TM 9-1765B BOMB SERVICE TRUCK M6 CHEVROLET

8/10/2019 TM 9-1765B BOMB SERVICE TRUCK M6 CHEVROLET

1/362

UN

L SSIF IED

T

M 9-176

5B

WAR EPRT

MENT

TECHNIC

AL

M

ANUAL

ORD

NANCE MAINTEN

ANCE

E N G I N E

P O W E R T

R A I N

B

R A K I N G

A N D S T

E E R I N G S Y

S T E M S FOR

B O M B S E

R V I C E T R U C

K M

Che

vrolet)

FEBR

U RY

25 1943

/ }

R E G R D ED U

N L SSIFIED

^

FO

R ORDN

NCEP RS

ONN L

ONL

Y

.1.


2/362

UN

LSS

IF IE

D

T E C H N I C

A L M

ANUAL

W A

R

D E P A R

T M E N T

N

o . 9-1765B

I

W a

shingto

n Feb

ruary 2

5 1943

ORD

N N

CE M

AINTE

NANC

E

E N

G IN E

, P O W

E R T R A I

N ,

B R A K

I N G A N D

S T E E

R I N G

S Y

S T E M S

F O R B O M

B S E

R V I E

T R U C K

M

6

C h e v r

o l e t )

Pr

epared

u n d

e r

t h e dir

ection of

th

e

Ch

ief of

Ordnan

ce

with

the cooperation

of

the

Chevrolet Motor

Divis

io n

Genera

l Moto

rs

C

orporati

on

CON T

EN TS

Parag

raph s

Pa ge s

CHAP

TER

1 I N

T R O D U

T I ON

1

3

5

CH

APTER

2 . E N G

I N E

4 63

6

1 3 1

S E T I O

N I . I ntrodu

ction

4 7

6

1 7

II. Trouble

shooting

8 1 3

1 8 2 4

II

I O

peratio

ns perf

ormed

w

ithout re

m ovi

ng engin

e ro

m veh

icle. 1

4 2 6

2 5

7 1

IV . En

gine re

moval f

rom

vehic

le. 2

7 28

72

74

V . En

gine

disas

sembly

29-30

7 5 7 9

VI .

Cleani

ng and insp

ection

3 1

3 3

8

0 82

V

I I .

E ngin

e

re

pair

3 4 5 2

8 3 1 1 9

VIII.

E ngi

ne

a

ssembl

y

5 3

5 8

1 2 0 1 2 2

I

Engine

installation

in

vehicle

5 9 6 1 123126

X.

Fit

s and to

lerance

s.

62

127-13

0

XI.

S

pecial

engine

tools

6 3

1 3 1

C

HAPT

ER

3 . E N

G IN E I G N

I T I O N

S Y S

T E M .

64 85

1 3 2 1

44

S

E T I O N

I . I nt

roducti

on

64 67

1 3 2 1

3 4

II. T

rouble

s

hooting

68

1 3 5

III

Operat

ions pe

rforme

d w

ithout

re

moving

units

from

ve

hicle.

6 9 7

3 1 3

6 1 3 7

IV.

Ignitio

n units

remo

val from

vehicle

7

4 77

1 3 8 1 3

9

V. Ig

nition

units

disas

sembl

y

7 8

1 4 0

VI.

Ign

ition system

parts

cleanin

g in

spectio

n a

nd repla

ceme

nt

79 80

1

4 1 1 4 2

V

II. Asse

mbling

distr

ibutor

81

1 4 3

V

III

Ignit

ion

un

its

installa

tionin vehicl

e

82 8

5 1 4 4


3/362

Paragraphs Pages

CHAPTER 4. F U E L

S Y S T E M

86-102 145-175

S E C T I O N

I .

Introduction

86-88

145

II. Trouble

shooting

89

146-147

III.

Fuel tank removal

from vehicle...

90-91 148-149

IV. Fuel pump, removal

and repair.

.. 92-93 150-153

V. Fuel

filter,

removal and repair.... 94-95 154-155

VI.

Carburetor,

removal and

repair.

96-100 156-174

VII. Air

cleaner,

removal and mainte

nance 01-102 175

CHAPTER 5. C L U T C H

A S S E M B L Y

03-115

176-192

S E C T I O N I . Introduction

03-106

176-179

II. Trouble

shooting 107

180

III. Operations

performed

without re

moving clutch

from vehicle.

....

108-109

181-182

IV.

C lutch

disassembly 110-111 183-185

V. C leaning and inspection......... 112 186-187

VI.

Clutch installation in vehicle.

13-114

188-191

VII.

Special tools

115 192

CHAPTER 6. T R A N S M I S S I O N .................116 131 193-217

S E C T I O N

I . Introduction

16-120

193-197

II. Trouble shooting 21-122 198-199

III. Operations performed without re

moving

transmission

from vehicle. 123-124

200-204

IV.

Transmission

removal

from

vehicle

125

205-207

V. Transmission disassembly and in

spection

26-127 208-209

VI . Transmission repair and assembly. 128-129

210-214

VII.

Transmission

installation

in

vehicle 130 215

VIII.

Fits

and tolerances. 131

216-217

CHAPTER

7 . TRANS FER CASE 32-148

218-241

S E C T I O N

I .

Introduction

32-136

218-220

II.

Trouble shooting 37-138 221-222

III.

Operations

performed

without re

moving transfer case from vehicle.

139-140

223-225

IV. Transfer case

removal

from vehicle

141

226-227

V. Transfer

case

disassembly........

142-143 228-231


4/362

ONT N

TS

aragraphs

ges

S E C

T I O N

VI.

Tra

nsfer case

repair and as

sembly. 14

4-145 232-238

VII. Tra

nsfer case installa

tion in

vehicle 146

239

VIII. Fits

and

tolerances

147

240

I..

Spec

ial tool

s

148

2

41

C

HAPTER

8 B R A

K E S Y S

TE M

49-

187

24

2-277

S E C T IO

N

I.

Introdu

ction

49-15

2

24

2-244

II. Trouble shootin

g

153 245-24

6

III. Op

erations pe

rformed wit

hout

re

mov

ing units fr

om

vehicle. 15

4

2

47

IV.

Br

ake syste

m

unit

s remov

al from

vehi

cle

5

5-160

248-252

V Bra

ke system

u

nits

disassemb

ly. .161-163 253-2

56

VI.

Brake system

parts

cleani

ng

in

spection

and repair.

64-

169 257-

260

VII. Brake sy

stem units

assemb

ly.

70-171

261-262

VIII.

Hydrovac

system

72-1

77

263

-270

I

Brake

system units

installation

in

vehicle

78-18

6

271-

276

X.

Fits and

tolerances.

187

277

CHA

PTER

9 S T E E R

I N G G E A R

8

8-208 278

-295

S E

C T I O N

I.

Int

roduction

88-1

91

2

78-279

II.

Trouble

sh

ooting

19

2

280

III. Steer

ing gear

remo

val.

93-194 281

-283

IV.

Steering

gear

disassembly

195-199

284-286

V.

Steering

gear parts cleaning

in

spection

and repla

cement. 200

-201 2

87

VI

. Assembling

steeri

ng g

ear. .202-204

288-2

92

VII. Steerin

g gear asse

mbly in

stallation

in

v

ehicle

05-206

293

VI

II. Fits an

d tol

erances

207

294

I.. Special

tools

20

8

295

CHAPT

ER

10 S H O C K

A B S O R

B ER S 20

9-223 296-308

S E C T I O

N

I.

In

troduction

.............

.....209

212 296-297

II. Shoc

k ab

sorber removal

fro

m

vehicle

.....

.............

..213 21

4 298

III.

Shock

ab

sorber

disassem

bly....

..215-21

6 2

99-301


5/362

aragraphs

ge

s

SECT IO

N IV.

Shoc

k

ab

sorber

parts clean

ing in

s

pection

and

re

placement.

....

.217-219 302-3 04

V.

Assembling

s

hock absorb

ers

..

....220 22

1 3

05-306

VI. Ins

talling shock

abso

rber on vehic

le

222

3

07

VII.

Spe

cial tools

223

308

C

HAPTER

11

.

STAR

TING

MOTOR .....

.........22

4 237 309-

320

SECT IO

N

I .

Introducti

on ..

.............

...224 2

27

309-310

II.

