duct Brace 5.15 -- 8.............
Figure 5.15-25. G Air Duct Support Bracket 5.15 -- 8..
Figure 5.15-26. GLD Deltec Dual Fuel
Carburetor 5.15 -- 8...........................
Figure 5.15-27. Deltec Air Duct Mounting 5.15 -- 9....
Figure 5.15-28. Air Duct Mounting Pad 5.15 -- 9......
Figure 5.15-29. Air Duct Support Bracket 5.15 -- 9....
Figure 5.15-30. Air Duct Brace 5.15 -- 9.............
Figure 5.15-31. F18/H24G IMPCO
Carburetor 5.15 -- 10..........................
Figure 5.15-32. GL Air Elbow Installation 5.15 -- 10...
Figure 5.15-33. GSID/GLD Upper Bracket 5.15 -- 10..
Figure 5.15-34. GSID/GLD Lower Bracket 5.15 -- 10..
Figure 5.15-35. GSID Carburetor 5.15 -- 11..........
Figure 5.15-36. Intercooler 5.15 -- 11................
Figure 5.15-37. Deltec Air Duct 5.15 -- 11............
Figure 5.15-38. F18GLD Deltec Dual Fuel
Carburetor 5.15 -- 11..........................
Figure 5.15-39. Air Actuator 5.15 -- 12...............
Figure 5.15-40. 4024 Governor 5.15 -- 12............
Figure 5.15-41. Throttle Valve 5.15 -- 12.............
Figure 5.15-42. Shaft Support Bracket 5.15 -- 12......
Figure 5.15-43. Control Panel 5.15 -- 13.............
Figure 5.15-44. Closed Breather System 5.15 -- 13....
Figure 5.15-45. Carburetor Air Connection 5.15 -- 13...
Figure 5.15-46. Intake Manifold Removal 5.15 -- 13...
Figure 5.15-47. Intake Manifold O--rings 5.15 -- 14....
Figure 5.15-48. Intake Manifold Installation 5.15 -- 14..
Figure 5.15-49. Carburetor Air Connection 5.15 -- 14...
Figure 5.15-50. Intake Manifold Assembly 5.15 -- 15..
Figure 5.15-51. Closed Breather System 5.15 -- 15....
Figure 5.15-52. Instrument Panel 5.15 -- 15..........
Figure 5.15-53. CEC Ignition Module 5.15 -- 16.......
Figure 5.15-54. 4024 Governor 5.15 -- 16............
Figure 5.15-55. Air Actuator 5.15 -- 16...............
Figure 5.15-56. Butterfly Valve 5.15 -- 16............
Figure 5.15-57. Shaft Support Bracket 5.15 -- 16......
Figure 5.15-58. Shaft Support Bracket 5.15 -- 16......
Section 5.20 -- Turbocharger
Figure 5.20-1. Heat Shield 5.20 -- 1.................
Figure 5.20-2. Heat Shield Attachment 5.20 -- 1......
Figure 5.20-3. Heat Shield Attachment 5.20 -- 1......
Figure 5.20-4. CSA Coil Heat Shields 5.20 -- 2.......
Figure 5.20-5. Heat Shield Attachment 5.20 -- 2......
Figure 5.20-6. Turbocharger Connection --
GL Engines 5.20 -- 2..........................
Figure 5.20-7. GLD/GSID Turbocharger Air
Inlet 5.20 -- 2................................
Figure 5.20-8. Turbocharger Connection 5.20 -- 2.....
Figure 5.20-9. Breather Ejector 5.20 -- 3.............
Figure 5.20-10. Wastegate Bypass Tube 5.20 -- 3.....
Figure 5.20-11. Exhaust Outlet Elbow 5.20 -- 3.......
Figure 5.20-12. Exhaust Outlet 5.20 -- 3.............
Figure 5.20-13. Turbocharger Oil Supply
Tubes 5.20 -- 3...............................
Figure 5.20-14. Turbocharger Oil Supply
Tubes 5.20 -- 4...............................
Figure 5.20-15. Turbocharger Removal 5.20 -- 4......
Figure 5.20-16. Turbocharger V--band
Coupling 5.20 -- 4............................
Figure 5.20-17. Turbocharger Compressor
Housing 5.20 -- 5.............................
Figure 5.20-18. Turbocharger Compressor
Wheel 5.20 -- 5..............................
Figure 5.20-19. Turbocharger Axial (End)
Play 5.20 -- 6................................
Figure 5.20-20. Check Turbocharger Radial
Play 5.20 -- 7................................

ILLUSTRATIONS
xxi
FORM 6243 Third Edition
Figure 5.20-21. Garret Turbocharger 5.20 -- 7........
Figure 5.20-22. Turbocharger Installation 5.20 -- 8....
Figure 5.20-23. Turbocharger Exhaust Inlet
Gasket 5.20 -- 8..............................
Figure 5.20-24. Turbocharger Oil Supply
Tubes 5.20 -- 8...............................
Figure 5.20-25. Turbocharger Oil Supply
Tubes 5.20 -- 8...............................
Figure 5.20-26. Exhaust Outlet 5.20 -- 8.............
Figure 5.20-27. Exhaust Outlet 5.20 -- 9.............
Figure 5.20-28. V-Band Coupling 5.20 -- 9...........
Figure 5.20-29. Wastegate Bypass Tube 5.20 -- 9.....
Figure 5.20-30. Wastegate Bypass Tube 5.20 -- 9.....
Figure 5.20-31. Breather Ejector 5.20 -- 9............
Figure 5.20-32. Turbocharger Air Outlet 5.20 -- 10....
Figure 5.20-33. Turbocharger Connection 5.20 -- 10...
Figure 5.20-34. Turbocharger Connection --
GL 5.20 -- 10................................
Figure 5.20-35. GLD/GSID Turbocharger
Air Inlet 5.20 -- 10............................
Figure 5.20-36. Heat Shield Attachment 5.20 -- 11....
Figure 5.20-37. CSA Coil Heat Shields 5.20 -- 11.....
Figure 5.20-38. Heat Shield Attachment 5.20 -- 11....
Figure 5.20-39. Heat Shield Attachment 5.20 -- 11....
Section 5.25 -- Cooling System
Figure 5.25-1. Jacket Water Pump 5.25 -- 1..........
Figure 5.25-2. Auxiliary Water Pump 5.25 -- 2........
Figure 5.25-3. Jacket Water Thermostat
Housing 5.25 -- 2.............................
Figure 5.25-4. Auxiliary Thermostat 5.25 -- 2.........
Figure 5.25-5. Surge Tank 5.25 -- 2.................
Figure 5.25-6. Thermostat Housing 5.25 -- 3.........
Figure 5.25-7. Jacket Water Header Air Bleed
Petcock 5.25 -- 3.............................
Figure 5.25-8. Intercooler Air Bleed 5.25 -- 4.........
Figure 5.25-9. Jacket Water Pump Seal
Inspection 5.25 -- 6...........................
Figure 5.25-10. Auxiliary Water Pump
Inspection 5.25 -- 7...........................
Figure 5.25-11. Jacket Water Pump 5.25 -- 7.........
Figure 5.25-12. Jacket Water Pump Inlet 5.25 -- 7....
