Desmontaje y Montaje D 379398 y 399

SERVICE MANUAL
DISASSEM BLY AN D ASSEM BLY
D379, D39EI A, DSs|s|

INIDIJSTFIIAL AND
MAFIII\IE EI\IGINES
SEBIAL NUMBERS
D379: 688254O-UP AND 6981227-UP

D398: 6683561-UP AND 6781391-UP
D399: 358688-UP AND 918387-UP
D379, D398, D399 INDUSTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBLY
ALPHABETICAL INDEX
Gears
Housing
AftercoolerCores
Aftercooler Housing
Air Cleaner Housings
Arstarter
Air Starter, Disassemble & Assemble
Accessory Drive
Accessory Drive
Camshaft
Camshaft Bearings
Connecting Rod Bearings
Crankshaft
ExhaustManifolds(lndustrial Engines)
Exhaust Manifolds (Marine Engines)
Expansion
.......25-28
.....23,24
....,|,|3
......1'11 ,112
.. . ... . .. 108
...115
61
. 116-1 18
62
.127-129
.....98,99
67
68
24
69
't2
25
64
48
..103,104
51
......'114
. . 35,36
60
...72-74
37
38
o
...
35
,22
31 -1
...21
....45,46
. . . . ,121,122
.....
..
Tank
.75,76
.. . ...
Flywheel
Flywheel Housng
FreshWaterPump .
FreshWaterPump, Disassemble&Assemble
Fuel FilterHousing
Fuel njection Lines
Fuel Inlection Pumps
Fuel nlection Pump Housing, Disassemble & Assemble
13
.119,120
.123,124
....37
....38-40
14
13
59
58
55
19
63
65
20
21
....'14
..........
7'l
.........
70
36
. .79-87
.&^
......77,78
.. . ..... . 90
..........
10
..... 11
.......50
........ 51
.-.,.,.,,..7
.....8,9
39
42
136,137
52
70
30
Fuel Injection Pump Housing, Safety Shutoff, Governor,
andGovernorDriveAsaUnit.
Injection Valves .
Priming Pump .
Priming Pump, Disassemble & Assemble
RatioControl withOverrde
RatioControlwithOverride,Disassemble&Assemble
TransferPump.
Transfer Pump, Disassemble&Assemble
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Generator
Governor
Governor, Disassemble &Assemble

Governor Drive Housing, Disassemble &Assemble
f
No.
.. 130
....43,44
Cylinder Heads
Cylinder Liners .
EfectricStartingMotors
Cooler
Oper.
No.
..
Crankshaft Front Seal Ring and Thrower

Crankshaft Main Bearings
Crankshaft Rear Seal Ring and Thrower
Engine Oil
Page
ntake Manfolds
.....
.....
....53-61
47
97
...... 15
..........
48
. -.......
29
.... 29
.. ..30
... 31-34
.
Pistons,Disassemble&Assemble
Piston Cooling Tubes .
PrecombustionChambers
PrefubricationOil Pump
Prelubrication Oil Pump,Disassemble&Assemble
Pistons
RearTimingGears..
.
Disassemble&Assemble
RockerShaftsandPushRods
RockerShafts,
........
Oil Filter Housing

Oil Pan Base
Assemble
4
28
29
31
41
......138,139
Oil Pressure Regulatng Valve ..

Oil Pressure Regulating Valve, Disassemble &
Oil Pumo
Oil Pump,Disassemble&Assemble
2E
......88,89
Gear
Marine
71
I
27
15
to
17
18
.. 100.101
.......1O2
.........
47
......9'l
.......41
........ 42
49
50
26
43
22
23
......125,126
.........92
.......93,94
66
44
45
AITD MARINE ENGINES
DISASSEMBLY AND
ALPHABETICAL INDEX
Page
No.
32
33
Safety Shutoff, Disassemble & Assemble
Sea Water Purnp

Sea Water Pump, Disassemble
Sump Pump
& Assemble
Turbochargers
Turbochariern"rtsr'Lli
rurbocharier r-uu'""ii "j;; ::::::.::::.::::

Turbocharier-uorcaiionVatve,Disassemoleanssemlie
Oper.
No.
10
107
54
.'"" 110
".... 10e
.:::::::::::::::l:::.:133
56
52
53
95,96
46
20
11
't2
57
Valve Covers
ValreLifters ...
Vibration Damper
Water Temperature Regulators
34
..
DISASSEMBLY AN D ASSEMBLY
SERVICE INDEX
OPERATION
NO.
COMPONENT OPERATIONS
Fuel Transfer Pump
Fuel Transfer Pump, Disassemble &
PAGE
NO.
7
Assemble
Fuel Priming Pump
Fuel Priming Pump, Disassemble &
Water Temperature Regulators
Exoansion Tank
Fuel Filter Housing
Oil Filter Housing
6,7
Sea Water Pumo
8,9
10
Assemble
11
't2
13
14
15
16
& Assemble
17-19
10
Sea Water Pump, Disassemble
11
Vibration Damper (D398 & D399 Enginesl
12
Crankshaft Front Seal Ring and Thrower
11
21 ,22
13
Accessory Drive Housing
1'l
23,24
14
Accessory Drive Gears
11,12,13
25-28
15
Oil Pressure Regulating Valve
16
Oil Pressure Regulating Valve, Disassemble &
17
Oil Pump
Assemble
OTHER NEEDED OPERATIONS
18
Oil Pump, Disassemble & Assemble
19
Engine Oil Cooler
20
Fresh Water PumD
21
Fresh Water Pump, Disassemble & Assemble
22
Prelubrication Oil Pump (D399 Engine)
23
Prelubrication Oil Pump (D399 Enginel,

Disassemble & Assemble
20
29
15
29
30
17
31-34
35,36
37
20
3840
41
22
42
Connecting Rod Bearings
15,17,',19,20
43,44
25
Crankshaft Main Bearings
15,17,19,20
45,46
26
Piston Cooling Tubes
15,17,19,20
47
27
Oil Pan Base
48
2A
Fuel Ratio Control with Override
50
29
Fuel Ratio Control with Override,
30
Governor
31
Governor, Disassemble & Assemble
32
Safety Shutoff
33
Safety Shutoff. Diassemble & Assemble
Valve Covers
69
35
Fuel Injection Pumps
70
36
Fuel Injection Lines
71
37
Exhaust Manifolds (lndstrial Enginesl
34,36
72-74
38
Exhaust Manifolds (Marine Enginesl
34,36,55
75,76
39
Fuel Injection Pump Housing, Safety

Shutoff, Governor, and Governor Drive,
Ac a I lnit
24
Disassemble & Assemble
2A
51
52
30
53-61
32
63-68
62
77.78
trDt,
E, re
irousrRrAl
AND MARTNE ENGTNEs
DISASSEMBLY AI\ ID
SERVICE IND EX
OPERATION
NO.
COMPONENT OPERATIONS
40
Fuel Injection Pump Housing, Disassemble
41
Governor Drive Housing, Disassemble &
& Assemble
Assemble
42
Fuel Injection Valves
43
Precombustion Chambers
NO.
30.32,34,36,37,38,39
79-87
30,32,34,36,37.38,39
88.89
90
41
91
44
Rocker Shafts and Push Rods
34
45
Flocker Shafts, Disassemble & Assemble
34,43
46
PAGE
OTHER NEEDED OPERATIONS
Valve Lifters
92
93,94
15,17,19,20,26,30.32
34,36,37,38,39
47
Intake Manifolds
48
Cylinder Heads
49
l'tstons
95,96
97
u,36,43,46
1
5,1 7,1
98,99
9,20,34,36,43,
46,47
50
t'rstons, Dsassemble & Assemble
100,101
5,17,1 9,20,34,36,43,
46,47,4A,49
51
Cylinder Liners
5,1
7 .1
102
9,20.34,36,43,
46,47,48.49
52
103 104
urbocharger Lubrication Valve
53
Turbocharger Lubrcation Valve,
54
Sump Pump
55
Air Cleaner Housings
Disassemble
105
& Assemble
56
Turbocharger Heat Shietd
57
Turbochargers
51
107
108
109
54,55
110
111,1't2
58
Aftercooler Housing
54.55
59
Aftercooler Cores
54,55,57
60
Electric Starting Motors
61
Atr Starter
62
Air Starter, Disassemble & Assemble
63
Flywheel
64
Crankshaft Rear Seal Ring and Thrower
106
113
114
115
61
16-1 18
119,120
62
121 .122
65
Frywheel Housing
54,55,57,59,60
66
tlear Timing Gears
123,124
54,55,57,59,60,64
67
Camshaft
125,126
I ,s6,37.38.39.54,
55,57,59,60,64
68
Camshaft Bearings
1,1 5,1 7,1
127-129
9,20,26,30,
32,34,36,37,38,39,il,
55,57,59,60,61 ,64,66
69
Crankshaft
70
Generator
71
Manne Gear
11
59,60,61',63,64
130
,12,19,46,V,55,57,
131-f35
r
36,137
38,1 39
REMOVE FUEL TRANSFER
l.
FUEL TRANSFER PUMP

PUMP 11_1256
Turn the fuel valve to the "OFF" position.
2. Remove the bolt (1) from the clamp that

holds fuel line to accessory drive housing.
3. Disconnect the fuel lines (2) from the

pump. Remove the two bolts (3) that hold
pump to accessory housing. Remove the
fuel transfer pump.
PUMP 12_1256
pump (l) on the en-
INSTALL FUEL TRANSFER
l.
Put the fuel transfer

gine. lnstall the two bolts that hold pump
to housing.
2.
Connect the fuel lines to the pump.
3. Install the bolt that holds
clamp to housing.
4. Turn the fuel valve to the "ON" position.
tii
DISASSEMBLY AND ASSE
FUEL TRANSFER PUMP

DISASSEMBLE FUEL TRANSFER
PUMP
15-1256
Tools Needed
958099
Bushing Driver
start by:
a) remove fuel transfer pump
1. Remove the bolts (l) that hold cover to
body.
2.
Remove the cover (2) from the body.
CAUTION: Do not cause damage to machined surface of the cover or body.
3.
Remove the lock ring (3) that holds cage to

shaft.
4. Remove the idler gear (6) and shaft (5)

from the body.
5.
Remove caee (4) from the body.
6. Remove carbon seal and
washer from case
7. Remove bearing, lip-type
seal, and retainer
(4\.
from the cage with tool (A).
8. Remove O-ring
seals
from the cage and the
retainer.
9.
Remove bearing from the body.
e60;5x
TX}79,
D3S, D399 INDUSTRIAL AND MARINE ENGINES
FUEL TRANSFER PUMP

ASSEMBLE FUEL TRANSFER
PUMP 16_1256
Tools Needed
958@9
Bushing Driver
1P529
Handle
1P462
Drive Plate
l.
Clean all parts before assembly.
2. Install bearing
(A).
3. Install lip-type
(l) in cage (5) with driver

seal
(2) in cage with lip of

of cage using tooling
seal toward pump end
(B).
4. Put lubricant on O-ring
seals and install seal
(4) on retainer (3).
5. Install retainer (3) in cage (5).

6. Install the O-ring
seals on cage (5).
7. Install the bearing in body (6) with driver

(A).
8. Install the washer in body (6).

9. Put a small amount of clean oil on the inside diameter of rubber ring and wea face
of carbon
10.
Put the carbon seal on body and install

(
ll.
seal.
cage
s).
Put tape over the square edges of shaft to

protect seals. Install the shaft and idler gear
in body. Install lock ring.
12. Plut a small amount of 856747 Liquid

ket to machined surface of bodv.
CAUTION: Do not let liquid gasket get
Gas-
in
the
pump.
13. Install cover and retaining bolts.

NOTE: Shaft must turn freelv after cover bolts are
tightened.
end by:
a) install fuel transfer pump
FUEL PRIMING PUMP

REMOVE FUEL PRIMING
PUMP
11_1258
1. Turn fuel valve to the "OFF" position'
2.
Disconnect inlet lines (3) from the pump'
3.
Remove outlet line (1) from the pump.
4. Remove the two bolts that hold the bracket. Remove the bolts (2) that hold the base'
5.
Remove the fuel Priming PumP.
INSTALL FUEL PRIMING
l.
PUMP
12_1258
Put the pump (1) on filter housing. Connect

the outlet line for the fuel.
2. Install the bolts that hold base to fuel filter

housing.
3. Install the two bolts for the bracket.

4. Connect the inlet lines
to the priming
pump.
5. Turn the fuel valve to the "ON" position.
lp
DISASSEMBLY AND
FUEL PRIMING PUMP

DISASSEMBLE FUEL PRMING PUMP 15_1258
l.
start by:
a) remove fuel priming pump
Remove the tube (2) from valve body
2.
Remove bracket (3) and retainer from tube.
3.
Remove knob, nut, plate, guide and spring.

Remove piston and rod from the tube.
4.
Remove the rings (4) and O-ring seals from

piston (5).
5.
Remove plug, washer, springs, valve, and Oring seal from valve body.
ASSEMBLE FUEL PRIMING
PUMP
(l).
?rt3x!
16_1258
Tools Needed
Compressor
l.
Install the O-ring seal, springs (3), valve (2),

washer and plug in the valve body ( l).
2. Put a small amount of 4L7464
Silicone
Grease on the rings and seals.

7t?l6xt
3. Put the O-ring
seals
on piston. Install the
rings over the O-ring seals.
Install the piston in the tube with tool (A).