Trou

ble

sh ooting

228

311

III.

Starting motor removal.

229

312-313

IV. S

tarting m

otor disass

embly.

230

314

V . Starting

moto

r pa

rts cleaning in

sp

ection and repair

.......

...231 23

3

315-3

17

VI. Assem

bling

star

ting

m

otor.....

..

234-235

318

VII. Starting

motor insta

llation

in

veh

icle

236

319

VIII.

Fits

an

d

t

olerances

237

320

CHAPT

ER 12

.

G

ENERATOR

N D

CONTROLS . ..

.. .2 38-265

321-

347

SECT ION

I . Introductio

n

..

.............

...238 2

41 321

-323

II.

Troubl

e shooting

242

324

III.

Operatio

ns

pe

rformed witho

ut

re

m

oving units

from vehicle

.

243-245 325-331

I

V . Removal of

generato

r and

controls

f

rom vehicle

4

6-247

332-33

3

V .

Generator

and

regulator

disas

semb

ly

....

............

.....248

249

334-335

VI. Generator

a

nd cont

rol

parts

clea

n

in g

in s

pection and rep

lacement.25

0-258

336-343

VII. A

ssembling generato

r and regu

lator. 259-261

344-345

VI

II. Gener

ator and

controls

i

nstallation

in

vehicle

....

.............

.262 26

4

34

6

I..

Fits

an

d toleranc

es

265

347

CH

APTER

13.

REFEREN CE

S

.......

...........2

66 267

348

I NDEX

349

-362


6/362

C H P T E R

INTRO UTION

Paragraph

Scope

Arrangement

of

manual

2

Characteristics

3

1

SCOPE

a.

This

manual is

published

for the info

rmation of

ordnance main

tenance

personn

el.

It contains detailed

instructions for inspe

ction

dis

assembly a

ssembly

mainten

ance

and

rep ir

of

Bomb

Service

Tru

ck

M6

Chevrolet),

supplement ry

to

those

in

the

field

and

technical

manuals p

repared for

the

using arms. Addition

al descriptive

mat

ter and

illustrations

are included to aid

in

providin

g a complete w

orking

knowl

edge of themateriel.

2 ARRANGEMENT

OF MANUAL

a. The ch pters of t

his

manual

cover the maintenance

operations

of

the

ollowing main

assemblies: engine ignition system

fue

l system

clutch

transmissio

n transfer case br ke

system steering gear sh

ock

absor

bers

frame

starting

motor and generator and

controls.

Each

chapter is

brok

en down

into sections which cover the

removal

di

s

assembly inspection

repairs assembly

and i

nstallation of the

main

assemblies. The section

index covers

the

p r gr phs of the

various

operations

within

the

section.

3

CHARAC

TERISTICS

a. The bomb

service

truck is

a

4

-wheeled vehicle

u

sed to

load

un

lo ad

and

tow bomb

carrying

trailers.

The

chassis

and

engine

are

basically the

same

as on the

regular

Chevro

let 4-wheel

drive truck

differing only fo

r

the installa

tion

of

a special

cab and

bomb handling

hoist.


7/362

CH

PTER

N IN

Section

INTR

O U TION

Paragrap

h

General

description

..............

...............

........ 4

D

ata ...

...............

..............

...............

..

5

Referenc

e

t

o operator'smanu

al.............

...............

6

Allocation

of

m

aintenance duties

by echel

ons

4 GENERAL D

ESCRIPTION

a.

The

heavy-duty

eng

ine show

n in

figures

1 2 and 3

is a

4-cyc

le

6-cy

linder-in-lihe valve-i

n-head

typ

e. The

engine number

is stamped

on a machined

surface on the righ

t side

of

the

block just back

of

the

distributor.

The

cyli

nders are num

bered

from

the

fan or front

end

of

the engin

e. The engine turns

in a clockwise di

rection viewed

from

th

e

front

or

cranking

location.

b

. It

is

often re

ferred to as a

3-story engine

;

the

oil pan the cylinder

block and

the cylinder

head.

c.

The

pan

is fitted with

oil tro

ughs oil pipes for

rod lubrica

tion

an

d the

oil gage

rod.

d. T

he

c

ylinder bl

ock

assembly

is the major

section

as it is fitted

with the

crankshaf

t camshaf

t

timing

gear plate

timin

g gears

pistons

piston

rings

connecting

rods

and other

miscellaneous parts.

In addition

to the

above parts which

are serviced

as part

of

the cylinde

r

b

lock

a

ssembly the

following units

are

at

tached to

this

ass

embly w

hen in

the tr

uck:

water

pump

oil pump distributor

starter

generator fly

wh

eel

clutch

housing harmonic

balanc

er fuel pump

valve lifter and

other

m

iscellaneous parts.

e. The cylinder head

as installed on

the truck

includes

th

e valve

guid

es

valves valve springs wa

ter outlet

manifolds carburetor tem

perature

indicator

fitting

rocker arm

assemblies

and

push

rod

cover.

5 DATA

Type

.............

...............

..............

.alve-in-head

Number

of cylinders

.........

..............

...............

..

Bore .............

...............

................

....3

i

n.

Stroke. .

..............

...............

...............

3

iQ

in .


8/362

I

NTRO U T

ION

R

PD

85

Piston

displacem

ent

235.5

cu in .

Compre

ssion ratio

.6 2 to

H

orsepower

SAE

30.4

Horsepow

er rated

at

3 1

00 rpm)

93

Firing

order

-5

-3-6-2-4

Maximum torque

92

ft-lb

Wei

ght of engine

a

nd cl

utch

74 Ib

Oil

cap

acity

5

qt

O il

filling

location

Breather

right side

Oil gage

ro

d.

R

ight si

de

bac

k of distribu

tor

O

il drain location

ottom rear

of pan

Cylinder

block

d

rain

ef

t rea

r

s

ide of

block


9/362


10/362

INTRO

U TION

6

REFERE

N E

T OP

ERATOR

'S MANU

AL

a.Many seco

nd eche

lon

operation

s describe

d

in

TM 9 765

are oft

en

d

one by

ordnance

main

tenance per

sonnel. Ref

erence

should

be madeto

TM

9 765 for low

er

echelon

operati

ons

not

cove

red

in

th

is ma

nual.

7

. ALLOCA

TION O

F MAINT

ENANC

E DUT

IES BY

E CH EL

ONS.

a.

Definitions

Echelons

and

words as used in

this

list of

mainte

nanc

e allocatio

ns a

re

d

efined

as follow

s:

SE C

OND E

CHELON: Line

org

anization

reg

iments, ba

ttalions,

comp

anies

f

irst and

sec

ond e

chelons)

.

T

HIRD ECHE

LON: O

rdnance

light

maintena

nce compan

ies, o

rdnance

medium

m

aintenanc

e

com

panies,

ordnan

ce divis

ional

mainten

ance

battali

ons, and

post ord

nance s

hops.


11/362


12/362

INTR

ODU TI

ON

ECHE LON

S

A

XLE . FRON

T onfd

2nd

3 rd

4fh

5*h

*Axle

a

ssembly

replace

X

Axle

assembly

repair

X

Axle

as

sembly

rebuild

E X

B

earing, whe

elrepla

ce

X

Gear, b

evel

and p

inion

adjust

X

R

etainer,

grease,

whe

elrep

lace

X

Rod,

tierep

lace

X

Rod,

tie

repair

X

Seal,

o

il, trunnio

nhousin

grep

lace

E

X

Shaftreplace

E X

St

op, st

eering

knuckle

replaceor ad

just

X

A XLE . REAR

Axle

asse

mblyre

place

X

Ax

le assem

blyre

pair

X

Ax

le

a

ssembly

rebuild

E

X

B

earing, w

heelrep

lace

X

G

ear,

bevel an

d

p

inion

adjus

t

x

Retainer

, grea

se,

wheel

replace

X

Shaftreplace

X

BO DY

B

ody asse

mblyre

place

x

Bo

dy asse

mblyr

epair

X

Body a

ssembly

rebuild

E

X

Cush

ion,

s

eatrepl

ace

X

Cushio

n,

s

eatrebu

ild

x

Glassr

eplace

x

Hoist, bo

mb h

andling

repair

x

Hoist, bom

b hand

lingre

build

x

Seatrep

lace

x

Seatr

epair

x

T

arpaulin,

cab

com

partmen

t

and

cover

replace.

x

Tarpa

ulin,

cab

compar

tment and

c

overr

epair...

x

U

pholstery

replac

e

x

Win

dshield

assembly

replace

x

W

indshield

ass

embly

repair

X

Windshield assemblyrebuild

E

X

W

iper assembl

y, windshie

ldrepla

ce

x

Wip

er assembly

, windshi

eldreb

uild

X

*T

he

se

cond echelon i

s

authorized

to re

move and

re

install items

marke

d by an

as

terisk. Howe

ver, when

it is necessar

y to

replac

e

an i

tem

marked by an

as

terisk

with a new

or reb

uilt

pa

rt, subasse

mblyor

unit assembly,

the ass

embly

marked

by

an

aste

risk

may

be remov

ed from

the vehicle

b

y

the

second echelon

only

fter

uthor

ity has

been obt

ined

fr

om hig

her

echelon of ma

intenance

11


13/362

ECHELONS

BRAKES.