Figure 5.25-13. Jacket Water Pump 5.25 -- 7.........
Figure 5.25-14. Water Pump Inlet Assembly 5.25 -- 8...
Figure 5.25-15. Jacket Water Pump Inlet 5.25 -- 9....
Figure 5.25-16. Jacket Water Connections 5.25 -- 9...
Figure 5.25-17. Air Bleed Tube Support 5.25 -- 9.....
Figure 5.25-18. Jacket Water Pump 5.25 -- 9.........
Figure 5.25-19. Jacket Water Pump 5.25 -- 10........
Figure 5.25-20. Jacket Water Pump 5.25 -- 10........
Figure 5.25-21. Auxiliary Water Pump
Inspection 5.25 -- 10..........................
Figure 5.25-22. Auxiliary Water Pump
Clamp 5.25 -- 10.............................
Figure 5.25-23. Jacket Water Pump 5.25 -- 10........
Figure 5.25-24. Jacket Water Pump
Mounting 5.25 -- 11...........................
Figure 5.25-25. Jacket Water Pump 5.25 -- 11........
Figure 5.25-26. Jacket Water Pump 5.25 -- 11........
Figure 5.25-27. Auxiliary Water Pump
Clamp 5.25 -- 11.............................
Figure 5.25-28. Jacket Water Pump 5.25 -- 12........
Figure 5.25-29. G Series Water Pump
Cover 5.25 -- 12..............................
Figure 5.25-30. Jacket Water Pump 5.25 -- 12........
Figure 5.25-31. Jacket Water Pump 5.25 -- 12........
Figure 5.25-32. Pump P/N A301060C For
Naturally Aspirated Engines 5.25 -- 13...........
Figure 5.25-33. Remove Impeller 5.25 -- 13..........
Figure 5.25-34. Pump P/N AC301060C
For Turbocharged Engines 5.25 -- 14............
Figure 5.25-35. P/N 301060A Pump Body
Rework 5.25 -- 15............................
Figure 5.25-36. Press Bushing Into Pump
Body 5.25 -- 15...............................
Figure 5.25-37. Water Pump Oil Seal 5.25 -- 15.......
Figure 5.25-38. Water Pump Bearing 5.25 -- 16.......
Figure 5.25-39. Water Pump Shaft/Bearing
Assembly 5.25 -- 16...........................
Figure 5.25-40. Water Pump Gear 5.25 -- 16.........
Figure 5.25-41. Water Pump Shaft 5.25 -- 16.........
Figure 5.25-42. Water Pump Seal 5.25 -- 17..........
Figure 5.25-43. Water Pump Seal And
Impeller 5.25 -- 17............................
Figure 5.25-44. Install Inner Race On Shaft 5.25 -- 17..
Figure 5.25-45. Water Pump Gear Housing 5.25 -- 17..
Figure 5.25-46. Water Pump Gear Housing 5.25 -- 18..
Figure 5.25-47. Pump Nut 5.25 -- 18................
Figure 5.25-48. Pump P/N D301060B 5.25 -- 18......
Figure 5.25-49. Auxiliary Water Pump 5.25 -- 18......
Figure 5.25-50. Auxiliary Water Pump 5.25 -- 19......
Figure 5.25-51. Auxiliary Water Pump
Inspection 5.25 -- 19..........................
Figure 5.25-52. Auxiliary Water Pump
Clamp 5.25 -- 19.............................
Figure 5.25-53. Auxiliary Water Piping 5.25 -- 19......
Figure 5.25-54. Auxiliary Water Pump And
Piping 5.25 -- 20..............................
Figure 5.25-55. Auxiliary Water Pump
Adapter 5.25 -- 20............................
Figure 5.25-56. Water Pump Mounting 5.25 -- 20.....

ILLUSTRATIONS
xxii FORM 6243 Third Edition
Figure 5.25-57. Auxiliary Water Pump
Adapter 5.25 -- 20............................
Figure 5.25-58. “G” Series Water Pump
Cover 5.25 -- 21..............................
Figure 5.25-59. Auxiliary Water Pump Shim 5.25 -- 21..
Figure 5.25-60. Auxiliary Water Pump
Clamp 5.25 -- 21.............................
Figure 5.25-61. Auxiliary Water Pump 5.25 -- 21......
Figure 5.25-62. Auxiliary Water Pump 5.25 -- 22......
Figure 5.25-63. Auxiliary Water Pump
Clamp 5.25 -- 22.............................
Figure 5.25-64. Auxiliary Water Pump
Shim 5.25 -- 22...............................
Figure 5.25-65. Auxiliary Water Pump 5.25 -- 23......
Figure 5.25-66. Auxiliary Water Piping 5.25 -- 23......
Figure 5.25-67. Auxiliary Water Pump 5.25 -- 23......
Figure 5.25-68. Impeller Shaft Seal 5.25 -- 23........
Figure 5.25-69. Adapter Housing 5.25 -- 24..........
Figure 5.25-70. Auxiliary Water Pump 5.25 -- 24......
Figure 5.25-71. Adapter Housing 5.25 -- 24..........
Figure 5.25-72. Impeller Shaft Seal 5.25 -- 24........
Figure 5.25-73. Auxiliary Water Pump Adapter
Housing 5.25 -- 24............................
Figure 5.25-74. Auxiliary Water Pump 5.25 -- 24......
Figure 5.25-75. Auxiliary Water Pump 5.25 -- 25......
Figure 5.25-76. Thermostat Housing
Connections 5.25 -- 25........................
Figure 5.25-77. Air Bleed Tube Support 5.25 -- 25....
Figure 5.25-78. Thermostat Housing 5.25 -- 26.......
Figure 5.25-79. Jacket Water Temperature
Gauge 5.25 -- 26.............................
Figure 5.25-80. Thermostat Housing 5.25 -- 26.......
Figure 5.25-81. Thermostat Housing 5.25 -- 27.......
Figure 5.25-82. Thermostat In Housing 5.25 -- 27.....
Figure 5.25-83. Thermostat Seal Location 5.25 -- 27..
Figure 5.25-84. Thermostat Open And
Closed 5.25 -- 27.............................
Figure 5.25-85. Thermostat Testing 5.25 -- 28........
Figure 5.25-86. Thermostat Seal Location 5.25 -- 28..
Figure 5.25-87. Thermostat Installation 5.25 -- 28.....
Figure 5.25-88. Thermostat Housing 5.25 -- 29.......
Figure 5.25-89. Thermostat Housing
Installation 5.25 -- 29..........................
Figure 5.25-90. Jacket Water Temperature
Gauge 5.25 -- 29.............................
Figure 5.25-91. Thermostat Housing
Connections 5.25 -- 29........................
Figure 5.25-92. Intercooler Water
Connection 5.25 -- 29.........................
Figure 5.25-93. Intercooler Water
Connection 5.25 -- 30.........................
Figure 5.25-94. Intercooler Connection 5.25 -- 30.....
Figure 5.25-95. Carburetor Intercooler
Connection 5.25 -- 30.........................
Figure 5.25-96. Carburetor Intercooler
Connection 5.25 -- 30.........................
Figure 5.25-97. Intercooler Mounting 5.25 -- 30......