Install the spring, guide, plate, nut and knob
on the rod (4). Install the bracket and retainer.
5.
Put the tube (5) on the valve body.

end by:
a) install fuel priming pump
11
D379, D398, D399 IN;USTRIAL AND MARINE ENGINES
DISASSEMBLY AND ASSEMBL
WATER TEMPERATURE REGULATORS

REMOVE WATER TEMPERATURE
11_1355
REGULATORS
l. Remove coolant from engine to a level be-
low the regulator housing.
2. Remove the four bolts (1) that hold elbow

of the expansion tank to the cover. Remove
line (3) on Marine engines.
engines only, disconnect the
from the cover. Remove
line
bypass
water
bottom. Remove the regfrom
the
the cover
3. On Industrial
ulators from the cover.
4.
Remove the cover (2).
5. Remove the regulators (4) from the
hous-
ing.
6.
Remove the seals from the housing.
INSTALL WATE R TEMPERATU
REGULATORS
RE
12_1355
Tools Needed
1P529
1P489
F
F
l.
2.
3.
Handle
Drive Plate
Put new seals (l) in the housing with tooling (A). Install seals with lip of seal away
from regulator.
Clean the machined surfaces and install new
gasket
.,
for cover.
Install the regulators (2) in the housing on

the Marine engines. Install the cover.
4.
5.
On Industrial engines, install the regulators

in the cover and install cover. Connect the
bypass ne for the water.
Install the bolts that hold elbow of the expansion tank to cover.
6. Fill the engine with coolant.
t2
EXPANSION TANK (MARINE ENGINES)

REMOVE EXPANSION TANK
(MARINE ENGINES)
11-1354
1. Remove coolant from engine. Disconnect

lines for switch from expansion tank. Remove two bolts that hold switch to expansion tank. Remove the switch.
2.
Remove the hose (l) and clamps from expansion tank. Remove ventilation line (3).
Remove bolts (2) that hold housine to expansion tank.
a hoist to expansion tank. Remove

bolts from the two braces that hold exDansion tank in position.
3. Fasten
4. Loosen clamp (5) that holds the
tubes ro_
gether. Remove the bolts (4) thathold tube
(7) to expansion tank. Remove bolts that
hold brackets (6) to oil filter housing. Re_
move expansion tank. Weight is 220 lb.
(100 ke).
INSTALL EXPANSION TANK

(MARINE ENGINES)
l.
12-13il
Use a hoist and put expansion tank in posi-
tion on engine. Install bolts that hold the

brackets to oil filter housing. Install bolts
that hold outlet tube (l) to expansion tank.

Tighten clamp that holds ouflet tubes to-
gether.
Install bolts that hold braces to expansion

tank. Remove hoist from expansion fank.
3.
Install bolts that fasten temperature
reg-
ulator housing and expansion tank together.

Install overflow hose and clamps on expansion tank. Install the ventilation line.
A
T
Install the switch (2) on expansion tank.
Connect the lines (3) to switch.
5. Fill the engine with coolant.
FUEL FILTER
REMOVE FUEL FILTER
HOUSING
11-1262
start bY:
a) remove expansion tank (Marine engines only)
b) remove fuel Priming PumP
1. Remove fuel from the filter housing'
2. Disconnect fuel line (2) for the
pressure
gauge.
3. Disconnect inlet line (1) for the injection

pump housing.
4. Disconnect fuel line (3) for the transfer

pump.
5. Remove the four bolts (4) that hold the

housing on the oil filter housing'
6.
Remove the fuel filter housing'
INSTALL FUEL FILTER
HOUSING
12_1262
1. Put the fuel filter housing in position on the

engine. Install the bolts that hold housing to
oil filter housing.
2. Connect
3.
the fuel line for the transfer pump'
Connect inlet line for the injection pump

housing.
4. Connect fuel line for the pressure gauge'
end by:
a) install fuel Priming PumP

b) install expansion tank (Marine
gines only)
en-
DISASSEMBLY AND
L FILTER HOUSI NG
OI
REMOVE OIL FILTER
HOUSING
11_1306
start by:
a) remove fuel filter housing
1. Remove oil from the filter housing.
2.
Remove bolt that holds clamp
(2) to mani-
fold.
3. Remove the clamp (1) that holds outlet

lines together. Install two 3lB"-16 NC
forged eyebolts, washers and nuts in bracket.
4. Fasten a hoist. Remove the four bolts (3)

that hold housing to block.
5.
Remove
(s0 ke).
oil filter housing. Weight is 1l0lb.
INSTALL OIL FILTER
l.
HOUSING
12-1306
Fasten a hoist to the filter housing.
2. Install a new seal in back of the housing.

3. Put the housing in position on engine. Install bolts that hold housing on engine.
4. Install clamp that holds outlet lines together. Install bolt that holds clamp to the
manifold.
5. Check the oil level in
crankcase.
Fill to the
correct level.
a) install fuel filter
housing
l5
SEA WATER PUMP

REMOVE SEA WATER PUMP
l.
11-1371
Remove plug from bottom of pump and remove sea water from PumP.
2. Disconnect
inlet line from cover (3).
elbow (1) and top tank (2) from

the pump.
3. Remove
4.
Remove the retainer assembly (4).
5. Remove cover (3) and gaskets from
the
pump.
6. Remove the six bolts that hold pump to

accessory drive housing.
7.
Remove the sea water pump.
INSTALL SEA WATER PUMP
l.
12-1371
Put the sea water pump (l) on the engine'

Install the bolts that hold pump to accessory drive housing.
2. Install the retainer assembly (4).
3. Install the cover (2) with enough gaskets (5)

to have a clearance of .005 to .020 in. (0.13
to 0.51 mm) between cover (2) and face of
impeller (3).
4. Install the toP tank and elbow.
5. Connect the inlet line to cover (2). Install

1
I
t
t
the plug in bottom of PumP.
DISASSEMBLY AND
D379, D3fN, D399INDUSTRIAL

AND MARINE ENGINES
SEA WATER PUMP
--]-
i-J
-llT97915x2
ENGINES
D379, D398, D399INDUSTRIAL AND MARINE
SEA WATER PUMP

DISASSEMBLE SEA WATER
PUMP
15-1371
A
1P2321
FT884
Puller
Assemblv
Les
start bY:
a) remove sea water PumP
-Needed
that
1. Remove the cotter pin' nut and washer
hold imPeller to shaft'
even with end of sh-aft' In2.
- Installtwothe5i nut
16"-18 NC x 2 in' long bolts in
tl"fi
irr.- Itnptti.t. Loosen the impeller from
taper ofshaft with tooling (A)'
3.
Remove tooling (A)' Remove nut' impeller'

plate and gasket (1)'
4. Remove the cotter pins (4) and ring (2)

from pins.
5.
Remove the Plate (3) and bellows

the housing.
6.
Remove six bolts and locks'
7.
Remove the gear (6) from shaft'
(5) from
four bolts (9) and locks that hold

8.
-' Remove on
retainer' Remove bearing (10)'
Ltuii"g
bolts (8) and locks that hold
9.
-' Remove twohousing'
Remove retainer assemi"tuin.t to
bly (7).
10. Remove the bearing (11) from retainer'

I I . Remove the seal ( 12) from retainer'
l8
DISASSEMBLY AND
SEA WATER PUMP

ASSEMBLE SEA WATER PUMP
16-1371
Tools Needed
1P529
lP475
1P466
I P483
l.
B
,|
Handle
Drive Plate
Drive Plate
Drive Plate
Install bearing in retainer with tooling (A)

Install bearing with oil hole in bearing in
alignment with oil hole in retainer.
2. Install
seal in retainer with tooling (B). Install seal with lip toward the bearing.
3. Put clean
engine
oil on lip of
seal.
4. Install retainer assembly (3). Install
the
bearing (4). Install the shaft (2).
5. Install the gear (l) on shaft.
6. Install the bellows

smooth side
and plate in housing. The
of plate must
be away from
housing.
7. Install the ring (5) and cotter
pins.
8. Install the gasket and plate. The smooth

side of plate must be away from impeller.
9. Install
the impeller (6).
Install the washer and nut (7). Tighten the

rrut to 55 t l0 lb.ft. (1.6 1.4 mkg) and
install cotter pin. If cotter pin cannot be
installed, tighten nut until it can be installed.
end by:
a) install
sea water
pump
l9
DISASSEMBLY AND
VIBRATION DAMPER (D398 and D399)

REMOVE VIBRATION DAMPER
(D398 & D399)
11-1205
1. On D398, remove the bolts (1). Put an

identification mark on bolts (3) and (4) and
housing. Remove the cover (2).
2. On D399, remove bolts that hold the cover.

Remove the cover.
J.
On D398, remove the bolts that hold vibration damper. Install two 1P7407 Eyebolts
in the tapped holes of the vibration damper.
Fasten a hoist.
4. On D399, remove the bolts that hold vibra-
tion damper. Install two bolts (6) as a guide.

Move the vibration damper out on the guide
bolts with forcing screws (5). Fasten a hoist
and remove vibration damper. Weight of
D399 damper is 2'70 lb. (122 kg) and the
D398 is l30lb. (59 ke).
CAUTION: Do not hit the vibration damper.
INSTALL VIBRATION DAMPER
(D3e8 & D39e)
li.
12-1205
l.
Install two bolts as guide. Fasten a hoist to

the vibration damper. Put the damper in
position on the adapter.
2. Put 953263 Thread Lock on the threads of
bolts for vibration damper. Put thread lock
on the two bolts with a mark for cover on
the D398.
3. Install the bolts and remove guide bolts.
Tighten the 1 in. bolts (1) to 6701 50lb.ft.
(92.7 x 6.9 mkg) on D399. Tighten the
bolts (l) on D398 to 280 x 20 lb.ft.
(38.7 t 2.8 mkg).
ftlitt
tlriii
'11
Rrli,i
,'
4. Install cover (2) on D399. Install
cover on
D398 with bolts that have a mark in respective place on housing.
20
CRANKSHAFT FRONT SEAL RING AND THROWER -f

)
REMOVE CRANKSHAFT FRONT SEAL

RING AND THROWER
11_1160
5F7341 Adapter
8H684 Ratchet Box Wrencn
E87561 Step Ptate
1P2321 PullerAttachment
start by:
a) remove vibration damper (D39g and
D399 onty)
On D379 only, remove the cover (l). put a
mark on two bolts (2) for installation.
I.
l.
Remove the bolts that hold adapter (3) to

the crankshaft.
Use tooling
(A) to remove the adapter (3).
Remove the baffle
(4) from
accessory drive
itoLlslng.
Remove
:1rower.
ring (5) and spring from
L-.stall tooling
the
(B) on the thrower. put heat
-:: the outer diameter of thrower with
an
-::n flame at a maximum temperature of

:-0'F (204"C). Remove the
trower im-
=.1iateiy
with toolinC (B).
l..:-.oie the ring from the

-:.- -
accessory drive
21
DI
SASSEMBLY AN D ASSEMBLY
CRANKSHAFT FRONT SEAL RING AND THROWER

INSTALL CRANKSHAFT FRONT SEAL
RING AND THROWER
12_1160
Tools Needed
FT105
T603
9H1031
Push Plate
Bolt
Washer
1. Put 8M8060 Quick Cure Primer and 953265

Retaining Compound on ring. Install ring in
accessory drive housing.
2. Heat the thrower (l) in oil to a maximum

temperature of 400'F (205"C). Install
thrower on crankshaft. Use tooling (A) to
install thrower in correct location on crankshaft.
CAUTION: Do not install a used oil thrower. seal

ring or spring.
3. Put
clean engine oil on the spring and ring.

Install spring and ring (2) on thrower with
the work "OIJT" on ring away from crankcase. Put the gap of the ring, to top of
crankshaft when installed.
4. Put clean engine oil on inside diameter

baffle (3). Install the baffle (3).
5. Put 953263 Thread Lock on threads of
:
il
bolts for adapter.
Install the adapter (4) on D379 only. Put

7M7456 Loctite Sealant on two of bolts
for cover.
7. Install the cover on D379 only. Put bolts

with Loctite in location with X mark.
end by:
a) install vibration damper (D398

D399 only)
22
and
D379, D398. D399 INDUSTRIAL AND MARINE

ENGINES
ACCESSORY DRIVE HOUSING

REMOVE ACCESSORY DRIVE
HOUSING
11-1207
Tools Needed
487il8
887550
5F7341
8H684
Push puller
A
1
Les
Adapter
Ratchet Box Wrench
start by:
a) remove vibration damper (D399 &
D399)
b) remove fuel transfer pump
c) remove oil pressure regulating valve
l. On D379 only, remove the adapter
cover.
Remove bolts for the adapter. Remove the

adapter (1) with tooling (A).
Remove the baffle (2) from the accessorv

drive housing.
3. Remove
thrower.
the seal ring and spring from the
4.
Remove the fuel lines (3) from fuel filter

housing. Remove eleven bolts (5) that hold
accessory drive housing to cylinder block.
5-
Remove four bolts that hold plate (4) for

oil pump to oil pan base.
t. Remove the four bolts (6) that hold water

pump to housing. Remove the four blts (g)
that hold oil pump to housing.
T- Remove or disconnect all connections from

cylinder block to oil pan base.
'1, Remove the bolts that hold timing gear
plate to accessory drive housing on left side
of engine.
!l- Faen a hoist to front of engine. Loosen
fu bolts that hold cylinder block to oil pan

hE- Lift the engine enough to install
STS (7) between cylinder block and oil
base.
n- h{l ttro l12"-13 NC bolts as a guide. In

d tro 3/8"-16 NC forged eyibolts in
rel. ory drive housing. Fasten a hoist and
rre the accessory drive housing. Weight
b ID Ib. l9l kg).
D379, D398. D399 INDUSTRIAL AND MARINE ENGINES
ACCESSORY DR IVE HOUSING