SERVICE

(FOOT)

2 n d

3rd

4th 5 th

Brakesadjust, replace

.....................

X

C

ontrols, brake

(electric

, trailer)replace. ..... X

Controls,

brake (electric, traile

r)rebuild. ..... X

Cylinder assembly, masterreplace,

service.....

X

Cylinder assembly, master

repair

.

........... X

Cylinder assembly,

masterrebuild

...........

X

Cylinder

assembly, power (Hydrovac)replace. x

Cylinder assembly,

power (Hydrovac)repair. .

.

X

Cylinder

assembly,

power

(Hydrovac)rebuild.. X

Cylinder

assembly, wheelreplace ............ x

Cylinderassembly,

wheelrepair ............. X

Cylinder assembly,

wheelrebuild

.....

....... X

Hose, flexiblereplace

...............

....... X

Shoe assemblyrepla

ce

.

.................... x

Shoe a

ssemblyrepair (reline) ....

...........

X

B R A K E

(HAND

OR PARKINS)

Band assemblyreplace

.................... X

Band assemblyrep

air

(

reline)............... X

Controlsrepl

ace ................

..........

X

Controlsrepair ..'.......

.................. X

C A S E TRAN S FE R

*Case assemblyreplace ......

............... X

Case

assemblyrepair .....................

. E

X

Case

assemblyrebuild

.......

.............. E X

Controlsreplace

..........................

x

Drum, brake, hand

replace E X

CL UTCH

C

lutchreplace ..........

..................

E

X

C

lutchrepair .....................

........

X

Clutc

hrebuild ................

............ E X

Pedal, free travel

service (adjust) ........

....

X

COOLING

SYSTEM

Belt,

fan,

generator

and water

pumpreplace.... X

Blades,

fanreplace ..................

...... X

Blades, fan

repair

...

...................... E x

12


14/362

INTROD

UCTION

ECHEL O N S

COOLIN

G SYSTEMCont d

2 n d 3 r d 4 t h 5t h

Hosereplace

.............................

x

Pump

waterrep

lace .....................

.

x

Pump,

w

aterrepair

X

Pump, water

rebuild

X

Radiator ass

emblyreplace ..........

....... X

Radiator assemblyrepair

.....

............. X

Radiator

assemblyrebuild

................. B

X

EL ECTRICAL SYSTEM

Batteryservice and

recharge,

replace......... X

Battery

repair ............

................

X

Batteryrebuild ................

........... B X

B

ox,

apparatus

assembly, generator regu

lator

B ox

,

apparatus

assembly, ge

nerator

regulator

repair

.........................

......... x

Box,

apparat

us assembly, generator

regulator

rebuild

........................

.........

x

Cables,

batteryreplace

.....................

x

Hornservice and replace

.................

..

x

Hornrepair .

............................. X

Lampsservice and replace

X

Switch assembliesreplace ..

................ X

Switch assemblies

repair ................

...

X

W

iringreplace .......................

.... X

ENGINE

Arm,

rockerreplace .................

......

x

Arm

,

rockerrep

air ........................

X

B earing,

connecting

rodreplace..............

E E X

B earing, crankshaft, mainreplace...........

..

E

E

B lock,

cylinder

rebuild (rec

ondition)

.........

E X

Carburetor assemblyreplace .....

........... X

Carbu

retor

assemblyrep

air ......

...........

X

Carburetor assembly

rebuild ................ E X

Cleaner,

airrepla

ce

....................

...

x

Cleaner, airrepair ..........

.............. X

Cover and

gasket, pushrodreplace...........

x

Cover and

gasket,

valv

ereplace.............. x

Crankshaftrebuild

(recondition) .........

... E

X

Enginerepair

X

Enginerebuild

E X

1 3


15/362

ECHELONS

ENGINECent

2n d

3r d

4th

5th

*Engine

assembly

replace

X

Filter asse

mbly,

oilservic

e,

repla

ce

X

Fl

ywheelrep

lace

E

X

Gaske

t, cylinder

headr

eplace

x

Gaske

ts, manifold

replace

x

Gears,

tim

ingreplace

E

X

Gen

erator

assemblyr

eplace

x

Genera

tor ass

emblyrepa

ir

Generator

assemblyrebuild

x

Gove

rnor asse

mblyrepla

ce

x

Governor

assembly

rebuild

E

X

Guid

e,

valverep

lace

E

E X

Head, cylin

derreplace

, repair

x

H

ead, cylinderre

build

E X

Lifter, valver

eplace

x

Line, o

il, internalr

eplace, repair

E

x

Manifoldsreplace

E X

Man

ifoldsrepa

ir

^

E x

Motor,

s

tartingrep

lace

x

M

otor, start

ingrepair

x

Mo

tor, starting

rebuild

x

P

an assembly, oilcle

an and

rep

lace g

askets.... x

Pan assem

bly, oilrep

air

and

r

eplace

x

Pin, piston

replace

E

E

X

Piston and

ring

assembly

replace

............. E

E

X

Pulley, crankshaft,

fan,

generator, water

pump

repla

ce

x

Pump asse

mbly, fuels

ervice,r

eplace x

Pum

p

ass

embly, fuel

repair

E

X

Pump assemb

ly, fuelreb

uild

E X

P

ump assembly, oilr

eplace

E X

Pump

ass

embly, oil

repair

X

Pump assemb

ly, oilr

ebuild

X

Rod, connec

tingreplace

E

X

Rod

, push

replace

X

Seat,

valver

eseat

X

14


16/362

INTRODUCTI

ON

EC

HELONS

ENGINEConl d

2 < l 3rd 4i 5t h

Springs,

valvereplace

.....................

E X

Thermostatreplace

........................

X

Tube, steam reliefreplace .............

..... X

EXHAUST

Muffler

and exhaust

pipesreplace............

X

EXTINGUISHER.

FIRE

Ext

inguisher,

fire,

carbon tetrachloridereplace,

refill ....

..............................

. X

Extinguisher,

fi

re, carbon tetrac

hloriderepair... X

Extinguisher, fire,

carbon

tetrachloriderebuild

.

E X

F R A M E

Bumperreplace

........................

...

X

Fram

e, assemblyrepair .................... x

Frame,

assemblyrebuild ...................

E X

Guard, bru

shreplace

....

.................

X

Gu

ard,

bru

shrepair .......................

X

Pintlereplace

............................

X

P

intlerepair .......................

...... X

FUEL SYSTEM

Filter and fuel

linesservice, replace

X

L

inesrepair, replace

...........

............

X

Tankserv

ice and replace.............

...... X

Tankrepair ...

...........................

X

GEAR. STEERING

Arm

(Pitman)replace

....................

X

Gear as

semblyreplace

..........

...........

E X

Gear assemblyrebuild .....................

E X

Link assem

bly,

dragserv

ice

and

replace.......

X

Link

assembly, dragrepair .............

.... X

IGNITION

S

YST EM ENGINE)

Coil, ignitionreplace

......

................

X

Condenser, distributorreplace ......

......... X

Distributor

assemblyreplac

e

..............

..

X

Distributor assembly

repair

.

................ x

Distribu

tor

assemblyrebuild ................

X

Plug,

s

parkreplace

......

.................. x

Plug, sparkrepair

......................... x

Points,

break

er,

dist

ributorreplace............

X

Wir

ing, ignition

replace

...................

.