Figure 5.25-98. Intercooler Assembly 5.25 -- 31......
Figure 5.25-99. Intercooler RTV Application 5.25 -- 32..
Figure 5.25-100. Intercooler Mounting 5.25 -- 32......
Figure 5.25-101. Carburetor Intercooler
Connection 5.25 -- 32.........................
Figure 5.25-102. Carburetor Intercooler
Connection 5.25 -- 33.........................
Figure 5.25-103. Intercooler Water
Connection 5.25 -- 33.........................
Figure 5.25-104. Intercooler Water
Connection 5.25 -- 33.........................
Figure 5.25-105. Intercooler Connection 5.25 -- 33....
Figure 5.25-106. Inlet Oil Cooler Water
Tube 5.25 -- 33...............................
Figure 5.25-107. Auxiliary Water Piping 5.25 -- 34.....
Figure 5.25-108. Auxiliary Water Piping 5.25 -- 34.....
Figure 5.25-109. Auxiliary Water Piping 5.25 -- 34.....
Figure 5.25-110. Auxiliary Water Piping 5.25 -- 34.....
Figure 5.25-111. Auxiliary Water Piping 5.25 -- 34.....
Figure 5.25-112. Auxiliary Water Piping 5.25 -- 35.....
Figure 5.25-113. Auxiliary Water Support
Bracket 5.25 -- 35............................
Figure 5.25-114. Intercooler Water Piping 5.25 -- 35...
Figure 5.25-115. Auxiliary Water Pump 5.25 -- 35.....
Figure 5.25-116. Auxiliary Water Pump 5.25 -- 35.....
Figure 5.25-117. Auxiliary Water
Thermostat 5.25 -- 36.........................
Figure 5.25-118. Auxiliary Water
Thermostat 5.25 -- 36.........................
Figure 5.25-119. Auxiliary Water
Thermostat 5.25 -- 36.........................
Figure 5.25-120. Auxiliary Water
Thermostat 5.25 -- 36.........................
Figure 5.25-121. Auxiliary Water
Thermostat 5.25 -- 37.........................
Figure 5.25-122. Auxiliary Water Thermostat
Inner Seal 5.25 -- 37..........................
Figure 5.25-123. Auxiliary Water Pump
Connections 5.25 -- 37........................
Figure 5.25-124. Thermostat Open And
Closed 5.25 -- 38.............................
Figure 5.25-125. Thermostat Testing 5.25 -- 38.......
Figure 5.25-126. Auxiliary Thermostat Seal 5.25 -- 38..
Figure 5.25-127. Auxiliary Thermostat
Installation 5.25 -- 38..........................

ILLUSTRATIONS
xxiii
FORM 6243 Third Edition
Figure 5.25-128. Auxiliary Water
Thermostat 5.25 -- 39.........................
Figure 5.25-129. Auxiliary Water
Thermostat 5.25 -- 39.........................
Figure 5.25-130. Flexmaster Coupling 5.25 -- 39......
Figure 5.25-131. High Temperature Water
Connections 5.25 -- 39........................
Figure 5.25-132. High Temperature
Connection 5.25 -- 40.........................
Figure 5.25-133. High Temperature
Connection 5.25 -- 40.........................
Figure 5.25-134. High Temperature Intercooler
Inlet 5.25 -- 40...............................
Figure 5.25-135. High Temperature Inlet
Flange 5.25 -- 40.............................
Figure 5.25-136. Intercooler Connections 5.25 -- 40...
Section 5.30 -- Lubrication System
Figure 5.30--1. Oil Pump 5.30 -- 1...................
Figure 5.30--2. Lube Oil Cooler Housing 5.30 -- 1.....
Figure 5.30--3. Piston Cooling Control Valve 5.30 -- 1..
Figure 5.30--4. VGF Inline Engine Lube Oil
Schematic 5.30 -- 2...........................
Figure 5.30--5. Lube Oil Filter Canisters 5.30 -- 9.....
Figure 5.30--6. Oil Cooler 5.30 -- 10.................
Figure 5.30--7. Oil Fill Location 5.30 -- 10............
Figure 5.30--8. Dipstick 5.30 -- 10...................
Figure 5.30--9. Microspin Centrifuge --
P/N 489300 5.30 -- 11.........................
Figure 5.30--10. Microspin Cleanable
Oil Filters 5.30 -- 11...........................
Figure 5.30--11. Cleanable Oil Filter
Assembly -- (Inline) 5.30 -- 12..................
Figure 5.30--12. Oil Pressure Differential
Gauge 5.30 -- 12.............................
Figure 5.30--13. Service And Cleaning Of
Microspin Centrifuge -- P/N 489300 5.30 -- 12....
Figure 5.30--14. Oil Cooler 5.30 -- 13................
Figure 5.30--15. Auxiliary Water Thermostat 5.30 -- 14..
Figure 5.30--16. Inlet Oil Cooler Water
Tube 5.30 -- 14...............................
Figure 5.30--17. Oil Cooler Water Tube 5.30 -- 14.....
Figure 5.30--18. Oil Cooler Outlet Elbow 5.30 -- 14....
Figure 5.30--19. Oil Filter Support
Mounting 5.30 -- 14...........................
Figure 5.30--20. Oil Filter And Cooler
Assembly 5.30 -- 15...........................
Figure 5.30--21. Oil Filter And Cooler
Assembly 5.30 -- 15...........................
Figure 5.30--22. Oil Cooler Elements 5.30 -- 15.......
Figure 5.30--23. Oil Cooler Cover 5.30 -- 15..........
Figure 5.30--24. Oil Cooler Elements 5.30 -- 15.......
Figure 5.30--25. Oil Cooler To Filter
Connection 5.30 -- 15.........................
Figure 5.30--26. Oil Filter To Oil Cooler
Installation 5.30 -- 16..........................
Figure 5.30--27. Oil Cooler Assembly 5.30 -- 17.......
Figure 5.30--28. Oil Cooler Elements 5.30 -- 17.......
Figure 5.30--29. Oil Cooler Cover 5.30 -- 17..........
Figure 5.30--30. Oil Cooler Elements 5.30 -- 18.......
Figure 5.30--31. Oil Filter And Cooler
Assembly 5.30 -- 18...........................
Figure 5.30--32. Oil Filter And Cooler
Assembly 5.30 -- 18...........................
Figure 5.30--33. Oil Filter And Cooler
Assembly 5.30 -- 18...........................
Figure 5.30--34. Oil Filter Support Mounting 5.30 -- 18..
Figure 5.30--35. Oil Cooler Outlet Elbow 5.30 -- 19....
Figure 5.30--36. Oil Cooler Water Tube 5.30 -- 19.....
Figure 5.30--37. Auxiliary Water Thermostat 5.30 -- 19..
Figure 5.30--38. “G” Oil Cooler Piping 5.30 -- 19......
Figure 5.30--39. Oil Cooler Detail 5.30 -- 20..........
Figure 5.30--40. Oil Cooler Detail 5.30 -- 20..........
Figure 5.30--41. Oil Cooler Service 5.30 -- 20.........
Figure 5.30--42. Oil Cooler 5.30 -- 22................