INSTALL ACCESSORY DRIVE
HOUSING
l.
12-1207
Install two I12"-13 NC bolts as a guide in

the cylinder block' Install two 3/8"-16 NC
forged eyebolts in drive housing' Fasteu a
hoist and put accessory drive housing on engme.
eleven bolts (5)

housing to cYlinder block.
2. Install the
that hold drive
3. Install the bolts (1) that hold drive
hottstug
to timing gear Plate (2).
4.
Connect the fuel lines (3) to fuel filter housing.
5.
Install bolts that hold the water pump and

oil pump to drive housrng.
Kts
a hoist and lift the front of engine

enough to remove the spacers from between
cyner block and oil pan base. Tighten the
bolts that hold cylinder block to base'
6. Fasten
7. Install the four bolts that hold plate (4) for

oil pump to oil pan base. Install or connect
ail f the lines for engine between cylinder
-ql
.\..
block and oil Pan base.
oil on spring'and seal ring'

and seal ring on thrower
spring
the
Install
on seal ring installed
"OUT"
word
the
with
Put the gap of seal
crankshaft.
from
away
when installed'
of
crankshaft
ring to top
8. Put
clean engine
9. Put clean engine oil on inside diameter of

baffle. Install the baffle'
10.
Put 953263 Thread Lock on threads of

bolts for adapter. Install the adapter on
D379 only. Put 7M7456 Loctite Sealer on

two of bolts for cover. Install the cover for
adapter. Put bolts with Loctite in locations
(6) and (7).
end by:
a) install vibration damper (D398 &
b)
c)
)/1
D399 onlY)
install oil pressure regulating valve
install fuel trausfer PumP
''
D379, D398. D399 INDUSTRIAL AND

MARINE ENGINES
ACCESSORY DRIVE GEARS
/,2
tr
"3;-.t'
SAE STANDARD ROTATION ILLUSTRATION D379
D379, D398, D399INDUSTRIAL AND MARINE ENGINES

REMOVE ACCESSORY DRIVE
GEARS
11-1206
A
Tools Needed
1P2321
FT884
Puller Assembly
Leg
start by:
a) remove accessory drive housing
l. Remove bolts and locks from water pump
drive gear (2). Remove gear from shaft.
2. Remove oil pump drive gear (4) from its
shaft.
3. Remove the main idler gear (l) and its
shaft. Turn the crankshaft to get bolts that
hold shaft to cylinder block and plate (3).
4.
Remove bearings from gears

(4).
(l), (2), and
5. On D379 only, install tooling (A) on the

thrower. Put heat on the outer diameter of
thrower with an open flame at a maximum
temperature of 400'F (205'C). Remove the
thrower immediately with tooling (A).
6. Remove the balancer gear (6).
1
Remove the bearing from balancer gear.
8. Remove
oil tube (5) from plate. If plate
is
to be removed, remove oil pump and fresh

water pump. Remove plate (3) from cylinder block.
NOTE: Check the mark on plate for correct installation. The front of plate for SAE standard rotation engine (counterclockwise as viewed from
flywheel end) is marked "FRONT STD. ROT."
The front of plate for SAE opposite rotation engine (clockwise as viewed from the flywheel end) is
marked "FRONT REV. ROT."
26
D379, D398, D3gg INDUSTRIAL AND MARINE

ENGINES

INSTALL ACCESSORY DR IVE
GEARS
1P473
12-1206
Drive Plate
l. Install the plate (3) on cylinder block.

Tighten five ll2" bolts to 90 t 5 lb.ft.
(12.5 0.7 mke).
!UTE:
Be sure the plate is installed on correct side
indicated in removal.
l-
.
.
Install the oil tube (1). Install small gaskets

unde nuts that hold right end of tube. put
7M7260 Liquid Gasket Material on sealing
surfaces of idler gear shaft oil tube (l), and
shaft for main idler gear (2).
3- On D379 engine only, install bearing in balancer gear with toolinC (A). Install the bal_
:rncer gear and shaft. Tighten bolts to 40 x 4
Ib.ft. (5.5 t 0.6 mkg).
{ Install bearings in the gears for oil pump
and main idler gear.
: The gear train of accessory drive are the
the 8, 12, and 16 cylinder engines, except

1m
bhnss gear used on 8 cylinder engine. On
engines,
_sEndard otation (counterclockwise)
,,B"
hbncer gear timing mark
must be in
with the tooth on crankshaft gear with
naks (four, five or six punch marks).
5- Istall main idler gear and shaft. Install engirc oil pump and fresh water pump. Install
cas for oil pump and water pump.
SAE Standard Rotation 8 Cylinder Engine
sary.
SAE OPPOSITE ROTATION

8 CYLINDER ENGINE
cation on crankshaft.
CAUTION: Do not use anoldoil thtower' seal ring

or spring.
end bY:
a) install
dt'
I
I
28
accessory drive housing
] J-9 D398, D399 INDUSTRIAL

AND MARINE ENGINES
OIL PRESSURE REGULATING VALVE
::.,:OVE OIL PRESSURE REGULATING

- : ]-VE
11-1304
Remove the bolts
:an.
(2) that hold
valve
to oil
- -1.,.ntove valve and tube from the tee fl).

: -: L L OIL PRESSURE REGULATING
,_ :
12_1304
:
-e valve and tube in the tee.
., the bolts that hold

.
::
-:i::"BLE
- - ---l\G
valve
to oil pan.
OIL pRESSURE
VALVE
1b_1304
.:]to\e oil pressure regulating valve

. the bolts (2) that hold tube to
= Remove the tube (l).
guide from
L PRESSURE
\,/ALVE
---t);Jl\.
,:._:rite
_-
16-1304
oil in the bore of housing
.-,: (l). spring (3), and piston

Install the tube (5) on hous_
'
rjSSur regulating valve
ll76x
29
ol
REMOVE OIL
2.
PUMP
L PUMP
11_1304
start by:
a) remove fuel transfer pump
Remove six bolts that hold adapter. Remove the adapter (2).
Remove the drive gear
(l)
for the oil pump.
(3) that hold elbow to the

tee. Remove three bolts that hold pipe (4)
to the oil pump. Remove two bolts that
hold oil pressure regulating valve to oil pan
base. Remove the valve, tube and tee as a
unit.
3. Remove the bolts
4. Fasten a hoist
to the pump.
5. Remove the bolts (5) that hold pump to

accessory drive housing. Remove the oil
pump.Weight is 100Ib. (45 kg).
INSTALL OIL PUMP
12-1304
1. Fasten a hoist to the oil pump. Put the

pump in position on accessory drive housing
and oil pan base.
2. Install the pressure regulating valve,
tube,
and tee as a unit (1).
3. Install drive gear assembly on the pump

shaft.
4. Install the adapter assembly on

drive housing.
end by:
a) install fuel
30
transfer pump
accessory
DISASSEMBLY AND ASSEMSLY
OIL PUMP
15-1304
DISASSEMBLE OIL PUMP
1P467
1P471
1P476
1P479
Drive Plate
Drive Plate
Drive Plate
Drive Plate
1112in.l.D.
::
Pipe 6 in. long
start by:
a) remove oil pump
Remove seven bolts (2) that hold cover to
ear manifold (l). Remove the cover (3).
Remove nine bolts (4) that hold rear manifold to intake manifold (5). Remove the rear
manifold
(l).
Put a alignment mark on manifolds and a

mark for longest bolt for installation.
!' }oove
the pressure manifold (6).
ltnow the shaft (7). Remove

d kc-r from the shaft.
be
rS,
tro
the gear (8)
idle gears (9) from the idler
rn bearings from
r-{r-
the idler
gears
3l
ASSEMBLY
DISASSEMBLY AND
AND MARINE ENGINES
D379. D398, D399 INDUSTRIAL
OIL PUMP
the idler
7. Use tooling (D) to {:T?ut
shafts
from the intake manllolo'
8.
(10) and locks that hold

Remove the bolts
manifold' Reretainer assembl; io intatte
(11)'
*o"" ,tt" retainei assembly
the retainer with

9. Remove the bearing from
tooling (C)'
manr-
10. Remove the bearin-s1lt"T't|:itake

(B)'
rnunil"old with tooling
fold and
"u'
D379, D398, D399 INDUSTRIAL AND MAR!NE

ENGINES
OIL PUMP
olL
16-1304
ASSEMBLE OIL PUMP

Tools Needed
1P529
1P467
1P471
1P475
1P479
1P482
1P495
l.
PUMP
Handle
I
1
Drive Plate
1
Drive Plate
Drive Plate
1
Drive Plate
Drive Plate
I
Drive Plate
in reUse tooling (A) to install the bearing

tainer ( 1).
mani2. Install the idler shafts (2 in the intake
fold.
tooling (B) to install the bearing in the
intake manifold'
3. Use
4.
in the
Use tooling (B) to install the bearings
idler gears (3).
5. Use tooling (C) to install bearing in
rear
manifold.
6. Install the retainer (4), locks
and bolts'
In7. Install the drive gear and key on shaft' (5)'

ttuff drive shaft(6) in the intake manifold
8. Install the idler
gears
(3) on the shafts'
9. Install the pressure manifold (7) on the inon

i;il manifold. Install rear manifold (8)that
pi"t.rrtt manifold. Install the nine bolts
irold manifolds together' Install the cover
(9) on the rear manifold'
end bY:
a) install oil PumP
34
7Aozxl
D(|79, D398. D399 INDUSTRIAL AND MARINE ENGINES
ENGINE OIL COOLER

REMOVE ENGINE OIL COOLER
11-1378
l.
Remove the coolant from the ensine.
l.
Remove the oil from oil cooler.
two bolts (4) and clamp (2).
3. Remove
move the elbow
(l).
Re-
.t. Remove two bolts from pipe (3).
Remove three bolts (5) that hold flange to

fl'wheel housing.
. Remove
oil line (6) and clip for
turbo-
charger lubrication valve.

'il_
Remove the bolts (7) that hold plate and

npport to the block.
it, Fmen a hoist to the oil cooler.

fmove the four
tc
rater pump.
bm
l-{{l
bolts that hold elbow to
the engine oil cooler. Weight is 90

ks).
the support
o1 .-ooler (9).
hilG
(8) and
connector
the elbow and tube assembly.
ENGINE OIL COOLER

INSTALL ENGINE OIL
l.
COOLER
(l)
Install support
12_1378
and connector on oil
cooler.
2. Install tube assembly (2)
and elbow
(3).
3. Fasten a hoist to oil cooler. Put the oil

cooler in position on engine. Install the oil
line (4) and clip for turbocharger lubrication valve.
4. Install the thrge bolts that hold flange to

flywheel housig.
5. Install bolts (5) that hold plate and support

to block.
6.
Install two bolts that hold tube assembly

(6) to the tee.
7.
Install elbow and clamp for oil line from oil

filter housing to the oil cooler.
8.
Install the bolts
(7) that hold
water pump.
9.
Fill the engine with coolant.
10. Add
oil to engine
as needed.
elbow to
FRESH WATER PUMP

REMOVE FRESH WATER PUMP
11_1361
l. Remove the coolant from ensine.
2.
Remove the oil from ensine oil cooler.
Remove two bolts (2) and clamp that hold

oil line (l) to oil cooler. Move oil line awav
from oil cooler. Remove water line (3).
Remove the bolts that hold elbow to oil

cooler and water pump. Remove the elbow
( s).
5. Remove cover
6_
(4) and bearing
cage.
Fasten a hoist to the water pump.
Remove the six bolts (6) that hold water

pump to accessory drive housing.
Remove the fresh water pump. Weight is 86
lb. (39 kg).
L FRESH WATER
PUMP
12_1361
Fasten a hoist to water pump. Put the pump
engine. Install the six bolts that hold

Fmp to accessory drive housing.
!- lsall the bearing cage (l) and cover (2).
bll
the elbow (3).
k e oil line (4) on the oil cooler. Install

& o bolts and clamp. Install water line
b p from water temperature regulator
hg
t
cagine with coolant.
D.qt|ne
as needed.
37
FRESH WATER PUMP
T96671X2
trD!. qTT8,
D399INDUSTRIAL AND MARINE ENGINES
FRESH WATER PUMP

ISiASSEMBLE FR ESH WATE R
iIP
15-1361
Tools Needed
lq4fz1
FIEa
rg)
'
Puller Assembry
Les
Step Plate
sart by:
a) remove fresh water pump
Remove the inlet elbow ( I ) from the water
pump.
Remove the bolts (3) and locks from drive
!Ear. Remove the drive gear (2).
S- Rmove the cover (4) from pump housing.
t- lcmove the cotter pin from nut (5) that

Hds impeller.
Loosen the nut.
n npeller.
H e impeller (6) from taper of shaft

t tooling (A). Remove tooling (A), nut,
r- impeller, ring and seal.
bc the four bolts that hold bearing (8)
=qiner. Remove the bearing (8). Rete
aft (9).
the bolt that holds retainer assemhousing. Remove the retainer
a Fmp
| -f
rle
seal
from retainer. Remove the
the retainer (7).
qbm
seal assembly
from housing.
39
FRESH WATER PUMP

ASSEMBLE FRESH WATER
PUMP
Handle
Drive Plate
Drive Plate
Tools Needed
1P529
1P471
1P466
1P479
l.
16_1361
Drive Plate
Install the bearing in retainer with tooling

(A). Be sure the hole in bearing is in alignment with hole in retainer for lubrication'
tooling (B) to install the seal in retainer
with lip toward bearing' Put clean engine oil
on lip of seal.
2. Use
3.
Install the carbon seal (3) in the housing.
4. Install the shaft
( 1).
and seal (4) with smooth surface

toward carbon seal (3)'
5. Install ring
6. Install impeller (2), washer, and nut (5)'

Leave the nut loose.
7. Install the retainer assembly (8)
and bearing
(7) on the housing.
8. Install the drive
9.
10
gear
(6) on the shaft'
Turn the pump over and tighten the nut (5)

to 55 lb.ft. 0.6 mkg)' If cotter pin cannot
be installed, tighten enough to install'
Install cover (9) with enough gaskets (10) to

have a clearance of .005 to .020 in. (0.13 to
0.51 mm) between cover (9) and face of
impeller (2).
end by:
a) install
40
fresh water PumP
PR E LUBR
ICATION OIL PUMP (D399)
REMOVE PRELUBRICATION OI L
ruMP (D39e)
l.
11-1319
Remove the bolts that hold inlet oil line (3)

to oil pan base.
2. Disconnect oil outlet line ( I ).