X

15


17/362

INSTRUMENTS

A N D G AG E S

ECHELON S

(No

t l i s ted I n d iv i d ua l l y 2n

d 3rd 4th 5t h

Instrum

ent

and

gagesreplace ...............

X

Instrument and gagesrebuild ...............

K

X

M E T A L

SHEET

Board, runningreplace

....................

.

X

Board, runn

ingrepair ......

................ X

B o x ,

toolrep

lace

....

..............'........

X

B ox, toolre

pair ......

.................... X

Fenderreplace

...........................

X

F

enderrepair

................

............

x

Hoodreplace

.......

...................... x

Hoodrepair

..............................

x

Pan, splashreplace

.........

...............

X

Pan, splashrepair

.

........................ X

M I SC ELLA N EO US

Chain, tirerepair ..

........................ X

Head, speedometerreplace

.................

X

Head, speedometerrebuild

.................

E X

Shaft assembly,

flexible drive, speedometerre

place

..........................

......... x

Shaft assembly,

flexible drive, speedometer

repair x

Weldinghe

avy

........................

... X

Weldinglight

.......................

.....

X

Weldingmedium

....................

...... X

SH A FT.

PROP

ELLER

Shaft assembly,

w/universal jointsreplace..... X

Shaft assembly,

w/u

niversal

jointsrepair......

x

Shaft assembly,

w/universal jointsrebuild.....

E X

SPRINGS

Shackle

and boltre

place X

Springsreplace

...................

........ X

Springsrepair

............................

X

Springsrebuild

....

....................... E X

Casingrepair

......................

.......

X

Casing and tubereplace

X

T

ube, innerreplace

..................

.....

E E

X

16


18/362

INTRODUCTION

TRANSMISSION

ECHELONS

2 n d

3rd

4th 5 th

Lever,

shiftreplace ........................ x

Lever, shiftrepair

.........................

*

Transmission assemblyreplace

..............

Transmission assemblyrepair ...............

Transmission assemblyrebuild

..............

TRUCK,

BOMB SERVICE

Vehicleservice

........................... X

Vehiclerebuild (with

serviceable

unit assemblies)

WH E E L S

Wheelsreplace

........................... X

Wheelsrebuild ...........................

x

E X

X E

E X

*The

second

echelon is authorized to remove and reinstall items marked by an

asterisk. However,

when it

is necessary

to

replace

an

item marked

by an

asterisk

with

a

new or

rebuilt part,

subassembly

or unit assembly, the

assembly

marked

by

an asterisk may be removed from the vehicle by the second echelon only

after

authority has

been obtained from a higher echelon

of

maintenance.

17


19/362

Sec t i on II

T R O U B L E SHOOTING

Paragraph

General

.............................................. 8

Lack of

power.........................................

9

Excessive oil consumpion............................... 10

Popping,

spitting, and

spark

knock........................

11

Rough engine idling.................................... 12

Engine noise .......................................... 13

a.

The

following chart is provided as a guide to possible engine

troubles, their

causes, and

probable remedy.

Prob a b l e Cause Prob a b l e R e m e d y

Incorrect

valve lash.

Adjust valve lash

according

to in

structions under valve

adjust

ment

procedure

(par.

21).

Leaky

valves.

Remove

cylinder

head

and grind

valves (par. 20).

Valve

stems or

lifters sticking. Free

or replace.

Valve springs weak or

broken.

Replace.

Valve timing incorrect. Retime valves.

See

timing gear in

stallation (par. 22).

Leaking cylinder

head gasket. Replace.

Piston

rings

broken.

Replace.

See

piston

ring replace

ment (par.

24).

Poor

fits

between pistons,

rings,

Overhaul engine (par. 35).

and cylinders.

Ignition

not properly timed.

Set ignition

according to

instruc

tions under

engine

tune-up (par.

26).

Octane selector not adjusted for Set

octane

selector (par. 26).

grade of fuel

being

used.

18


20/362

TROUBLE

Prob a b l e

C au s e

Spark

plugs faulty.

Distributor points not set correctly.

Dirt

or water

in carburetor.

Gas

lines partly plugged.

Dirt in gas tank.

Air

leaks

in

gas line.

Fuel pump not functioning

prop

erly.

Air cleaner dirty.

Carburetor

choke partly closed.

Cooling

system troubles.

'Improper

grade and

viscosity of oil

being

used.

Fuel mixture too lean.

Restricted air

cleaner.

Valves not timed

properly.

Defective ignition system.

Transfer case in 4-wheel drive on

hard surface roads.

Exhaust system

partly

restricted.

SHOOTING

Replace or

clean and

test spark

plugs

(par.

26).

Set distributor points and time en

gine

(par.

26).

Clean carburetor (par. 100).

Clean gas lines.

Clean

gas tank.

Tighten and

check

gas

lines.

Replace

or repair

fuel

pump (par.

93).

Clean air cleaner

(par.

26).

Adjust or replace choke mecha

nism.

See

section XVII,

TM

9-795,

for

procedure.

Change to correct oil.

See chapter

4 for

corrections.

Clean air cleaner (par. 26).

Retime.

See

timing

gear replace

ment (par.

22).

See engine

tune-up

(par. 26).

Shift

transfer

case

to

2-wheel

drive.

Clean or replace.

Oil

pan

drain plug

loose.

Oil pan

retainer

bolts loose.

Oil pan gaskets

damaged.

Timing gear cover

loose or

gasket

damaged.

Tighten drain

plug.

Tighten

oil

pan

bolts.

Replace pan gaskets (par. 17).

Tighten timing gear cover or re

place gaskets (par.

23).

19


21/362

Probab

le

Cause

Oil

return

from

timing gear

case

to block

restri

cted, causing leak

at

cran

kshaft

fa

n

pulley

hub.

Push

rod

or

rock

er arm cover gas

k

ets

da

maged or co

vers loose.

Fuel

pump

loose or

gaske

t dam

aged.

Rear

main bearing

leaking

oil

into

clutch housing.

B

roken pi

ston rings.

Rings not correc

tly

seated to cylin

de

r

walls

.

Piston rings

worn

exc

essively or

stuckin

ring

gro ov

es.

Pisto

n

ring

oil

return

holes

clogged

w

ith carbon.

Excessive

clearance bet

ween

pis-

to

n and cyl

inder walls

due to

wearor thei

r being impr

operly

fitted.

Cylind

er

wa

lls scored,

ta

pered,

or

out-

of-round.

Pro

bab le

Rem ed y

Remove

oil

pan and

clean

oil

re

turn passa

ges.

T

ighten push

rod and rocke

r

a

rm

c

overs, or r

eplace gaskets

par.

16).

Ti

ghten, fuel

pump

or

replace gas

ket.

Adjust

or

replace

main

bearing

p

ar. 19).

Replace

rings par. 24).

G

ive sufficient

time

for new

ring

s

to seat.

Rep

lace

if n

ecessary.

Replac

e piston rings

par. 24).

Replace

rings

par. 24).

Fit new

p

istons

pa

r. 35).

Recondi

tion cylin

ders

an

d

fit

new

pistons par. 35)

.

Manifold

heat contr

ol spring

not A

djust

accord

ing t

o

properly inst

alled.

Manifol

d

h

eat co

ntrol val

ve

stick

ing.

Lo

ose

wiring connec

tions.

Faulty

wiring.

instruct

ions

u

nder

en

gine tune-u

p par. 26)

.

Fr

ee heat con

trol

v

alve.

Faulty

spark

p

lugs.

Le

an combustion

mixture.

Tighten all wire con

nections.

Replace

faulty

wiring.

Clean

or

replace spark

p

lugs. S

ee

engine

tune-up par.

26).

Clean

and adjust

carburetor

pa

r.

100).

20


22/362

TROUBLE SHOOTING

Probable

Cause

Dirt in carburetor.

Restricted

gas supply to

carbure

tor.

Leaking carburetor or intake mani

fold gaskets.

Carburetormetering rod hole

cover not in place.

Valves adjusted too

close.

Valves

sticking.

Exhaust valves thin and heads

overheating.

Weak valve springs.

Valves

timed

early.

Excessive

carbon deposits

in

com

bustion

chamber.

Cylinder

head

water

passages

partly

clogged causing hot spot

in combustion

chamber.

Partly restricted exhaust ports in

cylinder head.