Figure 5.30--43. Oil Cooler Bonnet Bolt
Tightening Sequence 5.30 -- 22................
Figure 5.30--44. Oil Cooler Installation 5.30 -- 23......
Figure 5.30--45. Remote Cooler
Connections 5.30 -- 23........................
Figure 5.30--46. Lubrication Control Valves 5.30 -- 23..
Figure 5.30--47. Oil Filter Support Assembly 5.30 -- 24..
Figure 5.30--48. Lube Oil Pressure Regulator
Valve 5.30 -- 24..............................
Figure 5.30--49. Piston Cooling Control
Valve 5.30 -- 24..............................
Figure 5.30--50. First Production Piston
Cooling Jet 5.30 -- 25.........................
Figure 5.30--51. Piston Cooling Jet 5.30 -- 25.........
Figure 5.30--52. Piston Cooling Jet 5.30 -- 25.........
Figure 5.30--53. Second Production Piston
Cooling Jet 5.30 -- 26.........................
Figure 5.30--54. Cooling Jet Mounting Pad 5.30 -- 26..
Figure 5.30--55. Cooling Jet Assembly 5.30 -- 26.....
Figure 5.30--56. Current Production Piston
Cooling Jet 5.30 -- 26.........................
Figure 5.30--57. Piston Cooling Jet
Clearance 5.30 -- 27..........................
Figure 5.30--58. Oil Level Regulator 5.30 -- 27........
Figure 5.30--59. Oil Level Regulator 5.30 -- 27........
Figure 5.30--60. Oil Separator Drain 5.30 -- 27........
Figure 5.30--61. Fuel Regulator Brace 5.30 -- 27......

ILLUSTRATIONS
xxiv FORM 6243 Third Edition
Figure 5.30--62. Air/Gas Starter Motor 5.30 -- 28......
Figure 5.30--63. Air/Gas Starter Motor
Connections 5.30 -- 28........................
Figure 5.30--64. Oil Pump 5.30 -- 28................
Figure 5.30--65. Oil Pump 5.30 -- 28................
Figure 5.30--66. Oil Pump 5.30 -- 29................
Figure 5.30--67. Oil Pump Discharge Tube 5.30 -- 29..
Figure 5.30--68. Oil Pump Discharge Tube 5.30 -- 29..
Figure 5.30--69. Oil Pump Suction Tube 5.30 -- 29....
Figure 5.30--70. Oil Pump Suction Tube 5.30 -- 29....
Figure 5.30--71. Oil Pump Gear Backlash
Measurement 5.30 -- 30.......................
Figure 5.30--72. VGF Oil Pump 5.30 -- 30............
Figure 5.30--73. Oil Pump Gears 5.30 -- 30...........
Figure 5.30--74. Oil Pump Housing 5.30 -- 30.........
Figure 5.30--75. Measure Oil Pump Gear
Clearance 5.30 -- 31..........................
Figure 5.30--76. Measure Oil Pump Gear
Clearance 5.30 -- 31..........................
Figure 5.30--77. Oil Pump Housing 5.30 -- 31.........
Figure 5.30--78. Check Oil Pump End Play 5.30 -- 31..
Figure 5.30--79. Oil Pump Housing 5.30 -- 32.........
Figure 5.30--80. Oil Pump Cover 5.30 -- 32...........
Figure 5.30--81. Oil Pump Assembly 5.30 -- 34.......
Figure 5.30--82. F18/H24 Oil Pump Face 5.30 -- 34...
Figure 5.30--83. Oil Pump 5.30 -- 35................
Figure 5.30--84. F18/H24 VGF Oil Pump 5.30 -- 35....
Figure 5.30--85. Oil Pump Pressure Relief
Valve 5.30 -- 35..............................
Figure 5.30--86. Oil Pump Bypass Valve 5.30 -- 35....
Figure 5.30--87. Oil Pan Gasket Installation 5.30 -- 36..
Section 5.35 -- Exhaust System
Figure 5.35-1. Thermocouple Conduit 5.35 -- 2.......
Figure 5.35-2. Exhaust Manifold
Thermocouple 5.35 -- 2.......................
Figure 5.35-3. Exhaust Outlet Thermocouple 5.35 -- 2..
Figure 5.35-4. Turbocharger And Heat Shield 5.35 -- 3..
Figure 5.35-5. Breather Ejector 5.35 -- 3.............
Figure 5.35-6. Wastegate Actuator Vent
Tube 5.35 -- 3................................
Figure 5.35-7. Exhaust Outlet Thermocouple 5.35 -- 3..
Figure 5.35-8. Wastegate Bypass Tube 5.35 -- 3......
Figure 5.35-9. Exhaust Outlet 5.35 -- 4..............
Figure 5.35-10. Exhaust Outlet 5.35 -- 4.............
Figure 5.35-11. Exhaust Outlet Heat Shield 5.35 -- 4..
Figure 5.35-12. Exhaust Outlet 5.35 -- 4.............
Figure 5.35-13. Exhaust Outlet 5.35 -- 5.............
Figure 5.35-14. Wastegate Bypass Tube 5.35 -- 5.....
Figure 5.35-15. Breather Ejector 5.35 -- 5............
Figure 5.35-16. Exhaust Outlet
Thermocouple 5.35 -- 5.......................
Figure 5.35-17. Wastegate Actuator Vent
Tube 5.35 -- 5................................
Figure 5.35-18. Heat Shield 5.35 -- 6................
Figure 5.35-19. CSA Coil Heat Shield 5.35 -- 6.......
Figure 5.35-20. Standard Heat Shield 5.35 -- 6.......
Figure 5.35-21. CSA Coil Heat Shields 5.35 -- 6......
Figure 5.35-22. Wastegate Sensing Tube 5.35 -- 6....
Figure 5.35-23. Wastegate Sensing Tube 5.35 -- 7....
Figure 5.35-24. Wastegate Actuator Vent
Tube 5.35 -- 7................................
Figure 5.35-25. Wastegate Bypass Tube 5.35 -- 7.....
Figure 5.35-26. Wastegate 5.35 -- 7.................
Figure 5.35-27. Wastegate Bypass Tube 5.35 -- 7.....
Figure 5.35-28. Wastegate Bypass Tube 5.35 -- 8.....
Figure 5.35-29. Wastegate Sensing Tube 5.35 -- 8....
Figure 5.35-30. Heat Shield Attachment 5.35 -- 8.....
Figure 5.35-31. GSID/GLD Air Cleaner 5.35 -- 8......
Figure 5.35-32. Deltec GLD Vent Tube
Installation 5.35 -- 8...........................
Figure 5.35-33. Wastegate Assembly 5.35 -- 9.......
Figure 5.35-34. Wastegate Actuator 5.35 -- 10........
Figure 5.35-35. Actuator Adjustment 5.35 -- 10.......
Figure 5.35-36. Compressor Discharge And
Intake Manifold 5.35 -- 11......................
Figure 5.35-37. F18/H24 Turbocharger 5.35 -- 11.....
Figure 5.35-38. Jacket Water Connections 5.35 -- 12..
Figure 5.35-39. Thermocouple Conduit 5.35 -- 12.....
Figure 5.35-40. Cylinder Head Water
Elbow 5.35 -- 12..............................