3. Remove the bolts (2) that hold pump to
pump motor. Remove the prelubrication oil
pump.
GTALL
PRELUBR ICATION OI L
ifP (D399)
12-1319
l. Put the prelubrication oil pump on
the
motor. Install the bolts.
Install bolts that hold inlet line to oil pan

base.
J-
Connect oil outlet line.
TYPICAL EXAMPLE
PRELUBRICATION OIL PUMP (D399)

DISASSEMBLE PRE LUBR ICATION OI L
15-1319
PUMP (D399)
start by:
a) remove Prelubrication oil PumP
1. Remove inlet oil line (l) from pump.
2. Remove bolts (2) that hold head assembly'
Remove idler assembly from head assembly'
3. Remove rotor from PumP housing.

4. Remove seals from housing. Remove
screw
(socket head) from housing.
ASSEMBLE PRELUBRICATION OI L
PUMP (D399)
16-1319
Tools Needed
1P529
'1P482
l.
Handle
Drive Plate
Use tooling (A) to install seals in housing.

Install seals with lips away from each other.
Install screw (socket head) in oil outlet
port.
2. Install idler on head assembly- Install rotor

in housing. Put head assembly (l) on hous'
ing and install bolts.
3. Check end clearance of rotor with thickness

gauge (2). The end clearance must be -003
to .005 in. (0.076 to 0.127 mm).
4.
Remove head assembly again and add gasket

shims as needed to get the correct end cleaance.
5. Install inlet oil line on the pump,

end by:
a) install prelubrication oil pump
42
trI. TXg,
D399 INDUSTRIAL AND MARINE ENGINES
CONN ECTING ROD BEARINGS

RCTOVE AND INSTALL CONNECTING
1O_121g
trD BEARINGS
start by:
a) remove
b) remove
c) remove
d) remove
e) remove
engine oil cooler

fresh water pump
starters
engine oil pump
oil pressure regulating valve
l- Faste a hoist and remove
the prelubrica_
unit, (if so
equipped). Weight is 105 lb. (4g kg).
uon oil purnp and motor
I-
as a
Remove the wiring harness and plate for the

p'relubrication oil pump and moior.
^l- Rcmove the bolts (l) that hold inspection

trrs to block. Remove the inspection
soers (2) from each side of block.
fu
.-rankshaft
(in the direction of normal
uaion) until the rod caps (4)
-*d
-'ore
bre
can be re-
through the openings.
the bolts (3) from each.rod
cap.
the rod cap (4).
bearing (5) from the rod cap.
43
CONNECTING ROD BEARINGS

7. Push the connecting rods (6) away from
crankshaft.
8.
I
r
Remove the upper half of bearings from the

connecting rods.
9. Install the upper half of new rod bearings in
L--
the connecting rods. Put clean SAE 30 engine oil on the bearings and crankshaftjournal. Pull the connecting rods with bearing
into position on crankshaft.
NOTE: Be sure the tab on back of bearing fits in

tab groove (slot) in connecting rod.
10. Install lower half of new bearings in caps.
Put clean SAE 30 engine oil on bearings.
NOTE: Be sure the tab on back of bearing hts in
tab groove (slot) of cap.
ll. Install bearing cap on connecting rod. put
clean SAE 30 engine oil on theads of rod
bolts. Install the rod bolts.
12. Tighten the rod bolts first to a torque oi
4O x 4lb.ft. (5.5 t 0.6 mkg). put a mark on
bolt heads and bearing caps. Tighten the
bolts again 120" from the mak.
NOTE: Locks and cotter pins are not required *-ith
this method of tightening the bolts. even rhough
the bolt has a hole.
13. I nstall the inspection covers
with
ne$-
gaskets.
14. Install the plate and wiring harness for prelubriaction oil pump and motor (if so equipped). Install the prelubrication oil pump
and motor with a hoist. Weight is 105 lb.
(48 ke).
end by:
a) install
b) install
c)
d)
e)
fresh water pump

engine oil pump
install engine oil cooler
install starters
install oil pressure regulating valve
TYPICAL EXAMPLE
CRANKSHAFT MAIN BEAR INGS

REMOVE CRANKSHAFT MAIN
BEARINGS
Tools Needed
2P5517 Removal & Installation Tool

8M9379 Wrench
N_12O3
A
start by:
a) remove engine oil cooler
b) remove fresh water pump
c) engine oil pump
d) remove oil pressure regulating valve
e) remove starters
Fasten a hoist and remove the prelubrication pump and motor as a unit (is so equipped). Weight is 105 lb. (4S kg).
Remove the wire harness and plate for prelubrication oil pump and motor.
Remove the bolts (l) that hold inspection

covers to block. Remove the insoection
covers (2) from each side of block.
4-
Remove the nuts for main bearing caps with

wrench (B). Remove the bearing cap with
lower half of main bearine.
5-
tool (A) to roll the upper half f main

in normal direction of rotation.
Use
bearing by turning crankshaft
: On the bearing journal that
has no drilled
a thin piece of fiber, hardwood or plastic
i end of bearing, opposite tab. Hit the bearEhty with the above until tab of bearine is
rt
fuo
;: ;e"ihx,ii
cylinder block. Remove the upper half
45
CRANKSHAFT MAIN BEARINGS

INSTALL CRANKSHAFT MAIN
BEARINGS
Tools Needed
2P5517
8M9379
581161
Removal & Installation Tool

Wrench
Wire
12-1203
A
,|
852328 Dial Test Indicator Group

l. Put clean engine oil on bearing surfaces of
upper halves of bearings. Use tool (A) to
install upper half of bearing in cylinder
block. The bearing with oil hole is upper
1
half.
2. Clean main bearing caps and install lower
halves of bearings in caps.
a
Use wire (C) to check bearing clearance. Install caps and tighten both nuts with tool
(B) to 200 t l0 lb.ft. ( 27 .7 t 1.4 mkg). Put
a mark on nuts and end of studs. Tighten
nuts 120' from the mark. Remove caps and
check thickness or wire (C) to find bearing
clearance. Bearing clearance must be .005 to
.008 in. (0.127 to 0.203 mm) for new parts.
Maximum permissible clearance for used
parts is .015 (0.38 mm).
NOTE: Main bearing caps are numbered as to thei
location in cylinder block. Install bearing caps so
the number on cap is.same as number on cylinder
block. Both numbers must be on same side of cylinder block.
4. Put clean engine oil on threads of studs and
seat for nut. Install main bearing caps and
nuts. Install thrust plates on dowels on rear
cap. The dowels must not be extended more
than .160 in. (4.064 mm) from counterbore
face of bearing cap. Tighten nuts with

wrench (B) to 200 t 10 lb.ft. (2'l-'7 ! 1.4
mkg). Put a mark on nuts and ends of studs.

Tighten nuts an extra 120' from mark.
5. Use indicator group (D) to check end play
of crankshaft as controlled by thrust plates.
End play with new parts must be .005 to
.021 in. (0.127 to 0.533 mm). Maximum
permissible end play with used parts is .035
in. (0.89 mm).
6. Install the inspection covers. Install the wire
harness and plate for prelubrication oil
pump. Fasten a hoist and install prelubrication oil pump and motor as a unit (if so
equipped).
end by:
a) install oil pump
b) install fresh water PumP
c) install engine oil cooler
d) install oil pressure regulating valve
46
TYPICAL EXAMPLE
D379, D398, D399INDUSTRIAL

AND MARINE ENGINES
PISTON COOLING TUBES

REMOVE PISTON COOLING
TUBES
11-1307
l.
start by:
a) remove engine oil cooler
b) remove fresh water p mp
c) remove starters
d) remove engine oil pump
e) remove oil pressure regulating valve
Fasten a hoist and remove the prelubrica_
2.
equipped). Weight is 105 tb. (48 kg).

Remove the wire harness and plate for pre_
tion oil pump and motor a, u ,rril (if
so
lubrication cil pump and motoi.

3. Remove the bolts (l) that hold inspection
covers to cylinder block. Remove inspection
covers (2) fr< m each side of block.
4. Remove the bolt (3) and lock that hold
tube to bottom side of lifter bracket. Re_
move the piston cooling tubes (4).
GTALL
PISTON COOLING
TIBES
l. Install the piston cooling tubes (l)12_1307
in position on the lifter bracket. Install the locks
and bolts.
Of,UTION: Do not install a tube that is

bent or has
bge. Damage to the
"r,gin. "a;-rlrrli.
2 Install the inspection
covers on engine.
3- Install wire harness and plate for prelubrica_
tion oil pump and motor. Fasten hoist and
install prelubrication oil pump and motor
as
a unit (if so equipped).
end by:
a) install engine oil pump
b) install fresh water pump
c) install engine oil cooler
d) install oil pressure regulating valve
e) install starters
47
OIL PAN BASE

REMOVE OIL PAN BASE
l.
2.
11-1302
Remove the coolant from engine.

Remove the oil from oil pan base. Capacity
of D379 is 92 U.S. Gal. (348 liters); D398 is
I I 0 U.S. Gal. (41 6 liters); D399 is I 65 U.S.
Gal. (625liters).
3. Disconnect inlet water lines that are connected to engine. Disconnect fuel lines for
fuel supply to engine.
4.
Remove oil pressure regulating valve
(l).
5. Remove the four bolts that hold plate (3)

for oil pump to the base.
6. Remove bolts (2) that hold cylinder block

to the base.
7.
Lift the engine

from base. Weight of D379 is 8,000 lb.
(3629k; D398 is 10,000 lb. (4559 kg);
Fasten a hoist to the engine.
D399 is 13,000 lb. (5 920 ke).
8. Move the oil pan base. Weight of base on

D379 is 2,100 lb. (953 kg); D398 is 3,000
lb. (1360 ke);D399 is 3,800 lb. (1496k9.
INSTALL OIL PAN BASE
12-1302
Install a new gasket on the oil pan base.
2. Fasten a hoist to engine. Put the engine in

position on oil pan base. Put 953263
Thread Lock on the threads of bolts for
base. Install the bolts that hold engine on
oil pan base.
3. Install the four bolts that hold plate for oil

pump to the base.
4.
Connect inlet water lines to the engine.
5.
Connect fuel supply and return lines to engine.
6.
Install oil pressure regulating valve on
en-
gine.
7.
48
Fill the engine with oil and coolant to correct levels.
FUE L RATIO CONTROL WITH OVERRIDE

REMOVE FUEL RATIO CONTROL
WITH OVERRIDE
11-1278
l.
Remove the three bolts (2) that hold override assembly (l) to fuel ratio control.
2.
Remove the override assembly
(l).
3. Disconnect line (3) from fuel atio control.
. 4. Remove
the two bolts that hold the fuel

ratio control to governor. Move the fuel
ratio control (4) toward front of engine and

it from governor.
remove
INSTALL FUEL RATIO CONTROL

WITH OVERRIDE
l.
12-1278
Install the fuel ratio control on the governor. Make sure the bott (l) engages the
groove (slot) in rack stop collar (2). Install
the two bolts that hold fuel atio control in
place.
2. Connect line (3) for air to the fuel ratio

control.
3. Install the override

hold it in place.
-1. Make
trol.
assembly and bolts that
an adjustment to the fuel ratio con-
See FUEL RATIO CONTROL

SETTING IN TESTING AND ADJUSTING.
E!',
D398, D399 INDUSTRIAL AND MARINE ENGINES
FUEL RATIO CONTROL WITH OVERRIDE

:::
FUEL RATIO CONTROL
ITSASSEMBLE
OVERRIDE
rlTH
15-1278
start by:
a) remove fuel ratio control with override
l.
Remove the cover (l), spring (2), and

plunger (3) from override housing (4).
2. Remove the nut and screw that hold lever

assembly to the override housing (4). Remove the lever assembly and spring. Remove the seal from the housing.
3.
Remove the cover (5) from the housing. Remove the two springs. Turn bolt (6) and
remove the washer, diaphragm, retainer and
bolt.
ASSEMBLE FUEL RATIO CONTROL
.ttt ovERRtDE
l.
16_1278
Connect the bolt to the washer, diaphragm

and retainer. Put the diapfuagm assembly
and the two springs in housing. Install the
cover for fuel ratio control.
2. Install the
seal in override housing with lip

seal toward arm. Install the lever and
spring. Install the nut and screw that hold
the lever.
of
3. Install the plunger,
spring and cover on the
override housing.
end by:
a) install fuel ratio control with
override
,z*igxl
GOVERNOR
REMOVE GOVERNOR
l.
11-1264
Disconnect control linkage (1) from governor.
2. Disconnect line (3) for the fuel ratio
con-
trol.
3. Remove the cable (2) for safety shutoff

control.
4. Disconnect oil lines (6) and (5) from
the
governor.
5. Remove six bolts (4) that hold governor to

governor drive housing.
6. Remove the governor. Weight is 40 lb. (18

ke).
INSTALL GOVERNOR
l.
12-12@'
Put the governor on engine with lever on

governor engaged in groove (slot) in rack.
2. Install the bolts that hold governor to governor drive housing.
3.
Connect line for the oil pressure gauge.
4.
Connect the line for oil Dressure switch.
5. Connect the line to the fuel ratio control.