Cylinder head gasket blown be

tween cylinders.

Spark plugs glazed.

Wrong heat range plug being used.

Exhaust

manifold or muffler

re

stricted

causing back pressure.

Improper idling adjustment. Adjust according to instructions in

paragraph

2 6.

Carburetor needle valve not

seat- Clean

or replace'

(par.

99).

ing.

2 1

Probable R e m e d y

Clean carburetor (par. 100).

Clean

gas

lines

and

check

for re

strictions.

Tighten carburetor to

manifold,

and manifold to head

bolts,

or

replace

gaskets.

Replace

metering rod

hole

cover

(par.

99).

Adjust valve lash (par.

21).

Lubricate and

free.

Grind

valves

if

necessary.

Replace valves (par. 20).

Replace

valve

springs

(par.

20).

Retime. See timing gear installa

tion (par. 22).

Remove

head and

clean carbon

(par. 20).

Remove cylinder

head and

clean

water passages (par. 20).

Remove cylinder

head

and clean

exhaust ports (par. 20).

Replace cylinder head gasket

(par.

20).

Clean or replace

spark

plugs

(par.

26).

Change to

correct spark plugs.

Clean

or replace manifold and

muf

fler.


23/362

Pro b ab le Cause

Carbur

etor to manifold gasket

leaks.

Manifold to head

gasket leaks.

Air

leaks

in the windshield wiper

vacuum line.

Air leaks

in the

Hydrovac

lines.

c. Valves.

Improper

lash adjustment.

Valves

not

seating properly

.

Cracks in

exhaust

ports.

Head gasket

leaks.

Crankshaft

journals out-of-round.

Crankshaft journals

rough

.

Oil

passages

in

block

restricted.

Bearings im

properly fitted

.

Insufficient oil.

Improper grade and v

iscosity

of

oil

being used.

Oi

l

p

ump

fail

ure.

Contaminated oil.

Probab le Remedy

Tighten

carburetor to

man

ifold

bolts

or

replace

gasket.

Tighten

m

anifold

to

head bolts

or

replace gasket.

Check

for leak

s and

repair.

Check

Hydrovac

lines and correct

leaks.

Check

and adju

st valves

a

ccord

ing

to inst

ruction

in

paragraph

26.

Grind valves (par.

20).

Replace cylinder head

(par.

20).

Replace cylinder head gasket

(par.

20).

Replace

cran

kshaft.

Poli

sh or repla

ce crankshaft; ad

just

bearings.

Clean passages.

See oil line

cle

an

ing.

Readjust m

ain

bearings

(par.

19).

Adjust

or replace

b

earings

(par.

19). Re

plenish oil.

Adjust bearings. Change to

correct

oil.

Replace or rebuild

oil

p

ump. Re

place

or adjust ma

in

bearings

(pars. 1

8 and 19)

.

Wash motor thoroughly.

Adjust or

replace bearings,

and other

dam

age

d parts.

22


24/362

TM9-17

65B

1 3

Probable Cause

Improperly adjusted

bearings.

Cra

nkshaft journals rough.

Insufficient

oil.

Oil

pump

failure.

Connecting

rod

dipper broken or

damaged.

Oil,troughs or lines no

t

a

djusted

prope

rly or

restricted.

Improper grade an

d

viscosity

of oil

u

sed.

Excess

ive

cylinder

wear.

Improperly

fitted pistons or pins.

Contaminate

d oil.

Faulty fuel

or

ignition system caus

ing

unburned fuel to flush

the

oil from

cylinde

r

walls.

Pisto

n

pin or

bushing wear.

Be

nt connecting

rod.

Excessive

end play in

c

amshaft.

Excessive

crankshaft

end play.

Adjust bearings (par. 19).

Polish or replace shaft.

Adjust

or

replace

r

ods.

Adjust orreplace rods.

Replenish

oil.

Replace or ove

rhaul oil

pump

.

Re

place or adjust

rod bearings

(pars. 18 and 19).

Adjust or

replace rod

and

dipper

(par.

18).

Clean,

adjust,

or

replace oil tro

ughs

and

lines.

Adjust

or

replace rod

be

aringsand

use correct oil (par.

19).

Hone cylinder

s and fit

new

pistons

and rings.

Make sure all

a

bra

sives

that would cause

cylinder

wear

are removed

(par. 35).

Replace pistons or

pins (pars. 35

and 36).

Make ne

cessary replacements,

flush

oiling system,

and

use

new

oil.

Make

necessa

ry repairs to fuel or

ignition syste

m,

and

replace

worn parts.

Ream

bushings and install over

size

piston

pins

(par. 36).

Replace rod (par. 24).

Replace camshaft

thrust

plate, or

cor

rect

end play

by

pre

ssing

gear on further (par.

42).

Replace main

b

earings

(par.

38).


25/362

P r o b

able Cause P r

obable

R e m e dy

B

roken piston ring.

Replace broken

ring

and

check

condition of cylinder wall par.

24).

Loose tim

ing

gears.

Replace

timing

gears

(par. 42).

Dry push

rod

s

ockets.

Polish

and

lubricate push rod

so ckets.

B

ent oil

gag

e

rod.

Replace oil

gage rod.

Improperly

adjusted

valve lash.

Adjust valve lash (par. 21).

Sticking valves.

Free

or grind

valves

(par.

20).


26/362

S e c t i o n

III

OPERATIONS PERFORMED WITHOUT REMOVING

ENGINE

FROM VEHICLE

Paragraph

General .............................................. 14

Manifold gaskets,

replacement.

.......................... 15

Push rod cover gaskets, replacement. ..................... 16

Oil

pan

gaskets,

replacement.

............................

17

Oil

pump,

replacement

and

overhaul.......................

18

Main and connecting rod

bearings,

adjustment.............. 19

Cylinder

head

assembly

conditioning

(valve

grinding)

........

20

Valve adjustment ......................................

21

Valve timing .........................................

22

Timing gear cover gasket, replacement. .................... 23

Piston

rings,

replacement. ............................... 24

Engine mountings,

replacement. ..........................

2 5

Engine tune-up

........................................

26

a. There are

only

a few major service operations that cannot be per

formed individually without removing the engine

from

the chassis;

however, it is advisable to remove the engine for

an overhaul as

it is

much easier to clean

and

service when removed. There are numerous

individual operations in

servicing

an

engine,

many

of which

require

identical disassembly operations.

b.

In

the

service

operations

covered in

this

section,

complete instruc

tions

for removing and replacing

the

manifold assembly, cylinder head,

oil

pan,

push rod cover, and timing

gear

cover are

given.

c. Follow the

disassembly procedure

given in

this section

and the

cleaning

and

repair

instructions given

in sections

V and VI for other

service operations which might

occasionally

be required without engine

removal.

The

manifold

gaskets

may

be

replaced as

a separate

operation without removing

the carburetor

and manifold completely.

(1)

REMOVE, AIR

CLEANER.

Loosen

the

air cleaner clamp screw and

remove the

air cleaner.

25


27/362

A

C

Y

L

I

N

D

E

R

H

E

A

D

B

R

O

C

K

E

R

A

R

M

C

O

V

E

R

C

M

A

N

ff

O

L

D

G

A

S

K

E

T

D

E

X

H

A

U

S

T

M

A

N

IF

O

L

D

E

I

N

T

A

K

E

M

A

N

IF

O

L

D

ig

u

r

e

4

M

a

n

i

fo

l

d

G

a

s

k

e

t

n

s

t

a

ll

at

io

n

6

R

A

P

D

3

8

4


28/362

O P E R A T I O N S

P E R F O R M E

D

WITHOU

T REMOVING

EN G

INE

F R O M VEHIC L E

(2) DISCONN

ECT GAS LINE. Disconnect the

gas

feed

line at the car

buretor

end.

(3) DISCONNEC

T THRO

TTLE

ROD. Di

sconnect the

thro

ttle rod

at the

lower end.

(4) LOOSEN MANIFOLD.

Remove the 2

nuts

and 6 cap s

crews

which

atta

ch

th

e manifold to the cylinder head.

(5)

R EM O

V E

GASKETS.

Pull the manifold

away

from the

cylinder head

and remove theold gasket.

(6) INSTALL

G ASKET (fig. 4). Cl

ean the gasket

f

langes on

the m

ani

fold

and

cylinder head, install the

new

gaskets,

and

slide

the

manifold

in

place over the studs, ma

king

sure

the gaskets a

re

in p

lace.