Figure 5.35-41. F18/H24G Auxiliary Water
Pipe 5.35 -- 12...............................
Figure 5.35-42. Exhaust Manifold 5.35 -- 13..........
Figure 5.35-43. Cylinder Head Exhaust
Ports 5.35 -- 13..............................
Figure 5.35-44. Exhaust Manifold Drain
Hole 5.35 -- 13...............................
Figure 5.35-45. Exhaust Manifold 5.35 -- 14..........
Figure 5.35-46. Exhaust Manifold Torque
Sequence 5.35 -- 15..........................
Figure 5.35-47. Exhaust Manifold End
Cover 5.35 -- 15..............................
Figure 5.35-48. F18/H24G Manifold Heat
Shield 5.35 -- 15..............................
Figure 5.35-49. F18/H24G Manifold Heat
Shield 5.35 -- 15..............................
Figure 5.35-50. Thermostat Housing
Adapter 5.35 -- 15............................

ILLUSTRATIONS
xxv
FORM 6243 Third Edition
Figure 5.35-51. Wastegate Mounting Plate 5.35 -- 16..
Figure 5.35-52. Cylinder Head Exhaust
Port 5.35 -- 16...............................
Figure 5.35-53. VGF Exhaust Manifold Drain
Hole 5.35 -- 16...............................
Figure 5.35-54. F18GL Bracket Location 5.35 -- 16....
Figure 5.35-55. Thermocouple Installation 5.35 -- 17..
Figure 5.35-56. Inline Engine Exhaust
Thermocouple Installation 5.35 -- 17............
Figure 5.35-57. Water Elbow Assembly 5.35 -- 17.....
Figure 5.35-58. Previous—Water Elbow
Assembly 5.35 -- 17...........................
Figure 5.35-59. Jacket Water Thermostat
Housing 5.35 -- 18............................
Figure 5.35-60. F18/H24G Auxiliary Water
Pipe 5.35 -- 18...............................
Section 5.40 -- Crankcase
Breather System
Figure 5.40-1. Open Breather 5.40 -- 1..............
Figure 5.40-2. Oil Separator 5.40 -- 1...............
Figure 5.40-3. Ventilation System Baffle Box 5.40 -- 2..
Figure 5.40-4. Closed Breather System 5.40 -- 2......
Figure 5.40-5. Closed Breather System 5.40 -- 2......
Figure 5.40-6. F18/H24 Deltec GLD Breather 5.40 -- 2..
Figure 5.40-7. Vacuum Regulator 5.40 -- 2...........
Figure 5.40-8. GL Breather Ejector 5.40 -- 3..........
Figure 5.40-9. Deltec Closed Breather
System 5.40 -- 3..............................
Figure 5.40-10. GLD Closed Breather
System 5.40 -- 3..............................
Figure 5.40-11. Previous Closed Breather
System 5.40 -- 3..............................
Figure 5.40-12. Current Closed Breather
System 5.40 -- 3..............................
Figure 5.40-13. Ventilation System Baffle
Box 5.40 -- 4.................................
Figure 5.40-14. Previous Upper Oil Separator
Inlet Tube 5.40 -- 4...........................
Figure 5.40-15. Current Upper Oil Separator
Inlet Tube 5.40 -- 4...........................
Figure 5.40-16. GL Breather Ejector 5.40 -- 5.........
Figure 5.40-17. Previous F18/H24 Breather
System Adjusting Valve 5.40 -- 5...............
Figure 5.40-18. Oil Separator 5.40 -- 5..............
Figure 5.40-19. Separator Body 5.40 -- 6............
Figure 5.40-20. Current Breather Regulator
Assembly 5.40 -- 6............................
Figure 5.40-21. Breather Regulator 5.40 -- 7.........
Figure 5.40-22. Baffle Box Breather System
Common Parts 5.40 -- 8.......................
Figure 5.40-23. Ventilation System Baffle
Box 5.40 -- 9.................................
Figure 5.40-24. KDM Bracket/Baffle Box 5.40 -- 9.....
Figure 5.40-25. Six Cylinder Module
Installation 5.40 -- 9...........................
Figure 5.40-26. Eight Cylinder Module
Installation 5.40 -- 9...........................
Figure 5.40-27. Separator Inlet Tube 5.40 -- 9........
Figure 5.40-28. Oil Separator Support
Bracket 5.40 -- 10............................
Figure 5.40-29. Open Breather 5.40 -- 10............
Figure 5.40-30. Breather System Oil Drain 5.40 -- 10...
Figure 5.40-31. H24 Oil Drain Tube 5.40 -- 10........
Figure 5.40-32. GLD Closed Breather 5.40 -- 11......
Figure 5.40-33. F18/H24 Impco GLD 5.40 -- 11.......
Figure 5.40-34. GLD Closed Breather
System 5.40 -- 11.............................
Figure 5.40-35. GLD Closed Breather
System 5.40 -- 12.............................
Figure 5.40-36. G Closed Breather System 5.40 -- 12..
Figure 5.40-37. G Closed Breather System 5.40 -- 12..
Figure 5.40-38. Breather Ejector Installation 5.40 -- 12...
Figure 5.40-39. Ejector Support Bracket 5.40 -- 12....
Figure 5.40-40. Ejector Assembly 5.40 -- 13..........
Figure 5.40-41. GL Breather Ejector 5.40 -- 13........
Figure 5.40-42. Breather Ejector 5.40 -- 13...........
Figure 5.40-43. F18GL Ejector Breather 5.40 -- 13....
Figure 5.40-44. Vacuum Regulator 5.40 -- 13.........
Figure 5.40-45. Closed Breather System --
GSID/Deltec GLD 5.40 -- 14....................
Figure 5.40-46. Closed Breather Ejector
System 5.40 -- 15.............................
Figure 5.40-47. Upper Oil Separator Inlet
Tube 5.40 -- 16...............................
Figure 5.40-48. Drain Connections 5.40 -- 16.........
Figure 5.40-49. Lower Oil Separator Inlet
Tube 5.40 -- 16...............................
Figure 5.40-50. Oil Separator Support
Bracket 5.40 -- 16............................
Figure 5.40-51. Air Cleaner 5.40 -- 16...............
Figure 5.40-52. Oil Separator 5.40 -- 17.............
Figure 5.40-53. Oil Separator Filter Element 5.40 -- 17..
Figure 5.40-54. F18GL Bracket Location 5.40 -- 17....
Figure 5.40-55. H24GL Bracket Location 5.40 -- 18...
Figure 5.40-56. Pipe Tee Assembly --
F18GL 5.40 -- 18.............................
Figure 5.40-57. H24 GL Breather Assembly
Depicted 5.40 -- 19...........................
Figure 5.40-58. Pipe Tee Assembly --
H24GL 5.40 -- 19.............................
Figure 5.40-59. Crankcase Oil Drains 5.40 -- 19......

ILLUSTRATIONS
xxvi FORM 6243 Third Edition
Figure 5.40-60. Air Duct Assembly 5.40 -- 20.........
Figure 5.40-61. Oil Separator Drain Hose 5.40 -- 20...
Section 5.45 -- Starting System
Figure 5.45-1. Air/Gas Starter Motor 5.45 -- 1........