Install the cable for safetv shutoff control.
6- Connect control linkage to the governor.
f,1
T. tr!E!,TIiIAL
TXl,!,
AND MARINE ENGINES
GOVERNOR
DISASSEMBLE GOVERNOR
start by:
a) remove governor
b) remove fuel ratio control with override
Remove covers (l) and (2) from the governor.
l.
2.
Remove the high and low idle screws (3).
Remove the bolts

shaft.
(6) that hold levers to
Remove the levers (7). Remove the shaft

(4).
5.
Remove bolt (5) that holds housing to governor. Remove housing (g).
6.
Remove the seals from housing (g).
7.
Remove the stop group (9).
8. Remove the screw that holds the

collar. Remove the stop collar ( l0).
9.
stoD
Remove the spring and seat.
10. Remove the four bolts (l l) that hold gover_

nor housing. Remove the governor housing
(12).
Il
Remove speed limiter plug (l3), gasket

(14), spring (15), and plunger (16).
12. Remove the lever
(I
7) from the shaft.
fXI'g,
fxg,
tX}99 INDUSTRIAL AND MARINE ENGINES
GOVERNOR
13. Remove the governor spring, seat, spring
and washer.
14. Remove the bolt (19) that holds lever
as-
sembly ( l8) on shaft.
15. Remove the shaft (20) from governor housing. Remove the bearings and seal from governor housing.
16. Remove the lever assembly ( 18).
17. Push the pin (21) from lever (18).
18. Remove the spring (22)
and plunger (23).
the three bolts (27) and lock (28)

that hold weight assembly to governor drive
19. Remove
housing.
20. Remove the two bolts (26) and locks. Push

cover assembly (24) up and remove the
weight assembly (25).
'1.
Remove the ring (3) fom the seat. Remove
the pin (29).
UT'g, D398, D399 INDUSTRIAL AND MARINE ENGINES
GOVERNOR
22. Remove the seat (31), bolt (32),
washers
(33) and spring (34).
23. Remove the sleeve and bearing assembly

from the weight assembly.
24. Remove the ring (37) that holds bearing
as-
sembly on sleeve (35).
25. Remove bearing (38) and races (36) from

sleeve (35).
26. Remove the valve (42) from piston (41).
27. Remove the ring (39) that holds cylinder to

weight assembly. Remove the weight assemblv.
28. Remove piston (41) and sleeve (40) from

the cylinder (43).
29. Remove the O-ring
seal
from the
sleeve
(40).
Remove the cover and shaft assembly (44)

unit from the drive housine.
as a
31. Remove
gear
(45) from the pin assembly.
)J
D379, D398, D399INDUSTRIAL AND MARNE ENGINES
GOVERNOR
32. Remove the bolt (47) and washer from
shaft assembly.
33. Remove the gear (46) from the shaft,
34. Push the bearings (50) and shaft (49) out

the drive housing.
35. Remove the bearings, shaft, lever (48)
of
and
pin assembly (51).
36. Remove the valve assembly (52)
37. Remove the plug
and gasket.
assembly (53) and gasket.
38. Remove the cover (54) from drive housing.
39. Remove the bushing from drive housing.
E!I.
D398, D399 INDUSTRIAL AND MARINE ENGINES
GOVERNOR
GOVERNOR
ASSEMBLE GOVERNOR
16-126/-
Tools Needed
1P529
1P460
1P457
l.
Handle
Drive Plate
Drive Plate
Install the valve assembly ( l).
2. Install the plug assembly (2).

NOTE: For standard engine rotation, the valve (l)
must be located on the right side of governor drive
housing. For reverse engine rotation, change the
plug assembly (2) with the valve (l).
3. Install the cover (3).
4. Install the bushing in drive housing with

tooling (A).
NOTE: Install the bushing so it won't be extended

more than .465 to .475 in. (ll.8l to 12.96 mm)
above the bottom of pump bore.
5. Install the pin assembly (7).

6. Install the lever (4),
(
bearings (6), and shaft
s).
NOTE: Shaft (5) must turn freely in the bearings

with .02 to .06 in. (0.5 to 1.5 mm) end play.
7. Heat the drive gear (9) to 250"F to 300'F

( I 2 I " C to I 49'C), and install it on the shaft
and cover assembly (8).
$. [5tll the washer
5t
and bolt (10).
]S9
D3TIS, D399 INDUSTRIAL AND

MARINE ENGINES
GOVERNOR
:.
Install O-ring seal (13) on the sleeve (14).
Install.piston (12)
cylinder ( I 1).
and, sleeve
Put the weight assemblv

ring ( l5).
( I 7) and insrall
(14) in
the
l6) on cylinder
.1. Install the valve (19) in piston (12).
3. Install the bearing and races on sleeve,
i4. Install the sleeve and bearing

on valve (19).
assembly
(lg)
15. Put the seat (21), bolt (20),

washers and
spring on the valve.
6. Install the pin (22) and, rine (23).
59
T
D379, D3S, D399 INDUSTRIAL AND MARINE ENGINES
GOVERNOR
17. Install
gear
(25) on the pin assembly.
18. Install the cover and shaft assembly (24)in

the diive housing.
19. Push the cover and shaft assembly up and

install the weight assembly (26) on the
cover.
20. Install the locks and bolts (27) that hold

cover and shaft assembly to drive housing.
21. Install lock (28) and bolts that hold weight

assembly.
22. Install spring and plunger in lever (29)'lnstall pin in lever.
23. Install bearings and
seal
in governor housing
(30).
24. Install lever (29), shaft (32) and bolt (31)

that holds lever to shaft.
25- Install speed limite plunget, spring, gasket

and plug. Install rack stoP group'
60
GOVERNOR
26. Install the seat (35), spring (34)
(36) in governor housing (30).
and washer
27. Install the spring (33) on the bolt (20).
18. Install the governor housing on drive housing and install the bolts.
19. Install the spring and collar. Install the rack

stop collar.
30. Install
(37\.
screw (38) that holds rack stop collar
Install seals, shaft (42),lever assembly (40),

locks, and bolts in cover assembly. Install
the cover assembly (39). Install seals in
cover with lip of seal toward the inside.
-ll.
Install high and low idle screws (41).
-:-i. Install covers (43) and (44) on governor

housing.
\tlTE: Be sure pin (45) is in slot of rack stoo

end by:
a) install governor
b) make adjustment to governor (See
GO VERNOR ADJUSTMENTS jn
TESTING AND ADJUSTING)
c) install fuel ratio control with overide
6l
SAF ETY SH UTOF F

11-7418
REMOVE SAFETY SHUTOFF
t. Remove cable (4) from lever. Remove bolt

that holds cable bracket to channel. Remove nut
(l)
that holds clip to governor.
oil line (2) from governor to safety

3hutoff. Loosen oil line (3) at governor.
2. Remove
five bolts that hold safety shutoff

to fuel injection pump housing.
J. Remove
4. Remove safety
shutoff and cable
unit.
12-7418
INSTALL SAFETY SHUTOFF
l.
as a
Put safety shutoff in position on fuel injection pump housing. Install the bolts that
hold safety shutoff to injection pump
housing.
2. Install oil line to governor' Install oil line

from governor to safetY shutoff.
3. Install nut that holds clip for
cable to gover-
nor. Install bolt that holds cable bracket to

the channel. Install cable to the lever'
* 62
DISASSEMBLY AND ASSEMBI-Y
rT,9, D398, D399 INDUSTRIAL AND MARINE
ENGINES
SAFETY SHUTO
DISASSEMBLESAFETYSHUTOFF 15_7418
Tools Needed
1P232O
Puller Assembly
887560
start by:
a)
l.
xemove safety shutoff
Disassemble reset button and piston as fol_

lows:
a) Remove the
hold cover
cover.
b)
bolt (2) that
Remove pin (5), plunger (7)

(6) from cover (l).
c) Lift
d)
screws and
(l) to housing. Remove the
and, spring
piston (3) out of its bore in housine.
Remove bearing (4) from cover
(l).
Remove drive assembly as follows:
a) Remove two screws (g) that

adapter
(9) to
adapter.
b) Remove the
hold
housing. Remove the
snap ring (ll) and washer.

Remove the gear assembly (10).
FF
SAF ETY SHUTOF F
d)
Remove the pin ( l5) that holds gear ( 13)

to shaft ( 12). Remove the gear.
Slide shaft (12\ ottt of adapter (9)' Remove the two dowels (14) that hold gear
assemblY ( 1 0) together.
e)
Remove the bushings from adapter and
c)
gear'assembly.
3.
Disassemble carrier and weight as follows:

a) Lift carrier (24) ftom the housing'
b)
Remove screw (23) from carrier (24)'
NOTE: Remember the number of turns needed to

remove the screw ( 16) and use this same number
for installation.
c) Remove spring
(17), weight (18), pin
(22) and nut (21).

d) Remove gear
(19) from shaft (20) with
puller (A).
4. Remove emergency shutoff button as follows:
a)
b)
Remove button (27) and spring by loosening screw (26).

Push plunger (28) down through housing
(3
5.
t'
Remove plug (30) and gasket from housing'
Loosen
nut (29) and remove gasket and
cble assembly (25) as a unit.
SAFETY SHUTOFF
two pins from collar (35). Remove
the collar (35) and spring (33).
7. Remove
8.
Remove pin (32) and make a separation of

nut (34) from cable.
9. Remove
two cotter pins (37), washers (39)
and springs.
10. Push
latch (36) out of the way and
guide (38) from housing.
l.
lift
the
Remove plug (45) from end of housine.
12. Remove ring (41) from the shaft (43). Slide

shaft (43) and gear (42) from the housing.
13. Remove the pin that holds gear to the shaft.

Remove the gear (42) from shaft.
14. Remove bearing from the housing.
15. The foll

into the
(46), gu
to cause
(pressed)
the spring
necessary
16. Remove plug (47) from the housing.
17. Remove the spring and latch (release lever).
65
D379. D398, D399 INDUSTRIAL AND MARINE ENGINES
SAFETY SHUTOFF
ASSEMBLE SAFETY SHUTOFF
16-7418
A
Tools Needed
P529
1P458
1P455
1
t.
Handle
Drive Plate
'l
Drive Plate
Install latch (release lever) (2) and spring (4)

into housing (l).
It
(
is necessary to install new follower shaft

s).
3. Install
spacer, guide
(3) and spring (6)
shaft (5).
4.
Push (press) shaft (5) into housing ( 1).
5. Assemble worm shaft as follows:

a) Install bearing into housing ( I ) '
b) Install eear (7) on shaft (8) with pin.

c) Slide assembled gear and shaft (8) into
d)
housing ( I ) and hold with ring.

Install plue (9) in end of housing ( l).
Push latch out

guide ( I l).
7.
of
the way and install the
Install the springs (12), washers ( 13)
and
cotter pins ( 14).
tl
SAFETY
8.
Assemble the cable as follows:
a) Connect nut (15) to cable
assembly (17)
pin
(16).
with
b) Install spring (19) and collar (20) with
two pins (23).
c) Install cable assembly and gasket ( l8)
into housing and tighten nut ( 15).
d) Install gasket (21) and plte (22) into
housing.
Install emergency shutoff button as follows:

a) Push plunger (24) up through housing ( I ).
b) Install the spring (25) and button (26)
on the plunger. Tighten the screw (27).
741AZXI
[0.
Assemble carrier and weight as follows:
a) Install gear (31) on shaft (32).

b) Install nut (33), pin (34),weight (30) and
spring (29).
c) Install the screws (28) and (35).
\-O-FF: Tighten screw (28) the same number of

nrnl ttrat was needed to remove it.
d) Put a mark (stake) around the screw (28)

with a punch and hammer.
Install the carrier assembly (36) in the housine.
67
SAF ETY SH UTOF F

12. Assemble the drive and adapter as follows:
a) Install bushing (37), two gears (39), with
two dowels (38).
b) Install two bushings in the adapter (41).
c) Slide shaft (40) into adapter (41).
d) Install gear (43) on shaft (40) with pin
(44) and make a mark (stake) with
punch and hammer.
e)
Install gear assembly (42) into adapter

(41) with washer and snap ring.
Install drive assembly with two
screws
that hold adapter (41) to housing ( 1).
t3. Install bearing into cover (46) with tooling

(A).
14. Install plunger (50) and spring (49) into

cover (46) with pin (47).
15. Install piston (45) into bore.
16. Install cover (48) with two screws and one

bolt that hold cover (46) to housing (1).
end by:
a) install safety shutoff
68
CB'!',
E,
Tllg
INDUSTRIAL AND MARINE ENGINES
VALVE COVERS
REMOVE VALVE
l.
2.
COVERS
Remove the nuts

from the studs.
(l),
11_1107
washers. and seals
Remove the valve cover.
INSTALL VALVE COVERS
12-1107
Il
1. Install
a new seal
li
in the valve cover.
1l
l
I
I
t7:
iij
f1
it-'
.t,
'
7a\
I"
f,j
I
Install the valve cover onthe engine. Install

and nuts on th" studs.
the seals, washers
69
FUEL INJECTION PUMPS

REMOVE FUEL INJECTION
11-1251
PUMPS
l Remove dampers from fuel injection lines.
2. Disconnect the fuel line (l) for the pump to

be removed by removing nut (2). Put a protective cover over the open end of fuel line.
Move the fuel lines ( 1) out of the way.
3.
Remove the bolts (3).
4. Lift the pump body (5) straight up and
re-
move body.
5. Slide the plunger (4) from yoke of lifter.

Remove the plunger (4). Keep the plungers
with their respective pump bodies.
INSTALL FUEL INJECTION
12-1251
PUMPS
l.
Turn the pump plunger until tooth (2) of

plunger is in alignment with mark (l) on
rack. Install the plunger (3) by-sliding end
into yoke of lifter.
CAUTION: Be careful when installing pump barrels and plungers. Do not put plunger of one pump
in barrel of another pump.
2. Install new
seals. Install the pump body and

barrel carefully over plunger and dowels on
injection pump housing.
3.
Install the bolts. Tighten bolts first one then

another a small amount to at time starting
alternately, with the two nearest the fuel
rack.Tighten to 321 5 lb.ft. (4.4 0.7 mkg).
4. Remove covers from fuel lines. Connect fuel

lines. Tighten fuel line nut to 25 to 35 lb.ft.
(3.5 to 4.8 mkg).
5. Install dampers on fuel

70
lines.
fx7g, D398, D399 INDUSTRIAL AND MARINE ENGINES
FUEL INJECTION LINES

TINES
11-1252
1. Remove the dampers (1) from the fuel lines
at fuel injection pumps. Disconnect the fuel
line from the pumps. Disconnect
linkage
from governor and remove governor control

channel.
2. Remove the clips and remainder

dampers from fuel lines.
of
the
3. Disconnect fuel lines from fuel injection

valves. Remove the fuel injection lines. Put
covers and plugs over openings to keep dirt
and dust out.