(7)

T IG HT EN

M ANIFOLD.

Install the 6 cap

scre

w s with

lock

pla

tes

or

washers

and the

2 nuts

and

tighten them

securely.

(8) C

O N N E CT

T HROT T LE

ROD.

Connect the lower

end

of thr

ottle

rod

a

nd install key.

(9) CO N NECT GAS

LINE. Attac

h

the gas feed l

ine to

the

carburetor

and tighten

secu

rely.

(10)

INSTALL

AIR CLE

ANER. Install air clean

er

on ca

rburetor

and

tighten clamp

screw.

(1) R E

M O V E PACKING. Remove the

2

nuts

that retain

the

exhaust

pipe to the

man

ifold.

Push

e

xhaust pipe

down to

clear the ma

nifold

and lift

out

the old packing.

(2) INSTALL

PACKING. Place

new

packing

between

the

manifold and

exhaust pipe

and

place

flange

in

position overstuds.

Install the 2 nuts

and tighten

them

alte

rnately until theflange is

secure.

(1)

Remove

the

rocker

arm

cover retai

ning nuts and remove the

cover andgasket

s.

(2) R E M O VE

COIL.

Remove

the

2

screws

which attach the

coil to

the

cylinder head and pull

the

high

tension

wire

out

of

the

coil.

Lay

the coil on the cowl

out

of the way.

(3)

DISCO N N ECT GAS

LINE. Disconnect the

gas

lin

e at

the

carburetor

e

nd

and remove the

clamp

screw

at the

front

of the

push rod cover.

(4)

R EM O V E

SPARK PLUGS

. Remove the

wirejs

from th

e spark plugs

and

remove

the

6 sparkpl

ugs.

27


29/362

(5) REMOVE PUSH

ROD

COV

ER. Remove the remaining 9

push

rod

cover retaining screws, and

remove the push

rod

cov

er

and

gasket.

(6) CLEAN GASK

E T SEATS.

Clean

the gaske

t

seat

on

the

push

rod

cover, cylinder head, and block.

Check

the

push rod cover se

als at

the

spark

plug

holes and

if necessary, replace.

(1) INSTALL COVER A N D

GASKET.

Place

the gasket

on

the

push rod

cover

and carefully

work it down in p

lace.

NOTE: Make

sure

th

e

gas

ket is in place

all

the

way

around

and that all 6 seals

at

the spark

plug

holes

are

in

place before installing the retaining

screws.

(2)

IN STALL RETAININ

G SCREWS. Line

u

p

the bol

t holes in the

gas

ket with the

cover

and

block. Install

th

e 9 retaining

screws loosely.

Place

the coil inposition and replace the

2 screws through the

coil

bracke

t

and

push rod

cover.

Install the

screwat

t

he front which

retains

the

gas line clip as wellas

t

he push

rod

cover.

Tighten the 12 screws

securely.

(3)

INSTALL

SPA

R K PLUGS. Setthe spark

plug gaps at

0.040.

Place

new

gaskets on

the

6 plugs

and

install them in the

cylinder

head

finger-

tight,

then

give from

V a

to % turns

with

the

wrench.

NOTE:

Care

mus

t

be used when

installing these 10

-millimeter plugs as it

is

very

easy

to

strip the threads in the head

or

distort

the

plug

which upse

ts

the point

setting.

(4) CONNECT

GAS

L I

NE . Connect

the

gas line to the carburetor

conn

ection.

Replace spark

plug

wires.

(5) Connect the

wires

to the coil

and

sp

ark plugs.

(6)

INSTALL ROCKE R ARM COVER. Install

a

new

gasket

and

carefully

seat

the rocker

arm

cover

on the

gasket. Install

the

2 retaining nuts

and tighten

them

securely.

(1) Place the drain pan under the

engine and r

emove the

drain

plug. Allow pan to

drain

c

ompletely

and

replace dr

ain plug.

(2) REMOVE OIL

GAGE ROD

TUBE.

Remove the oil gage

rod, loosen

the tube cla

mp on right side of pan,

loosen

the

clampat

th

e right side

of the cylinder block and

remove

the

tube.

(3

)

R

EMOVE OIL

PAN.

Remove the 18 stove

bolts

and

the 4 cap

screws that attach the oil

pan. Bump the oil pan to break it lo o

se f

rom

the gaskets and lower the pan,

being careful

not

to damage the oil

screen or oil

tro

ughs in the

pan.

2

8


30/362

OPERATIONS

PERFORMED WITHOUT

REMOVING ENGINE

FROM VE HICLE

(4) CLEANING. Clean the

gasket

flange on the

oil

pan and

block

and

the

grooves

for

the 2 end

corks.

Wash the

oil

pan and

blow

out

the

oil

lines.

(5) INSTALL GASKETS. Place

a

light

coating

of grease on

gasket

and

place

gasket on engine flange, leaving the oil pan free to install without

hindrance

to gasket. Grease

the

end corks and place them in

the grooves

in the bearing caps.

(6)

INSTALL PAN.

Place the

oil pan

in

position

against

the

engine

flange and make sure the gaskets

are

in place. Start all the cap screws

and

bolts.

NOTE:

It

may

be

necessary

to

use a

taper

punch

to line

up

the gasket holes

with

the bolt

holes

in

the

pan.

Tighten

all bolts

securely.

(7) INSTALL OIL GAGE ROD

A N D

TUBE. Install lower end of the

oil

gage rod tube in

the

bracket on right side of

oil

pan

and the

upper

end

of tube in bracket at bottom of cylinder block. Tighten the clamp

screws securely. Install the oil

gage rod.

(8) R E F I L L O I L PAN. Make sure

the

oil pan drain plug

is

tight

and

refill

the

oil

pan

with

the

correct

grade

and

quantity

of

new

oil

accord

ing to instructions in the lubrication

section.

(1) REMOVE OIL

PAN.

Follow procedure

given

in

paragraph

17 a

(1)

to

(3) inclusive.

(2) DISCONNECT T H E OIL LINES. Disconnect the oil suction and

feed lines from the

oil

pump.

(3) REMOVE PUMP. Loosen the oil

pump retaining bolt lock nut

and

remove

the lock bolt.

Turn the

oil pump

slightly and

pull it out

of

the

bracket.

(4)

DISASSEMBLE PUMP (fig.

5). Remove the 4 pump cover screws,

remove the cover gasket,

idler gear

and shaft with drive gear.

(5)

CLEAN A N D INSPECT PARTS*

Wash all pump parts in

cleaning

solvent

and

inspect

them

for

excessive

wear

or damage.

(6) REASSEMBLY

OF

PUMP. Replace any

parts

that

are

questionable.

Install

the drive shaft

and

gear,

the idler gear,

a

new

gasket, and the

cover.

Install

the 4 screws

and

tighten them securely. NOTE: When

assembling the pump make sure that the ground

(smooth)

side

of

the

idler gear

is

toward the cover. Always use a new

genuine

Chevrolet

gasket as

the thickness

of

this, gasket controls the clearance in the pump.


31/362

PUM P

B O D Y

COV E R

G A S K E T

IDL

E G EA R

COVER

(7)

INSTALL P U M

P . Work

the

pump up into

the

bracket. Start

the

lo

ck bolt and move

the

pump sligh

tly until it is certain that

the

lo

ck

bolt enters

the

hole in

the

p

ump. Tighten t

he

clamp

bolt securely

and

tight

en the

lock nut.

(8)

C O N N E C T

O I L LINES. Conne

ct the oil pump suction and feed

lines

and tighten

secu

rely.

(9)

REP L A CE

O I L

P AN

. Follow the procedure

given

in

paragraph

17

a

(4)

to

(8)

inclusive.

(1)

Follo

w

proc

edure given in

paragraph

1

7 a (1) to (3) inclusiv

e.

(2)

R E M O V E

S P A R K P LU GS. Disconnect

the spark plug wires an

d

re

move

the

6

spark pl

ugs.