Figure 5.45-2. Air/Gas Starter Motor 5.45 -- 1........
Figure 5.45-3. Air/Gas Starter Motor
Connections 5.45 -- 1.........................
Figure 5.45-4. Air/Gas Starter 5.45 -- 2..............
Figure 5.45-5. Air/Gas Starter Assembly 5.45 -- 3.....
Figure 5.45-6. Air/Gas Starter Motor 5.45 -- 3........
Figure 5.45-7. Air/Gas Starter Support 5.45 -- 3.......
Figure 5.45-8. Air/Gas Starter Lubricator Oil
Supply 5.45 -- 3..............................
Figure 5.45-9. Air/Gas Starter Control 5.45 -- 4.......
Figure 5.45-10. Control Valve Mounting 5.45 -- 4......
Figure 5.45-11. Start Push Button Valve 5.45 -- 4.....
Figure 5.45-12. Air/Gas Starter Push Button
Vent 5.45 -- 4................................
Figure 5.45-13. Air/Gas Starter Local
Control 5.45 -- 5..............................
Figure 5.45-14. Air/Gas Starter Local Control
Tubes 5.45 -- 6...............................
Figure 5.45-15. Air/Gas Starter Local Control
Tubes 5.45 -- 6...............................
Figure 5.45-16. Air/Gas Starter Control 5.45 -- 6......
Figure 5.45-17. Remote Start Solenoid
Valve 5.45 -- 6...............................
Figure 5.45-18. Air/Gas Starter Remote Start
Option 5.45 -- 7..............................
Figure 5.45-19. Electric Starter 5.45 -- 8.............
Figure 5.45-20. Alternator Adjustment 5.45 -- 8.......
Figure 5.45-21. Alternator Belt Adjustment 5.45 -- 9...
Figure 5.45-22. Alternator Mounting Brackets 5.45 -- 9..
Figure 5.45-23. Alternator Drive Pulley 5.45 -- 9......
Figure 5.45-24. Alternator Adjusting Bracket 5.45 -- 9.
Figure 5.45-25. 24 Volt Alternator
Installation 5.45 -- 10..........................
Figure 5.45-26. Alternator Adjustment 5.45 -- 10......
Section 6.00 -- Control Panel
Figure 6.00-1. Control Panel 6.00 -- 1...............
Figure 6.00-2. Ignition Switch 6.00 -- 1..............
Figure 6.00-3. Ignition Switch 6.00 -- 1..............
Figure 6.00-4. Control Panel 6.00 -- 2...............
Figure 6.00-5. Temperature and Oil Pressure
Gauge 6.00 -- 2..............................
Figure 6.00-6. Manifold Pressure Gauge
Connections 6.00 -- 2.........................
Figure 6.00-7. Instrument Panel 6.00 -- 2............
Figure 6.00-8. Instrument Panel 6.00 -- 2............
Figure 6.00-9. Instrument Panel Installation 6.00 -- 3..
Figure 6.00-10. Instrument Panel 6.00 -- 3...........
Figure 6.00-11. Auxiliary Control Panel 6.00 -- 4......
Figure 6.00-12. Oil Temperature Gauge
Probe 6.00 -- 4...............................
Figure 6.00-13. Oil Temperature Gauge
Probe 6.00 -- 4...............................
Figure 6.00-14. Oil Temperature Gauge
Wiring 6.00 -- 4..............................
Figure 6.00-15. Control Panel -- Rear View 6.00 -- 4...
Figure 6.00-16. Jacket Water Temperature
Gauge 6.00 -- 5..............................
Figure 6.00-17. Control Panel -- Rear View 6.00 -- 5...
Figure 6.00-18. Tachometer Magnetic Pickup
Location 6.00 -- 5.............................
Figure 6.00-19. Alternative Speed Sensor
Location 6.00 -- 5.............................
Figure 6.00-20. Ring Gear Tooth Alignment 6.00 -- 6..
Figure 6.00-21. Install Pickup Sensor 6.00 -- 6.......
Figure 6.00-22. Manifold Pressure Gauge
Connections 6.00 -- 6.........................
Figure 6.00-23. Manifold Temperature Fitting 6.00 -- 6..
Figure 6.00-24. Oil Gauge Supply Tube 6.00 -- 7.....
Figure 6.00-25. Oil Pressure Gauge 6.00 -- 7.........
Figure 6.00-26. Manifold Pressure Gauge
Connections 6.00 -- 7.........................
Figure 6.00-27. Ignition Switch 6.00 -- 7.............
Figure 6.00-28. Air/Gas Starter Control Valve
And Vent 6.00 -- 7............................
Figure 6.00-29. Instrument Panel Gauge
Installation 6.00 -- 8...........................
Figure 6.00-30. Control Panel Reset Switch 6.00 -- 8..
Section 6.05 -- Engine Protection System
Figure 6.05-1. Manual Shutdown Lever 6.05 -- 1......
Figure 6.05-2. Ignition Switch 6.05 -- 1..............
Figure 6.05-3. Optional Instrument Panel 6.05 -- 2....
Figure 6.05-4. Typical Switchgage 6.05 -- 2..........
Figure 6.05-5. Thermocouple Quick
Disconnect 6.05 -- 4..........................
Figure 6.05-6. Thermocouple Installation 6.05 -- 4....
Figure 6.05-7. K--type Thermocouple 6.05 -- 5........
Figure 6.05-8. Thermocouple Installation 6.05 -- 5....
Figure 6.05-9. K--type Thermocouple 6.05 -- 5........
Figure 6.05-10. Exhaust Thermocouple
Installation 6.05 -- 5...........................
Figure 6.05-11. Thermocouple Installation 6.05 -- 6...
Figure 6.05-12. Thermocouple Connector 6.05 -- 6....
Figure 6.05-13. Thermocouple Conduit
Mounting 6.05 -- 6............................
Figure 6.05-14. Flexible Conduit Routing 6.05 -- 6....

ILLUSTRATIONS
xxvii
FORM 6243 Third Edition
Figure 6.05-15. Current Junction Box
Mounting 6.05 -- 6............................
Figure 6.05-16. Thermocouple Junction Box 6.05 -- 7..
Figure 6.05-17. Exhaust Manifold
Thermocouple 6.05 -- 7.......................
Figure 6.05-18. Exhaust Outlet
Thermocouple 6.05 -- 7.......................
Figure 6.05-19. Thermocouple Connections 6.05 -- 7..
Figure 6.05-20. Thermocouple Installation 6.05 -- 8...
Figure 6.05-21. Overspeed Shutdown 6.05 -- 8.......
Figure 6.05-22. Knock Detection Module 6.05 -- 9.....
Figure 6.05-23. Rear Knock Sensor 6.05 -- 9.........
Figure 6.05-24. Knock Sensor Seating
Surface 6.05 -- 10............................
Section 6.10 -- Miscellaneous Equipment
Figure 6.10-1. Current Production Jacket Water
Heater 6.10 -- 1..............................
Figure 6.10-2. Jacket Water Heater 6.10 -- 2.........
Figure 6.10-3. F18/H24 Jacket Water Heater 6.10 -- 2..