LINES
l.
12-1252
Remove the covers and plugs from fuel lines
and openings.
Install the fuel lines (2) on the fuel injection

valves and pumps.
Tighten the fuel line nuts (3) to a torque of

25 to 35 lb.ft. (3.5 to 4.8 mkg). Instalt the
dampers and clips (1) on the fuel lines.
Install governor control channel. Corinect

linkage to governor.
EXHAUST MANI FOLDS (INDUSTR IAL ENGINES)

REMOVE EXHAUST MANIFOLDS
(INDUSTRIAL ENGINES}
11--1059
start bY:
a) remove fuel injection lines
b) remove valve covers
l.
Remove the plugs from the shield assembly'
2. Remove the bolts that hold shield (l) to

manifold. Put the shield (l) to the side of
manifold.
3.
Remove tube (3) from the shields.
4. Install a
7f
16"-14 NC forged eyebolt in
hole (2).
5. Disconnect the
elbows
(5) from the shield'
6. Remove the bolts (6) that hold shields together.
7.
Remove the oil line (4) from engine.
a 3f8"-16 NC forged eyebolt in

shield. Fasten a hoist and remove water
shield. Weight is 107 lb. (4S kg) on D379;
127 lb. (5S ke) on D398; 199 lb. (90 ke) on
D399.
8. Install
the bolts (8) that hold manifold to

turbocharger. Remove water line from back
of shield.
9. Remove
10. Fasten a hoist .o manifold. Remove the

bolts (9) and brackets (10) that hold manifold to the cYlinder heads.
EXHAUST MAN I FOLDS (tNDUSTRtAL ENGTNES)

1
l.
Remove the exhaust manifold ( I l) and

shield (7) as an assembly. Weight is 90 lb.
(41 ke) on D379; 120 tb. (54 ke) on D398;
165 lb. (75 kg) on D399.
12. Remove the bolts (12) that hold shield to

exhaust manifold.
13. Remove the shield (7) from manifold.

INSTALL EXHAUST MAN I FOLDS
(INDUSTRIAL ENGINES)
l.
12_1059
Put new gaskets on the exhaust manifold

(2).
2. Install the shield (l). Tighten the bolts (3)

to l0 lb.ft. ( 1.4 mkg).
3. Put 9M3110 Anti-Seize Compound on the

threads of all bolts that hold exhaust mnifold to cylinder heads and turbocharger.
hoist to the exhaust manifold. Put

the exhaust manifold in position on engine.
4. Fasten a
5. Put new gaskets between
shield and cylinder

heads. Install the bolts (5) and brackets that
hold manifold to cvlinder heads.
6. Install the bolts (4) that hold turbocharger

to exhaust manifold. Tighten these bolts to
36 to 44lb.ft. (5.0 to 6.1 mkg).
7. Install the water line (6) on the shield.
73
EXHAUST MAN I FOLDS (TNDUSTRtAL ENGTNES)

8. Put grease on the seal (7)
and bore
of water
temperature regulator housing.
9.
10.
Install a 7 f 16"-14 NC forged eyebolt and a

318"-16 NC forged eyebolt in the water
shield. Fasten a hoist and put the water
shield on the exhaust manifold and elbow in
the water temperature regulator housing.
Install the oil line (8) for the turbocharger

lubrication valve.
1. Install bracket (1 1).
for elbows. Install the

bolts that hold elbows (9) to water shield.
12. Install new gaskets
13.
Install the bolts ( 10) that hold the shields

together.
14. Install the tube ( I 2) on front of shields.

15.
Put the shield ( 13) in position and install

the bolts.
t6. Install the plugs.

17.
Fill the engine with coolant to correct level.

end by:
a) install valve covers

b) install fuel injection lines
D379, D398, D399 INDUSTRIAL AND

MARINE ENGINES
EXHAUST MANI FOLDS (MARINE ENGINES)

REMOVE EXHAUST MANIFOLDS
(MARINE ENGINES)
11-1059
start by:
a) remove turbocharger heat shield
b) remove fuel lines
c) remove valve covers
l.
Remove the water line (3) from manifold.
2. Remove oil line (2) for turbocharger

cation valve (right side onlv).
lubri_
3. Remove the shield (11.

4. Remove
bolts that hold elbows (4) to
ex_
5. Hit the elbows with a soft hammer to
dis_
haust manifold.
connect them from manifold.
6. Remove four bolts that hold water

nectors (6) to the exhaust manifold.
con_
7. Remove the bolt that holds brace (5) to
manifold.
r:
1l
8. Remove bolts (7) that hold exhaust

fold to the cylinder
{}
li
mani_
heads.
9. Remove bolts and nuts that hold

manifold to the turbocharger.
.i
exhaust
:
ir,'
ri'
11,
ii
i
,ii
75
EXHAUST MANI FOLDS (MARINE ENGINES)

INSTALL EXHAUST MANIFOLDS 12_1059
(MARINE ENGINES)
l. Install a3f 8"-16 NC forged eyebolt and a
5/16"-18 NC forged eyebolt in manifold'
Fasten a hoist.
2.
Install the (watercooled) exhaust manifold

on the engine with a hoist. Install new
gaskets.
3.
Put
4.
Connect brace to exhaust manifold.
9M3710 Anti-Seize ComPound on

threads of bolts. Install the bolts that hold
manifold to cylinder heads. Tighten bolts to
a torque of I 10 t l0 lb.ft. (15.2 t 1.4
mkg).
(l) in position. Install the

bolts that hold elbow to manifold.
5. Put the elbow
6. Install the bolts that hold elbow (2) to
ex-
haust manifold.
7.
Put
9M3710 Anti-Seize Compound on

of bolts. Install the bolts (3) that
hold exhaust manifold to turbocharger.
Tighten the bolts to 40 t 4 lb.ft'
(5.5 t 0.5 mke).
threads
8. Install the shield (4).

9. Install the water line for turbocharger heat
shield. Install the oil line for turbocharger
heat shield. Install the oil line for turbocharger lubrication valve.
end by:
a) install valve covers

b) install fuel lines
c) install turbocharger
heat shield
FUEL INJECTION PUMP HOUSING, SAFETY SHUTOFF,

GOVERNOR AND GOVERNOR DRIVE
REMOVE FUEL INJECTION PUMP
HOUSING, SAFETY SH UTO FF, GOVERNOR,
AND GOVERNOR DRIVE AS A UNIT
start by:
a) remove fuel injection lines
b) remove exhaust manifold (one side
only)
1. Remove the bolts (2) that hold exhaust
elbow to support (3).
2.
Remove bolts (4) that hold support (3) and
(l) to cylinder block. Remove

the support and lifting eye from engine.
lifting eye
3. Disconnect water line connection from

water temperature regulator housing and
the manifold. Fasten a hoist to regulator
housing. Remove the bolts that hold front
lifting eye and support to cylinder block.
Remove the water regulator housing, manifold, and lifting eye as a unit. Weight is 150
lb. (68 ke).
4. Remove the line (5) for air to fuel ratio

control. Remove the oil line from back of
governor.
5. Remove fuel line (7) from injection
pump
housing.
f
i
6. Remove the bolts (6) that hold housing to

cylinder block.
7. Install a 3f8"-16 NC forged eyebolt in

back of housing. Fasten a hoist and remove
the fuel injection pump housing, safety
shutoff, governor and governor drive as a
unit. The weight for a D3l9 is 350 lb. ( 159
kg); for a D398 is 425 lb. (193 kg); for a
D39B is 500lb. (227 k.
CAUTION: Do not cause damage to the oil tube

tor fuel pump and governor drive when unit is renoved.
ri
il
ii
f'
il
tr
t,'
l;f
FUEL INJECTION PUMP HOUSING ' SAFETY SHUTOFF,

GOVERNOR AND GOVERNOR DRIVE HOUSING
INSTALL FUEL INJECTION PUMP
HOUSI NG, SAFETY SHUTOF F, GOVERNOR,
AND GOVERNOR DRIVE AS A UNIT
1. Put 7M7260 Liquid Gasket material on bottom of housings and surface of contact with
cylinder block.
2. Put four 3/8"-16 NC bolts (l) for
a guide
in the cylinder block.
3. Install a 3f8"-16 NC forged eyebolt in

back of housing. Fasten a hoist and put the
injection pump housing, safety shutoff, governor, and governor drive in position on engine.
4. Lower the unit on the guide bolts (l). Install the bolts that hold unit to cylinder
block.
5.
Fasten a hoist to water temperature regulator housing, manifold, lifting eye and support (2). Install as a unit. Install the bolts
and connect the water lines.
6.
Install the fuel line (3) on front of injection

pump housing.
7. Install oil line (6) on the governor, Install

air line to fuel ratio control.
8. Install the lifting eye and support (4)
on
back of governor drive housing.
9. lnstall the bolts (5) that hold exhaust
elbow
to support.
of timing; See TIMING

INJECTION PUMP CAMSHAFT iN TESTING AND ADJUSTING.
10.Make adjustment
THE FUEL
end by:
a) install exhaust manifold

b) install fuel injection lines
78
D379, D398, D399 INDUSTRIAL

AND MARINE ENGINES
FUEL INJECTION PUMP HOUSING

DISASSEMBLE FUEL INJECTION
PUMP HOUSING
15-1253
852241
Camshaft Bearing Removal and

I nstallation Tool
Group
P459
1P456
Drive plate
Drive Ptate
start by:
aJ remove fuel injection pump housing
and governor as a unit
b) remove governor
c) remove safety shutoff (if so equipped)
I
Remove governor drive housing ( 1) from

fuel injection pump housing.
Remove plate assemblv (2) from fuel

3.
Remove the cover
(3) from
side of housins.
Remo.ve^the cover (5). Remove the plug

and
seal
(4) from housing.

s and clamps that hold fuel in-
5.
PS to the housing' Pull the

(6) straight uP to remove them
from housing.
the injection PumP housing'
inCAUTION: Be very careful when removing fuel

surplunger
to
damage
prevent
jection pumps to
fu".r. The body and plunger of each are put togit
at the factory and cannot be used with the
"t
bodies or Plungers of other PUmPS'
7.
Remove the fuel rack (8) from housing'
8.
Remove the three bolts (10) and locks that
hold thrust Plate. Remove the thiust Plate

(e).
D379, D398, D3gg INDUSTRIAL AND MARINE

ENGINES
FUE
L INJECTION PUMP HOUSING
9. Use wrench (A) to hold yoke screw (11).

Loosen locknuts fi 2).
10. Remove yoke screws (ll). put identifica_

tion on each yoke screw by its location in
11. Install S1605 bolts (13) (3/8,,-24 NF x 3

| 14" long) and needed washers in the lifters.
2. Tighten the bolts ( l3)
enough to hold lifters

away from the camshaft.
13. Remove the camshaft from housine.
CAUTION: Be careful when removing the camshaft. Do not cause damage to camshaft or
bearings.
8t

14. Remove the bolts (13) from the fuel pump
lifters and remove lifters (14) and springs
( 15) from the bottom of the housing'
NOTE: Put identification on each of the lifters by
its location in the housing.
15
'
Use tool group (B)
to
remove camshaft
bearings from the housing.
16. Use tooling (C) to remove the bearings for

fuel rack from the housing'
qI79, D398, D399 INDUSTRIAL AND MARINE ENGINES
1t

ASSEMBLE FUEL INJECTION PUMP
HOUSTNG
16-1253
A
9M4568
Wrench
1P529
Camshaft Bearng Removal
and Installation Tool Grouo
852241
Cam Bearing Tool Group
1P529
Handle
1P456
Drive Plate
1P459
Drive Plate
l.
Use tooling (C) to install bearings for fuel

rack in housing.
2. Use tool group (B) to install camshaft

bearings. Be sure the oil holes ( l) in
bearings are in alignment with oil hole in
housing.
CAUTION: Be sure the tool group (B) is in center

position on bearing while installing bearings, so no
damage will be caused to them.
3. Put clean engine oil on lifters (2). Install the

lifters (2) in their respective position in
housing.
4. Push the lifters in the housing against their

springs.
5. Install 51605 bolts (3) (3/8"-24 NF x3

ll4" long) and needed washers (4) in the
lifters.
Tighten the bolts (3) enough to hold lifters

up to install camshaft.
t4

7.
Put
clean engine
oil on the
camshaft
bearings.
8. Install the camshaft in the housine.
NOTE: If the engine has a counterclockwise rotation, the camshaft is installed with the arrow and
the F-mark (5) at the front of pump housing as
shown. For clockwise rotation of engine, the camshaft is installed with the F-mark and arrow at the
rear of pump housing.
9. Remove the bolts and washers that were

used to hold lifters up.
10. Install the thrust plate (6), locks and bolts

that hold camshaft in housine.
Install yoke screws (7) and locknuts in their

respective position in housing. Use wrench
(A) to hold yoke screw while locknut is
tightened.
12.
Make adjustment to lifters. See FUEL

PUMP TIMING DIMENSION SETTING
(OFF ENGINE) in TESTING AND AD-
JUSTING.
85

13. Put clean diesel fuel on the fuel rack. Install
the fuel rack (8) in the pump housing.
14. Install fuel injection pumps in their respective positions as follows:
a)
Remove the plunger (9) from the pump

(10) to be installed.
b) Put clean diesel fuel on the plunger and

barrel of the pump.
c)
Install the pump in housing. Turn the

plunger until the mark (12) on gear is in
alignment with mark on fuel rack (11).
d) Slide
screw
e)
the end of plunger into the yoke

of the lifter.
Install new seals for the pump and install

the pumps in the housing.
NOTE: Be sure the pumps are on flre dowels. Install the bolts and clamps.
f)
Tighten the bolts next to fuel rack first,

and then tighten bolts on other side.
Tighten the bolts to 32 t S lb.ft.
(4.4 t 0.07 mkg).