30


32/362

OPE

RAT

IONS

PER

FOR

MED

WITH

OU

T R

EM O

VING

E

NGIN

E

FROM

VE

HICL

E

R EA

R A

X LE

FIL L

ER PLU

G

R A D I

A TOR

R E

A R A

X L E

D R

AIN

PL

U G

T RA N

SFER

SE R

VICE

PLA

TE S

C A SE

FO

R TR A

NSM

ISSIO

NS

R A

P D 5 6

7

3)

L O O

S E N

B E A R

IN G C A

P S

Rele

ase th

e lo

ck plate

tabs

at al

l 4

b

earin

gs an

d loos

en the

bolts

one

turn

.

4)

C

H E C K

C R

A N K S

H A F T

M O

V E M E

N T

Tu

rn the

crank

shaf

t

a

fe

w

tu

rns

to det

ermin

e th

e am

ount

of

drag

with

all b

earin

gs loo

se.

5)

A

DJUS

T

REA R

M

A IN.

Rem

oveth

e

4 cap

scr

ews

w

hichreta

in

the

rear

m

ain

b

earin

g

c

ap

and r

emov

e the

cap

an

d shim

s. Re

mov

e

one

0

.002

-inch

sh

im

fro

m the

s

ide

wh

ich

has th

e

mos

t

shim

s. In

stall

the

o

ther

shim

s, cap

, loc

ks,

and

bolts

. Ti

ghten

bo

lts sec

urely

and

chec

k

the

b

earin

g

fi t

by

t

urnin

g the

crank

shaf

t and

not

inga

ny

pron

ounc

ed

dra

g. If

no

drag

wa

s

f

elt, r

emov

e the

ca

p and

tak

e

a

shi

m

fr

om the

opp

osite s

ide of

b

earin

g.

Inst

all

cap

a

nd

tigh

ten

secur

ely.

Cont

inue th

is

un

til

a sli

ght

d

rag is

f

elt. I

nstal

l

t

he l

ast

0.00

2-inc

h shim

whic

h wa

s

r

emov

ed, an

din

stall

c

ap.

Tig

hten

se

curely

andc

heck

t

o

se

e

tha

t

the

d

rag

is go

ne.


33/362

(6

)

ADJUST RE MAIN IN G

B E

A R INGS.

Adjust all

remaining main bear

ings

according

to the

proc

edure

given

for therear m

ain bearing

. Work

fro

m the rear bear

ing t

o

the rear

int

ermediate,

the

front in

termediate,

and

then the front

bearing.

(7)

T

IGHTEN

BEARIN G

CAPS. Ti

ghten all bearing

caps securely

an

d

check

to

see

that the crank

shaft

turns

w

ithout a noticeable

increase

i

n

drag.

(8)

LO C K

ALL

M

AIN B EARING CAPS.

Be

nd

the lo

ck plates up

against

theflat of

the cap screw on

all ma

in

bearing b

olts.

(1) R E M O V E

R O D

B O L T

NUTS .

Remove the 2 pal

nuts, bolt

nuts,

and oil

dipper.

(2)

ADJU ST BEARING (fig

.

6

). Remov

e the b

earing cap and remove

a shim

from

the side that

has the greater num

ber, or if the same nu

mber

of shim

s is on each

side, remove a

shim

fr

om

t

he

side opposite the

camshaft. Install

bea

ring

cap,

dipper, and nuts,

and tighten sec

urely

Try

snapping

the

rod back

and

fo

rth on the jou

rnal.

If the

rod can

be

snapped back and

forth,

remove

the

cap

and

a

shim from

the

opposite

s

ide

and

insta

ll

the cap.

Re

check

by

snapping the

rod back and forth.

When

the

rod cannot

be snapped

back

and

forth on the c

rank pin

by

hand

but can be

tapped back and

forth with a

light

b

low of

an

8-oun

ce

ham

mer, remove

the capand

replace

t

he last

sh

im

whi

ch was

removed.

NOTE

: During all adjusting

op

erations

a

s

well

as final

assemb

ly

it is

important

that

the

rod cap

be installed correctly

.

Th

e number on the

face of

rod

bars

of both

rod and cap w

ill

be

on the

camshaft side. The

dipper must

be

installed

with

the

open

side

toward the

camshaft.

(3)

C HE C K CONNECTI

NG RO D

B

EARING

SID E CLEARANCE

(fig

.

7).

Check

connect

ing

rod

si

de clearance

between

the

upper

half

o

f

the

conn

ecting

rod (not

the

rod

cap)

and the sid

e

of

crank pin. This

should

be

be

tween

0.004 i

nch and

0.011

in

ch.

(4) TIGHTE

NING R

O D (fig.

7).

Install cap,

dipper,and n

uts.

Tigh

ten

nuts

s

ecurely and

recheck rod

fit.

Install new pal

nuts with the

open

side of the nut to

ward the

end

of the

bolt. Tighten

the pal nuts

finger-tight

and

V i z

turn

more.

(5)

A D J U S T R E M A

IN IN G

RO

DS. Repeat

above

instructions on

remain

ing

rod

s

until all

rod

b

earings

have been properly

adjusted.

(6)

INSPE

CTION. Make

sure that all rod and

main

b

earings h

ave been

pro

perly adju

sted,

that the

main

bear

ing bolts are

properly

loc

ked, t

hat

the r

od oil

dippers a

re properly ins

talled, and

that

all

pal

nuts are

tight.

32


34/362


35/362

R A PD 32407

(3 ) DISCONNECT

T HROT T LE

ROD.

Remove

the cotter key and dis

connect

the

lower

end o f the throttle rod.

(4) D I S CO N N ECT THE

GAS LINE. Disconnect

the

gas feed line

at the

carburetor

e

nd.

(5) DISCONNECT MANIFOLD.

Remove

the

2 nuts and 6 cap

screws

which

attach manifold

to cylinder head.

Pu

ll the manifold

away from

the

engine

until

it clears

the manifold

studs

and block under

the mani

fold

to support its weight.

(6)

R

E M O V E

R O C K E R

A R M COVER. Remove

the 2 nuts

a

nd washers

that retain

the

r

ocker arm

cover

and

re

move

the

cover and gasket.

(7) R E M O V E SPA R K PLUG S. Disconnect

the spark

p

lug wires

and

remove

the

6

spark

plugs.

(8) R E M O V E P USH R O D C

OVER. Remove the

h

igh-tension

wire from

bottom of coil, remo

ve the 2

scre

ws that attach

the coil

and

lay the

coil back

out of th

e

way. Remove

the

remaining

push rod cover screws,

push rod co

ver, and

gasket.

(9) R E M O V E THERMO S TA T HOUSING. D

isconnect radiator hose an

d

remove

the 2 bolts that retain

the

the

rmostat

housing

and remove

the

housin

g.

(10)

R E M O V E ST EAM

RELIEF

T U B E .

Disconnect the relief

tube

from

the

temperature

indicator

fitting and

the hose.

(

11) R E M O V E T EM P E R

AT URE INDICATOR

FIT T ING .

Dis

connect the

tem

perature

indicator

from

the

fitting

and remove the fitting.

(12) D I S CO N N ECT RO C

K E R A R M OIL

LI NE. Disconnect the oil line

at the rocker arm connector.

34


36/362

O P E R A T I

ONS

PERFORMED

WITHOUT R EMOVING ENGINE

FR O M VEHICLE

R A PD 32 411

(13) R E

M O V E R O C K E R

AR M

ASS

EMBLIES. Remove th

e 4

bolts and

2 nuts that retain

the rocker arm

shafts

and

supports to the cylinder

head and r

emove the assemblies. Remov

e valve spring covers .

(14

) R E M O V E PUSH RODS.

Remove the

12 va

lve push rods.

(15

) R E M O V E CYLINDER H

EAD. Remove

the

15

cylinder

head bolts,

cylinder head, and gasket.

(figs. 8 and 9). Using

a

cyl

inder head holding fix

ture KM-J982A

clamp the

valve

rest

on

to

the

bottom of the cylinder

head and place th

e

head on

the holding fixture

KM-J982A

and u

se

the

spring compressor to

hold the springs

while

remo

ving

the

valve-

lo

cks. Remove th

e

locks, v

alve caps, springs, seats,

and

valves.

(1)

Clean the cylinder head externally.

(2)

Clean

a

ny

foreig

n

material

from the water

passages in the cylin

der head.

(3) Clean

the

carbon

from

the valve stems,

valve heads, valve

guides, valve ports, combustion

chambers, and piston he

ads.