Figure 6.10-4. Water Heater Fittings 6.10 -- 3........
Figure 6.10-5. Jacket Water Heater
Mounting 6.10 -- 3............................
Figure 6.10-6. Heater Outlet Tube 6.10 -- 3..........
Figure 6.10-7. Jacket Water Heater
Connection 6.10 -- 3..........................
Figure 6.10-8. Heater Inlet Tube 6.10 -- 4............
Figure 6.10-9. Temperature Controller Support
Bracket 6.10 -- 4.............................
Figure 6.10-10. Temperature Controller
Probe 6.10 -- 4...............................
Figure 6.10-11. Heater Wiring Conduit 6.10 -- 4.......
Figure 6.10-12. Surge Tank 6.10 -- 5................
Figure 6.10-13. Surge Tank 6.10 -- 5................
Figure 6.10-14. Surge Tank Thermostat
Housing 6.10 -- 5.............................
Figure 6.10-15. Surge Tank Bracket 6.10 -- 5.........
Figure 6.10-16. Surge Tank 6.10 -- 6................
Figure 6.10-17. Surge Tank Installation 6.10 -- 7......
Figure 6.10-18. Oil Level Regulator Mounting 6.10 -- 8..
Figure 6.10-19. Oil Level Regulator 6.10 -- 8.........
Figure 6.10-20. Oil Level Regulator 6.10 -- 8.........
Figure 6.10-21. Oil Level Regulator Vent
Tube 6.10 -- 8................................
Figure 6.10-22. Oil Level Regulator Vent
Tube 6.10 -- 8................................
Figure 6.10-23. Alternator Drive Pulley 6.10 -- 9......
Figure 6.10-24. Crankshaft Pulleys 6.10 -- 9.........
Figure 6.10-25. Alternator Guards 6.10 -- 9..........
Figure 6.10-26. F18 Vibration Damper
Guard 6.10 -- 9...............................
Figure 6.10-27. F18/H24 Vibration Damper
Guard 6.10 -- 10..............................
Figure 6.10-28. Vibration Damper Guard 6.10 -- 10....
Figure 6.10-29. Vibration Damper Guard 6.10 -- 10....
Figure 6.10-30. Vibration Damper Guard 6.10 -- 11....
Figure 6.10-31. Vibration Damper Guard 6.10 -- 11....
Figure 6.10-32. Vibration Damper Guard 6.10 -- 11....
Figure 6.10-33. Vibration Damper Guard 6.10 -- 11....
Figure 6.10-34. Guard Cover 6.10 -- 11..............
Figure 6.10-35. Alternator Guard 6.10 -- 13..........
Figure 6.10-36. Pulley Guard 6.10 -- 13..............
Figure 6.10-37. Alternator Guard 6.10 -- 14..........
Figure 6.10-38. Alternator Adjusting Rod 6.10 -- 14....
Figure 6.10-39. Alternator Rear Guard 6.10 -- 14......
Figure 6.10-40. Flywheel Stub Shaft 6.10 -- 15.......
Figure 6.10-41. Alternator Guard 6.10 -- 15..........
Figure 6.10-42. Stub Shaft Assembly 6.10 -- 15.......
Figure 6.10-43. Checking Stub Shaft
Runout 6.10 -- 16.............................
Figure 6.10-44. Indicate Flywheel Face 6.10 -- 16.....
Section 6.15 -- CEC Generator
Figure 6.15-1. CEC Generator System 6.15 -- 1......
Figure 6.15-2. CEC generator installation 6.15 -- 2....
Figure 6.15-3. Voltage Regulator Installation 6.15 -- 2.
Figure 6.15-4. Wiring Harness Routing 6.15 -- 2......
Figure 6.15-5. CEC Type I Generator Wiring
Schematic 6.15 -- 3...........................
Figure 6.15-6. CEC Type II Generator Wiring
Schematic 6.15 -- 4...........................
Figure 6.15-7. CEC Type I System With
Battery 6.15 -- 5..............................
Section 7.00 -- Troubleshooting
Figure 7.00-1. Engine Compression
Pressures 7.00 -- 10..........................
Figure 7.00-2. Correction Factor 7.00 -- 10...........

TABLES
xxixFORM 6243 Third Edition
LIST OF TABLES
Section 1.00 -- Warning Tag And Decal
Locations
Table 1.00-1. VGF 6 And 8 Cylinder Engine
Safety Labels 1.00 -- 1........................
Section 1.10 -- Rigging And Lifting
Engines
Table 1.10-1. Engine Dry Weights 1.10 -- 1..........
Section 1.15 -- General Information
Table 1.15-1. Special Tools 1.15 -- 16...............
Table 1.15-2. Test Pigtail Adapters 1.15 -- 16.........
Table 1.15-3. Model F18 And
H24G/GSID/GL/GLD Specifications 1.15 -- 17....
Table 1.15-4. F18/H24 Specific Engine
Torques 1.15 -- 21............................
Table 1.15-5. Metric Standard Capscrew
Torque Values
(Untreated Black Finish) 1.15 -- 24..............
Table 1.15-6. Metric Standard Capscrew
Torque Values
(Electrically Zinc Plated) 1.15 -- 25..............
Table 1.15-7. U.S. Standard Capscrew
Torque Values 1.15 -- 26.......................
Table 1.15-8. Metric Bolt Diameter To Hex
Head Wrench Size Conversion Table 1.15 -- 26...
Table 1.15-9. English To Metric Formula
Conversion Table 1.15 -- 27....................
Table 1.15-10. Metric To English Formula
Conversion Table 1.15 -- 27....................
Table 1.15-11. Sealants, Adhesives, and
Lubricants 1.15 -- 28..........................
Section 1.20 -- Specifications
Table 1.20-1. Cylinder Liner 1.20 -- 1................
Table 1.20-2. Crankcase 1.20 -- 2...................
Table 1.20-3. Piston 1.20 -- 3......................
Table 1.20-4. Piston Pin 1.20 -- 3...................
Table 1.20-5. Piston Rings 1.20 -- 4.................
Table 1.20-6. Crankshaft 1.20 -- 5..................
Table 1.20-7. Camshaft Followers 1.20 -- 6..........
Table 1.20-8. Valve Spring Clearances 1.20 -- 7......
Table 1.20-9. Flywheel And Housing 1.20 -- 8........
Table 1.20-10. Connecting Rod, Bushing And
Bearing 1.20 -- 9.............................
Table 1.20-11. Valve Clearances 1.20 -- 10...........
Table 1.20-12. Cylinder Head Clearances 1.20 -- 11...
Table 1.20-13. Rocker Arm Assemblies 1.20 -- 12.....
Table 1.20-14. Camshaft 1.20 -- 13.................
Table 1.20-15. Cross Bar And Guide 1.20 -- 13.......
Table 1.20-16. Oil Pump 1.20 -- 14..................
Table 1.20-17. Front Gear Train Backlash 1.20 -- 15...
Table 1.20-18. Valve Seat Clearances 1.20 -- 16......
Section 2.00 -- Cylinder Head Removal
Table 2.00-1. Special Tools For Cylinder
Head 2.00 -- 1...............................
Section 2.05 -- Crankcase Removal
Table 2.05--1. Special Tools For Crankcase 2.05 -- 1..