15. Install the plug and seal. Install the cover
(13) for fuel rack.
16. Install plate (14) on side of pump housing.
17. Install governor drive housing (15) on the

fuel injection pump housing.
18. Install plate assembly on pump housing.
end by:
a) install safety shutoff (if so equipped)

b) install governor
c) install fuel injection pump housing
and governor as a unit
87
GOVERNOR DRIVE HOUSING

DISASSEMBLE GOVERNOR DR IVE
HOUSING
Tools Needed
1P529
1P457
15-1288
A
Handle
Drive Plate
start by:
a) remove fuel injection pump housing,
governor, and governor drive as a unit
b) remove governor
c) remove safety shutoff
l. Remove the governor drive housing from

the fuel injection pump housing with a
hoist. Weight of governor drive for D379 is
80 lb. (36 kg); for D398 andD399 is 125
lb. (57 kg). Remove coupling.
2.
Remove ring, plunger, spring, and retainer

for safety shutoff.
3. Remove pin that holds shaft assembly. Remove lever (2), spring (4), key and shaft
assembly (5). Remove the seal from houslns.
4. Remove governor drive pinion

5. Use
(3).
tooling (A) to remove gear from thrust

(l). Remove the bearing from hous-
washer
rno
,s.
Remove ring (9). Remove bolts, locks, and

gear (8).
1. Remove
thrust plate (10) and shims. Keep
shims together for installation.

8.
Turn puller bolt ( l2) counterclockwise and

remove drive gear ( I
1)
locknut (6), gear (7) and key. Remove the drive shaft (13). Rernove bearings
for the shaft from the housine.
9. Remove
GT'g, D398, D399 INDUSTRIAL AND MARINE ENGINES
GOVERNOR DRIVE HOUSI NG

ISSEMBLE GOVERNOR DRIVE HOUSING 16-1288
Tools Needed
1P529
1P472
1P475
852328
Handte
Drive Plate
'l
Drive Plate
Dial Test Indicator Grouo
l. Install the bearings (l) in housing with

toling (A).Put clean engine if on
bearings.
l.
Install the drive shaft (2) and locknut. key
and gear (3).
3. Install the drive
gear. Turn the puller bolt
hold gear on shaft.
to
must be .015 to .045 in. (0.39 to 1.14 mm)
end cleaance.
5. Install seal (6) in housing with lip of seal to

inside. Install lever and shaff assemblv
(5). Install spring, key and pin.
\OTE: Be sure the pin is engaged with groove in

iaft and shaft turns freely. The spring must hook
rt'er the
pin and around shaft lever.
6. Install plunger,
safety shutoff.
7.
Install
shims
( l0) a
ll.
liil
spring, retainer and rins, for
ir
i
rive pinion (g). Install
l'
ak (7).Install bevel sear

play of drive shaft with
new parts is .005 to .009 in. (0.13 to 0.23
mm). Maximum permissible end play with
ilir
l
used parts is .015 in. (0.3g mm).
8. Use the tool group (B) to check the

'ance
clear_
(backlash) between pinio

gear (10). Make adjusrment of
removing or adding shims (9) b
plate (7). Amount
ck_
lash) between beve
be
.002 to .006 in. (0.
9. Install coupling on shaft. Fasten a hoist and
install governor drive housing on the fuel
end by:
a) install safety shutoff
b) install governor
c) install fuel injection pump housing,
governor, and governor drive as a unit
89
FUEL INJECTION VALVES

VALVES
l.
11-12il
( l) of the fuel line for valve

to be removed. Put a cover on end of fuel
Remove the nut
line to keep dirt out.
(3) that holds valve in the precombustion chamber.
2.
Remove nut
3.
Remove the seals from the nut.
4. Lift fuel injection valve (2) from the precombustion chamber.
5.
Remove thenozzle from bodv.

VALVES
l.
12-1254
Turn the nozzle (1) on the threads of body

(2) finger tight.
2. Install the valve into the precombustion

chamber.
3. Install a new seal on the nut (4).
4.
Install the nut (4) that holds valve in precombustion chamber. Tighten the nut to a
torque of 100 to ll0 lb.ft. (13.8 to 15.2
mkg).
5.
Install a new seal on top of nut between

valve body and the nut.
6.
Install fuel line nt () to valve. Tighten the

nut (3) to a torque of 25 to 35 lb.ft. (3.5 to
4.8 mkg).
D379, D398, D399 INDUSTRIAL AND MARINE

ENGINES
PR
ECOMBUSTION CHAMBERS
REMOVE PRECOMBUSTION
CHAMBERS
Tools
11-1106
Needed
5F8353 Wrench
start by:
a) remove fuel injection valves
l. Remove coolant from engine.
2. Remove
precombustion chamber (1) with
wrench (A).
3.
Remove the gaskets from precombustion

chambers.
INSTALL PRECOMBUSTION
CHAMBERS
Tools
12-1106
Needed
5F8353 Wrench
l. Put
9M3710 Anti-Seize Compound
on
threads of the precombustion chamber (2).

2.
Put a small amount of grease on gasket (3)

to hold gasket on chamber.
3.
Put liquid soap on the seal

the cylinder head.
(l)
and bore in
Tighten
4.
pre combustion chamber with

wrench (A) to a torque of 225 r 15 lb.ft.
(31.5 t 2.1 mke).
5.
Fill the
engine
with coolant to correct level.
end by:
a) install fuel injection valves
ROCKER SHAFTS AND PUSH RODS

REMOVE ROCKER SHAFTS AND PUSH
11-1102 & 1208
RODS
l.
start by:
a) remove valve covers
Loosen the adjustment screws (l) to get
maximum valve clearance. Disconnect oil
line (4) from shaft.
2. Remove nuts (3) and studs (2) that hold

shaft on head.
If
studs (2) arc removed when nuts are

loosened, install the studs in the head. Tighten the
studs to a torque of 40 5 lb.ft. (5.5 t 0.7 mkg).
NOTE:
3. Remove
rocker shaft. Remove the push rods
(5) from the cylinder head.

INSTALL ROCKER SHAFTS AND PUSH
12-1102 & 1208
RODS
lnstall push rods
(l)
into position on the
lifters.
2. Install rocker shaft (2) on cylinder
head'
3. Install the nuts and studs that hold rocker

shaft to cylinder head. Connect oil line to
the shaft.
It
NOTE: Be sure the studs and nuts are tightened to

a torque of 40 t 5 lb.ft. (5.5 t 0'7 mkg)'
4.
Make an adjustment of the valve clearance'

The cold clearance must be: intake '015 in'
(0.4 mm) and exhaust .035 in' (0'9 mm)'
SEE VALVE CLEARANCE ADJUSTMENT
iN LUBRICATION AND MAINTENANCE.
end by:
a) install
9:
valve covers

MARINE ENGINES
ROCKER SHAFTS
DISASSEMBLE ROCKER
SHAFTS
15_1102
start by:
a) remove rocker shafts and push rods

l. Remove cotter pins (l), washes and
sprrngs.
2.
Remove the intake rocker arms (5) from the

rocker shaft.
3.
Remove the brackets (4) and exhaust rocker

arms (3) from shaft. Remove the fitting (6)
and spring (2).
4. Remove the bearings from the rocker arms

with toolinC (A). Remove the nut and screw
for the adjustment from the ur.r. R.-ou.
the rings and buttons from the arms.

ASSEMBLE ROCKER SHAFTS
16-1102
Tools Needed
1P529
1P466
1P469
Handte
1
Drive plate
Drive plate
1
NOTE: Be sure the oil holes of the bearings

are in
alignment with oil holes in arms.
2. Install the spring and fitting on the shaft.

3. Install the rocker arms, brackets, washers
(l), springs (2) and cotter pins on each end
of shaft.
NOTE: Be sure exhaust rocker arms and intake

ocker arms are installed in .orr".i--Lcation
on
shaft.
end by:
a)
install rocker shafts and push rods
93
ROCKER ARMS. PUSH RODS AND VALVE LIFTERS
D379, D398, D399INDUSTRIAL AND

MARINE ENGINES
VALVE LI FTE RS
REMOVE VALVE LIFTERS
11-1209
start by:
a)
b)
housing,
c)
l.
gover-
remove valve covers
Loosen the adjustment screws for valves to
get maximum clearance.
)*IOTE: Flywheel housing removed for

illustration
only.
2.
Remove the push rods (2).
3. Remove the oil tubes (1) away from

brackets.
the
4. Put a wire or large rubber band around the

lifters (3) to hold them in place in bracket.
5. Remove the bolts and locks that hold brack_
et assembly to cylinder block. Remove the
brackets and lifters (3).
.s
VALVE LIFTERS
INSTALL VALVE LIFTERS
Tools Needed
12-1209
A
3P2243 Installer
I. Put clean engine oil on lifters. Install lifters
in bracket.
1
2.
Put wire or large rubber bands (l) around

lifters to hold them in bracket.
3.
Put the bracket and lifters in position on

dowels. Install the locks and bolts that hold
brackets to cylinder block. Remove the wire
or rubber band from lifters.
4.
Put the oil tubes (2) on the brackets
and
install locks and bolts.
5.
Put the seals between the bracket
assem-
blies.
Use installer
(A) to put the
seals
in their
respective position.
'7
Install the push rods.

of valves to get .015 in.
(0.38 mm) clearance (cold) on intake valves;
.035 in. (0.89 mm) clearance (cold) on exhaust valves. See VALVE CLEARANCE
ADJUSTMENT iN LUBRICATIO AND
MAINTENANCE GUIDE.
8. Make an adjustment
end by:
a) install piston cooling tubes

ction PumP
b) install fu
c)
housing,
governor, and goversafety sh

nor drive, as a unit
install valve covers
D379, D398, D399 INDUSTRTAL

AND MARINE ENGINES
INTAKE MANIFOLDS
REMOVE INTAKE
l.
MANIFOLDS
Remove the bolts

housing (l).
(2)
11_1058
that hold manifold to
NOTE: On the D399 Engines, the intake manifold

can be removed as one section for each
two cylin_
ders. Remove spacer that connects ihe
manifolds.
2. Remove the clamp (4) thatholds the oil line

for the oil cooler to the manifold.
3.
(3) that hold manifold to the

cylinderheads. Remove the intake manifbld.
Remove bolts
INSTALL INTAKE
MANIFOLDS
12_1058
l.
Install new manifold gaskets.
2.
Put intake manifold ( I ) in position on engine.

Install the bolts that hold manifold to cytin_
der heads.
NOTE: On the D399 Engines, the manifolds can

be
installed as one section for each wo cylinders.
3. Install the bolts that hold manifold to hous_

ing. Install the clamp that holds line for the
oil cooler to the manifold.
97
TXT79.
CYLINDER
REMOVE CYLINDER HEADS
l.
2.
11-1100
start by:
a) remove rocker shafts and push rods
b) remove intake manifolds
Remove the instrument panel from cylinder
head to be removed (if so equipped)'
Remove the coolant from engine.
3. Remove the eight bolts for each cylinder

head from the exhaust manifold on the
marine engines.
4. Remqve the bolts that hold the plate
(2) on
botto of exhaust shield. Let the plate lay

in the "V" of engine.
5. Remove the plugs
(1) from the shield.
Remove the eight bolts that hold the exhaust manifold to each cylinder head.
the fuel lines (5) for the head to be

removed. Put covers on fuel valves, lines,
and pumps. Remove two elbows (4) for
each cylinder head. Remove the governor
control channel for cvlinder heads on left
hand side only.
1. Remove
D3S, D399INDUSTRIAL AND MARINE ENGINES
8. Remove
9.
Remove
the oil line (3) for the rocker shaft.
the nuts (6) from the cylinder
head.
q
t0. Install two lf 2"-13 NC forged eyebolts in

head.
ll.
Fasten a hoist to the eyebolts and slowly

remove the cylinder head. Weight is l90lb.
(86 ke).
EADS

AND MARINE ENGINES
CYLINDER HEADS
INSTALT CYLINDER HEADS
12-1100
1. Clean the block and cylinder head.Install
new head gaskets, new water seals,

and fer_
rules.
2. Install two lf 2,,_13 NC forged eyebolts in

head. Fasten a hoisf and slw1y lower
the
head ove the studs until it iJ in
correct
position over head gaskets and
seals. Weight
is 190 lb. (86 ke).
3.
Put 9M3710 Anti_Seize Compound on

threads of head studs, un o"-tili
bolts fo
exhaust manifold. Install nut,
an washers
on studs. Tighten nuts in following
step se_
quence:
Step
Step
.
.
Step
by number to a torque
tb.ft. (20.7 t 1.4 mig.
of 250 t
; by number to a torque
lb.fr. (34.6 x l a mt!).

Tighten nuts again by number
(hand tgr-gr9 onty to a torque
of
250 t 10 tb.fr. (34.6 t 1.4 mke).
t0
l4o ol5
too
03
20 ot
07
60 05
on \
)
80
4. Install new gaskets for the exhaust

mani_
fold. Install rtre bolts (f tfraifroiJ.rnuurt
)
manifold to head. Tighten Uoit, (l)
to u
torque of 110 I 10 lb.ft. (15.2
; l'.4 mkg)
M.a1i1e Fngines. Tigfrtrn
Uolt, (l)
9n
dustrial Engines to 75 r o i.rt."iid.+ on t,r_
r.+
mkg).
5. Install the plate and plugs on the

shield for
the manifold bolts (if so quipp.Jl.'
6. Install the oil tine (2) fqr the rocker
shaft.
7. Install the two elbows (3). Install

Ure fuel
lines. Tighten nuts (4)'on fr.i*firr!.
to u
torque of 25 to 35 lb.ft. (3.S
t;
+.S _tgl.
Install governor control .t urrrr.t
ln left
hand side only).
8. Install the instr
r'.uJl..ud?# H'd,|trp|"i on cvrinder
9. Fill the engine with coolant to

correct level.
end by:
a) install intake manifolds

b) install ocker shafts an
push rods
99
PISTONS
REMOVE PISTONS
11-1214
start by:
a) remove cylinder heads
b) remove engine oil cooler
c) remove jacket water pump
d) remove engine oil pump
e) remove oil pressure regulating valve
l.
Fasten a hoist and remove the prelubrication oil pump and motor as a unit (if so
equipped). Weight is 105 lb. (48 kg).
2. Remove the wire
harness and plate for the

prelubrication oil pump and motor.
3. Remove the bolts (l) that hold

covers
inspection
to block. Remove the covers (2).
the
ft (in the direction of normal rota
il the rod caps (4) can be
removed through the openings. Remove the
bolts (3) and rod caps (4).
4. Turn
5.
Remove the carbon ridge (5) from the top

of the cylinder liner.
q,
Push the connecting rod and piston up until

rings arc out of the cylinder liner.
Remove the piston and connecting rod from

the cylinder liner. Weight is 45 lb. (21 kg).
100
T'g. D3S, D399 INDUSTRIAL AND MARINE

ENGINES
PISTONS
INSTALL PISTONS
12-1214
ools Needed
6H4140
Piston Ring Compressor
Put clean SAE 30 engine oil on the piston,

rings, connecting rod bearings and walls of
cylinder liner. Install upper bearing in con-
necting rod.
Install piston in liner with compressor (A).