35


37/362

V

A LV

E

GU

ID E RE

M O

VE R

K

M J

267

4

) I

ns

pec

t

th

e

cy

lind

er

h

ead

f

or

c

ra

cks

i

n

the

e

xh

au

st p

ort

s o

r

c

om

bu

sti

on

c

ha

mbers.

5

) I

ns

pec

t

the

va

lve

sf

or

c

he

ck

ed or

e

xc

ess

ive

ly

w

arp

ed

he

ad

s.

6

) C

he

ck

the

f

it of

th

e

v

alv

e

ste

ms

in

the

v

alv

e g

uid

es

. Th

e

int

ak

e

v

alv

e s

tem

cle

ara

nc

e in

th

e

gu

ide

s

sh

ou

ld b

e

b

etw

ee

n 0.0

01

in

ch a

nd-

0.0

03

i

nch

,

wh

ile

th

e

exh

au

st

va

lve

to

g

uid

e c

le

ara

nce

sho

uld

be

0

.00

2

in

ch

t

o 0.0

04

in c

h.

If

th

ere

i

s

e

xc

ess

ive

cl

ea

ran

ce

it

w

ill be

ne

ces

sar

y

to

rep

lac

e

ei

the

r t

he

va

lve

so

r

gu

ide

s o

r b

oth

to

g

et

c

or

rec

t c

lea

ran

ce

.

Ex

ce

ssi

ve

cl

ea

ran

ce

w

ill

p

ro

du

ce l

ac

k of

po

w e

r,

rou

gh

id

lin

g,

and

noi

sy

valves.

1

)

R E

M O

V

E

G

U ID

E S

. Pla

ce

th

e

cyl

ind

er

hea

d

on

an

ar

bo

r

p

res

san

d

p

res

s th

e1

2

g

ui

des

f

ro

m

the

c

yli

nd

er

he

ad

us

ing

va

lv

e g

ui

de

r

em

ov

er

K

M-

J26

7.

2)

IN

S T

A L

L

N E

W

G

U

ID E

S . Th

e

gu

ide

s d

o

no

t

h

ave

a

sh

ou

lde

r

to

de

ter

mi

ne

t

he

dis

tan

ce

t

he

y

wo

ul

dbe

p

res

se

d int

o

th

e

cy

lin

der

he

ad;

3

6


38/362

O P E R A T I O N S

P E R F

O R M E D

WITHOUT

REMOVING ENGINE

F R O M VEHI CL E

R A

PD

32413

Figure

1 1

Valve

uide ight

therefore,

it is impo

rtant that the

special

replacers

KM-J1089 for

intake

and

KM-J1090 for

exh

aust be used, as they

have a shoulder to

position

the guides.

Press the

guides into

t

he c

ylinder

head a

nd

roug

h ream them

wi

th

a

0.341-inch

reamer and finish ream with

a

0.343-inc

h reamer.

f. Reseat

Valve

Seats in Cylinder Head.

Use

valve

seat grinder KM-

KMO1

67C.

(1)

Reconditioning

valve seat

s on

modern

high

compression engines

is

becoming mo

re

and

more important, because

the

seating of valves

must be perfect

in

or

der for the

engine to deliver

the

power and per

formancethat

has

been built

into it .

(2) Anoth

er important fact

or

is the c

ooling of the valv

e heads.

Good

contact between

the

valve

and

its

seat

is

necessary

if

the heat

in

thevalve h

ead

is

to be properly dissipated.

(3)

Various

types

of valve seat

grinders and valve reseating

equip

ment

are on the market.

When using them the

instructions o f

the

ma

nufacturer sho

uld be followed.

(4')

A

grinder

of

th

e eccentric type

for

the

reconditioning o f valve

seats

is

described in

the

following paragraphs.

37


39/362

RA

PD 32414

(5)

Before

attempting to

grind

any

valve

seat,

clean carbon

thor

oughly

from the valve port; wipe seat

with

SOLVENT, dry-cleaning,

removing any

grease or foreign

matter. Great

care should be

taken to

clean

the

inside

of the

guide with a

wire brush and

make sure

it is

free from carbon

and

dirt. These precautions permit

proper

centering

of the

pilot

in the guide.

(6) INSTALL EXPANDING PILO T

(fig.

12). Install the expanding pilot

in the

guide using the special wrench; expand the pilot with

the knurled

knob

on

the top

of

the

wrench,

and

remove

the

wrench.

(7) DRESSING

T H E

GRINDING W H E E L (fig. 13).

The

grinding

wheel

should

be dressed

before

commencing any valve regrind job. Set the

grinder over

the

2

top pilots

of

the

dresser

stand. When the grinder is

seated on these

pilots, the

wheel

will

pass

over

the

stud projecting

through

A

and the grinder will

be

in

position

to dress the wheel. Set

the diamond dressing tool

at

the 30-degree

angle.

Turn on the switch

38


40/362

OPE

RA

TIO

NS PE

RFO

RM

ED

WI

THO

UT

REM

OV

ING

ENG

INE

FR

OM

VE

HIC

LE

R

A PD

324 5

an

d dre

ss

the

grin

ding

wh

eel. N

OT

E: N

eve

r l

et t

he g

rind

ing

w

hee

l

be

com

e g

laze

dor

lo

ade

d

a

s

it

wil

lnotgri

nd fr

eely

or

do

acc

urat

ew

or

8)

S

ETT

IN G

THE

G

R IN

DER

fig.

1

4).

Plac

e the

grin

der

ov

er th

e

ex

p

andi

ngp

ilot

; t

hen

lo

ose

n th

e so

cke

t-hea

d s

et s

crew

an

d pu

sh

dow

n

th

e

adju

stin

g ro

d ag

ains

t the

top

of

the

pilo

t.

The

n lock

th

e set

scre

w

tightly.

Turn

the

feed

screw

to

the

right

until

the

grinding wheel

just

c

lears

the

sea

t.

Ba

lanc

e th

e

g

rind

er

wi

tht

hecom

pen

sati

ng h

and

le.

9)

GR

IN D

IN G TH

E

SE

AT

fig

. 1

5).

Star

t th

e m

otor

and

fee

d

the

g

rind

ing

whe

elint

o

the

se

at

by

tu

rnin

g th

e fe

ed scre

w

to

the

lef

t, on

e

no

tcha

t a tim

e,

unt

il

the wh

eel

is grin

ding

al

l

arou

nd th

eface

of

the

valv

e se

at. Be

fore

sh

uttin

g

off

the

grin

der,

s

top

fe

edin

gt

hew

hee

l in

to

the

se

at a

ndgi

ve

it

tim

e togr

ind

itse

lf f

ree.

Tu

rn

off

the swi

tch

an

d

allo

w th

e g

rind

er

to co

me

to

a

st

op

be

fore

l

iftin

g i

t f

rom

the

pilo

t.

39


41/362

ADJUSTING

ROD SOCKET HEAD SET SCREW

(10)

CHECKING T H E

SEAT

(fig. 16).

Mount the

valve

seat

dial indi

cator

on

the

stationary

pilot;

set

the

indicator

at

ZERO

and

turn

the sleeve of the

indicator with thumb

and

finger.

When the

seat

is

properly ground

the

indicator reading will be within 0.001 inch.

(11)

NARROWING

T H E

SEAT

(fig.

17). Using valve seat

cutter

KM-

KMO105-7,

the

valve seat may now be narrowed down to the proper

width by

machining

both the port and

top

of the valve seat. A 70-degree

grinding

wheel may

be

used in the port, but a form cutter KM-

KMO105-7 must be used

to thin down the

valve

seat

from

the top, and

40


42/362

OPE

RATION

S PERFO

RMEDWIT

HOUT R M

OVING

E

NGINE

FRO

M VEHIC

L E

RA

PD 32 4 7

F igu re

75 G

r ind in g

alve e t

at

the

same

time machine the

edge

of

the

valve

recess,

thereby

pre

venting

restrict

ion of free flow

o

f the incom

ing gas

es. NOTE:

Go

od

jud

gment

must

be

us

ed w

hen nar

rowing a

valve seat t

o m

ake sure the

sea

t conta

cts

t

he

center ofthe

v

alve f

TM 9-1765B BOMB SERVICE TRUCK M6 CHEVROLET

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Transcript of TM 9-1765B BOMB SERVICE TRUCK M6 CHEVROLET