Section 3.00 -- Cylinder Head
Table 3.00-1. Special Tools For Cylinder
Head 3.00 -- 1...............................
Table 3.00-2. Rocker Arm Assemblies 3.00 -- 2.......
Table 3.00-3. Cross Bar ID Specifications 3.00 -- 3....
Table 3.00-4. Cross Bar Guide OD 3.00 -- 3..........
Table 3.00-5. Cross Bar To Guide Clearance 3.00 -- 4..
Table 3.00-6. Cross Bar Seat Specifications 3.00 -- 4..
Table 3.00-7. Valve Clearances 3.00 -- 10............
Table 3.00-8. Valve Guide Clearances 3.00 -- 11......
Table 3.00-9. Valve Seat Insert Grinding
Stones 3.00 -- 14.............................
Table 3.00-10. Valve Seat Clearances 3.00 -- 15......
Table 3.00-11. Valve Spring Clearances 3.00 -- 16....
Section 3.05 -- Crankcase Disassembly
Table 3.05-1. Crankcase Tools 3.05 -- 1.............
Table 3.05-2. Camshaft 3.05 -- 6....................
Table 3.05-3. Camshaft Follower Tolerances 3.05 -- 8...
Table 3.05-4. Piston Tolerances 3.05 -- 10...........
Table 3.05-5. Piston Ring Dimensions 3.05 -- 11......
Table 3.05-6. Piston Pin 3.05 -- 11..................
Table 3.05-7. Connecting Rod, Bushing And
Bearing 3.05 -- 13............................
Table 3.05-8. Connecting Rod, Bushing And
Bearing 3.05 -- 13............................
Table 3.05-9. Connecting Rod, Bushing And
Bearing 3.05 -- 14............................
Table 3.05-10. Cylinder Liner Dimensions 3.05 -- 17...
Table 3.05-11. Crankcase Dimensions 3.05 -- 18......
Table 3.05-12. Main Bearings 3.05 -- 23.............
Table 3.05-13. Crankshaft Specifications 3.05 -- 24...
Section 4.00 -- Crankcase Assembly
Table 4.00-1. Special Tools 4.00 -- 1................
Table 4.00-2. Gear Train Backlash 4.00 -- 26.........

TABLES
xxx FORM 6243 Third Edition
Section 4.05 -- Cylinder Head Installation
Table 4.05-1. Special Tools For Cylinder
Head 4.05 -- 1...............................
Section 4.10 -- Valve Adjustment
Table 4.10-1. Valve Clearance -- Cold 4.10 -- 3.......
Section 5.10 -- Ignition System
Table 5.10--1. Spark Plug Specifications 5.10 -- 10....
Table 5.10--2. Spark Plug Troubleshooting 5.10 -- 10..
Table 5.10--3. Spark Plug
Recommendations 5.10 -- 10...................
Table 5.10--4. Special Tools For Testing
Ignition Coil 5.10 -- 11.........................
Table 5.10--5. Ignition Module Selector Switch
Settings 5.10 -- 30............................
Table 5.10--6. Firing Order For VGF 6
Cylinder Engines 5.10 -- 31....................
Table 5.10--7. Firing Order For VGF 8
Cylinder Engines 5.10 -- 31....................
Table 5.10--8. F18/H24 CEC Ignition Module
Switch Positions 5.10 -- 31.....................
Section 5.20 -- Turbocharger
Table 5.20--1. Turbocharger Shaft
Specifications 5.20 -- 5........................
Section 5.25 -- Cooling System
Table 5.25--1. Jacket Water Outlet
Temperature Settings 5 F (5 C) 5.25 -- 3.........
Table 5.25--2. Jacket Water Capacity --
Engine Only 5.25 -- 4.........................
Table 5.25--3. Auxiliary Water Capacity --
Engine Only 5.25 -- 4.........................
Table 5.25--4. Air Bleed Petcocks 5.25 -- 4...........
Table 5.25--5. Air Bleed Petcocks 5.25 -- 5...........
Table 5.25--6. Water Drain Petcocks 5.25 -- 5........
Table 5.25--7. Jacket Water Capacity --
Engine Only 5.25 -- 6.........................
Table 5.25--8. Jacket Water Thermostat --
All Models 5.25 -- 28..........................
Table 5.25--9. Auxiliary Cooling Water
Thermostat 5.25 -- 38.........................
Section 5.30 -- Lubrication System
Table 5.30-1. Oil Recommendations 5.30 -- 3.........
Table 5.30-2. Recommended Lube Oils For
Cogeneration Applications (Using Pipeline
Quality Gas) 5.30 -- 4.........................
Table 5.30-3. Recommended Lube Oils Landfill
Gas Applications 5.30 -- 5.....................
Table 5.30-4. Used Oil Testing And
Condemnation 5.30 -- 7.......................
Table 5.30-5. VGF Sump And Header
Temperatures And SAE Number 5.30 -- 7........
Table 5.30-6. Oil Consumption 5.30 -- 8.............
Table 5.30-7. Recommended Oil Change
Intervals For Engines Receiving
Normal Maintenance 5.30 -- 9..................
Table 5.30-8. Recommended Oil Change
Intervals For Engines Receiving Normal
Maintenance And Using Gaseous Fuel
Containing H2S 5.30 -- 9......................
Table 5.30-9. Duty Cycle Definitions 5.30 -- 9.........
Table 5.30-10. Second Production VGF
Cooling Jet 5.30 -- 25.........................
Table 5.30-11. Current VGF Cooling Jet --
One Piston 5.30 -- 26.........................
Table 5.30-12. Oil Pump 5.30 -- 33..................
Table 5.30-13. Oil Pump Torques 5.30 -- 34..........
Section 5.35 -- Exhaust System
Table 5.35--1. Preliminary Wastegate
Adjustments 5.35 -- 10........................
Table 5.35--2. F18GL And H24GL LCR
Wastegate “A” Dimensions 5.35 -- 10............
Section 5.40 -- Crankcase Breather
System
Table 5.40--1. Crankcase Pressure 5.40 -- 4..........
Section 6.05 -- Engine Protection System
Table 6.05--1. VGF Shutdown Limits 6.05 -- 3........
Section 7.00 -- Troubleshooting
Table 7.00-1. Troubleshooting 7.00 -- 1..............
Section 7.05 -- Maintenance And Storage
Table 7.05--1. VGF F18/H24 Routine
Maintenance Chart 7.05--2....................
Table 7.05--2. Recommended Oil Change
Intervals For Engines Receiving Normal
Maintenance 7.05--4..........................
Table 7.05--3. Recommended Oil Change
Intervals For Engines Receiving Normal
Maintenance And Using Gaseous Fuel
Containing H2S 7.05--4.......................
Table 7.05--4. Duty Cycle Definitions 7.05--4.........
Table 7.05--5. F18 Maintenance Parts
Reference 7.05--5............................
Table 7.05--6. H24 Maintenance Parts
Reference 7.05--5............................
Table 7.05--7. Preservative Oils 7.05--6..............
Table 7.05--8. Protective Materials 7.05--6...........
Table 7.05--9. Preservative Oil Capacity 7.05--6......