Use the liner as a guide.
3. Install the piston in the liner slowly on to

the journal of crankshaft. Be sure the ,.V,,
mark on piston is in alignment with the .,V,'
mark (2) on the block.
CAUTION: Be careful not to cause damage to con_

necting rod bearing or journal on crankshaft when
piston is installed.
4. Install the lower bearing (5) in the cap (3)

for the connecting rod (4). Be sure the tab
on back of bearing fits in groove for tab in
cap. Install the cap.
5. Put clean SAE 30 engine oil on threads of

rod bolts. Install rod bolts. Tighten the rod
bolts to a first torque of 40 t 4lb.ft. (5.5 t
0.6 mkg). Put a mark on bolt heads and
bearing caps. Tighten the I olts again l20.
from the mark.
6. Put inspection
covers in position on engine.

Install the bolts that hold covers to cylinder
block.
7. Install the wire harness and

prelubrica ion oil pump and
equipped).
the
so
8. Put the prelubrication oil pump and motor
on engine with a hoist.

end by:
a) install oil pressure regulating valve
b) install engine oil pump
c) install jacket water pump
d) install engine oil cooler
e) install cylinder heads
ryPICAL EXAMPLE
l0l
PISTONS
15-1214
DISASSEMBLE PISTONS
Tools Needed
5H9621
Piston Bing Expander
start by:
a) remove pistons
l.
Remove the retainers (1) and pin (2) from

the piston. Remove the connecting rod (3).
a33&XZ
2. Use ring expander (A) to remove piston

rings from the piston.
3. Remove the carbon from ring
grooves on
piston with a stick of hard wood.
CAUTION: Do not use a broken ring or carbon

scraper to clean carbon. They will cut the ring
grooves or cause damage to piston.
16-1214
ASSEMBLE PISTONS
Tools Needed
5H9621
Piston Ring Expander
l.
Use the ring expander

ton rings.
2.
Install spring for oil control ring (bottom

ring) in the bottom ring groove of piston.
Install oil control ring.
Install center ring in center groove of piston
so the mark "UP-2" on ring is toward top of
3.
(A) to install the
pis-
piston.
4.
Install top ring in top groove ${ piston so

the mark "UP-I" on ring is tot,",rd top of
pistch.
5.
Turn the piston rings in the grooves so the

ring gaps arc l2O" apart.
6.
Put the connecting rod (5) so the bearing

cap (4) is turned up. Put the piston with
elief (8) for valves is turned up and "V"
mark (10) is down. Install pin (7) and two
retainers (9). Each retainer (9) must fit in a
groove in piston on each end of pin (7).
end by:
a) install
l0l
pistons
;1::',::::rrr
CYLINDER LINERS
REMOVE CYLINDER LINERS
11-1216
Tools Needed
P2399 Cylinder Liner Puller

1P2398 Puller Plate
start by:
a) remove pistons
1. Put a piece of gasket material or a cover
over crankshaft journals as a protection before liner is removed.
1
1
1
2. Put tooling (A) in the cylinder liner.
(A) to remove the liner from its

in cylinder block.
Use tooling
seat
CAUTION: Do not cause damage to piston cooling

tube (l) when installing tooling (A).
Remove the cylinder liner from its bore in

cylinder block.
5.
Remove the seals from the
liner. \
i.3
103
CYLINDER LINERS
INSTALL CYLINDER LIN ERS
Tools Needed
2Pa26O Cylinder Liner
Installer
12-1216
A
1P2398
Puller Plate
887548
1P5510
Push Puller
Liner Projection Tool Group
l. Clean the counterbore in cylinder
block.
Clean the liner thoroughly.

2.
Install new seals on the ner. Put liquid

soap on the seals and in the bore of cylinder
block. Put the liner in the bore of cvlinder
block.
3.
Use liner installer (A) to put liner into correct position.
4. Put the puller plate of tooling (B) on the

liner. Install the remainder of tooling (B)
with two washers, two spacers 2 in. (51
mm) long. Tighten the two nuts for studs to
50lb.ft. (6.9 mke).
5.
Measure liner projection as close as possible

to puller plate and at four locations around
the liner. Liner projection must be .004 to

.008 in. (0.102 to 0.203 mm).
end by:
a) install
pistons
TURBOCHARGER LUBR ICATION VALVE

REMOVE TURBOCHARGER LUBR ICATION
VALVE
1 1-1309
l.
Disconnect oil lines (l) and (2) from top of

turbocharger lubrication valve.
2. Loosen other ends and clips of upper oil

lines enough to move upper lines from
valve.
3. Disconnect the other three oil lines (5) from

valves.
4.
(3) that hold valve (4) to

channel. Remove the turbocharser lubrication valve.
Remove four nuts
INSTALL TURBOCHARGER LUBRICATION

VALVE
12-1309
l.
Install turbocharger lubrication valve

channel with four bolts (2) and nuts.
2.
Connect five oil lines to valve.
fl)
to
.i\
3. Tighten all connectors
andt.,hos.
105
TURBOCHARGER LUBRICATION VALVE

DISASSEMBLE TU RBOCHARGER
LUBRICATION VALVE
15-1309
start by:
a) remove turbocharger lubrication

valve
1. Remove the bolts and cover (3).
and adapter (l). Remove the plunger and spring from body.
2. Remove the body (2)
ASSEMBLE TURBOCHARGER
LUBRICATION VALVE
l.
16-1309
Clean all parts before assembling valve.
2. Install spring (2) and plunger
(l) in body
(3).
3. Install adapter,
cover and bolts.
end by:
a) install turbocharger lubrication
lf5
valve

AND MARINE ENGINES
SUMP PUMP
REMOVE SUMP PUMP
11_1319
1. Remoye six bolts (I) that hold

cover (2) to
housing.
2.
Remove cover from housing.
3.
Remove rotor (6), vanes (5)

and springs
from housing.
4. Remove
nut (3) from the shaft.
5. Remove handle
6.
(4) from shaft.
Remove packing
covef.
7.
nut and packing
from
Remove shaft from cover.
INSTALL SUMP PUMP
1. Install shaft (7) in
12-1319
cover (2).
2. Install
packing (6) and nut in

cover.
3. Install
handle
(l)
on shaft.
4. Install nut on shaft.
5. Install three
\rl
cat
rotor (4) i"

.and
;:?."irffi
(5)'
sprines (3)
6.
Install. cover (2) with pin

in shaft! (7)
/,'
in rotor. Install sii bolt;. --^$' \
gaged
en_
t07
AIR CLEANER HOUSINGS

REMOVE AIR CLEANER
HOUSINGS
11-1051
l.
Loosen clamp (2) for turbocharger hose to

air cleaner housing.
2.
(3) that hold air

cleaner housing to supports. Loosen two
upper bolts (4) that hold air cleaner housing
to supports.
Remove two bottom bolts
3. Remove bolt (l) that holds brace to
air
housing
cleaner housing. Remove air cleaner
(s).
INSTALL AIR CLEANER
ousrucs
12-1051
1. Install air cleaner housing by installing two

upper bolts into notches in support for air
cleaner housing.
Install bolt that holds brace to air cleaner

housing.
Install two lower bolts that hold air cleaner

housing to iupport and tighten two upper
bolts that hold air cleaner housing to support.
"ia.,
.'.V
4. Tighten4lamp for turbochargr hose to air
cleaner housing.
3.
r(B
D379, D398, D399INDUSTRIAL

AND MARINE ENGINES
TURBOCHARGER HEAT SHI E LD

REMOVE TURBOCHARGER HEAT
SHIELD
1. Remove coolant from
11-1073
engine.
2. Remove the bolts that hold braces (l) for

air
cleaner housings. Remove
shields from the heat shield.
ifri
two
3. Disconnect the water lines (2) and(4) from

the heat shield.
4. Loosen the three bolts (3) that hold
.
5.
Fasten a hoist and remove the

turbocharger
heat shield.
INSTALL TURBOCHARGER HEAT
SHf
heat
shield to aftecooler. Remve the

bolts that
hold heat shield to exhaust maniiotds.
ELD
.t2_1073
1. Put the three bolts (l) that hold

the heat
shield to aftercooler in the fieai
sfrief.
2. Fasten
a hoist and install the heat shield

in
position on engine. Tighten
the bolts to the
aftercrwler.
'At
3. Connect the water lines to the heat

4 Install
exhaus
(2) on
s.
shield.
that hold heat shield to
fnstall the two
shields
Install bolts that hold braces for

afu cleaner
housings.
6. Fill the engine with coolant to

corect level.
109
TURBOCHARGERS
REMOVE TURBOCHARGERS
11-1052
start by:
a) remove turbocharger heat

b)
l.
shield
(Marine Engines only)

remove air cleaner housings
Remove the line (2) for oil supply to the

turbocharger. Remove return line (4) for oil
from turbocharger.
2. Remove shield (3) from turbocharger
(Ma-
rine Engines only).
3. Loosen clamp (l) that holds coupling to
ex-
haust elbow (Marine Engines only).
4. Loosen clamp that holds elbow to the aftercooler.
in the openings for oil in

turbocharger. Install a 3/8"-16 NC forged
eyebolt in top of turbocharger.
5. Install covers
6.
Remove bolts that hold turbocharser to exhaust manifold.
7. Fasten a hoist and remove turbocharser.

Weight is 50 lb. (23
INSTALL
kg.
TURBOCHARGERS
12_1052
l.
Put a 318"-16 NC forged eyebolt in top of

turbocharger. Fasten a hoist and put turboer in position on engine.
2.
9M3710 Anti-Seize Compound on
threads of bolts (l) that hold turbocharger
to exhaust manifold. Install the bolts and
nuts. Tighten the bolts to a torque of 40 t 4
lb.ft. (5.5 t 0.6 mke).
3. Tighten clamp that holds elbow to aftercooler.
4. Remove the covers from openings and in-
stall the supply line and return line (2) for

oil to turbocharger.
5. lnstall the shield for turbocharger. Tighten
the clamp that holds coupling (Marine Engines only).
end by:
a) install turbocharger heat shield

b)
ll0
rine Engines only)

install air cleaner housings
(Ma-

MARINE ENGINES
AFTERCOOLER HOUSING
REMOVE AFTERCOOLER HOUSING 11_1063
start by:
a) remove air cleaner housines
b) remove turbocharger heaishield (Ma_
rine Engines only)
l.
Remove the coolant from engine. Loosen

the clamps (l) that hold air elbows to after_
cooler housing. Move the clamps away from
aftercooler housins.
3. Remove bolts (2) that hold aftercoole

housing to flywheel housing.
4.
bolts (5) from top

0
of after_
D'
5.
Fasten a hoist to the aftercooler housing.

ds
Remove aftercooler housing from engine.

Weight of aftercooler housing is 2O lU.
(1
l8
kg).
lll
AFTERCOOLER HOUSING
INSTALL AFTERCOOLER HOUSING 12_1063
l.
Fasten a hoist and put the aftercooler housing in position on engine.
2. Install the bolts that hold aftercooler
hous-
ing to flywheel housing.
3. Put the tubes
(l) in position on flywheel
housing. Install the bolts that hold the tubes
to
aftercooler housing and the flywheel
housins.
4. Put the clamps (2) that hold air elbows to

aftercooler into position. Tighten the
clamps.
5. Fill the engine with coolant to correct
level.
'f-lt'
endrV:
a) install air cleaner housings

b) install turbocharger heat shield
rine Engines
only)
(Ma:'

MARINE ENGINES
AFTERCOOLER CORES
CORES
REMOVE AFTERCOOLER
11_1063
start by:
a) remove aftercooler housing
l.
(2) from aftercooler

ve bolts that
Remove channel
hous_
i
t
housing. Rem
(3) that hold
2.
Remove the top housing.
3.
Remove sleeves (4) from the cores.
4. Fasten a hoist to the cores and remove the
cores from bottom housing. Weight of each

core is 75 lb. (34 kg).
INSTALL AFTERCOOLER
CORES
12_1069
Fasten a hoist and put the cores (l) in position in bottom housins.
Install the top housing.
s!
Put clean engine oil in bores for sleeves. Install sleeves in housings. Install bolts (2)
that hold housings together.
&
In3tall pipe (3) on the top housing. Install

the bolts that hold pipe in position.
Install channel on aftercooler housing.

end by:
a) install aftercooler housins
l t3
ELECTRIC STARTI NG MOTORS

REMOVE ELECTRIC STARTING
MOTORS
11-1453
1. Disconnect wires from the starting motor

and the solenoid.
2.
Put identification on wires and terminals for
installation.
3.
to starter. Remove the three

(1)
hold
starter to the flywheel
that
bolts
Fasten a hoist
housing. Remove the electric starter. Weight

is 80 lb. (36 ke).
INSTALL ELECTRIC STARTING
MOTORS
l.
12-1453
Fasten a hoist and put the starting motor on

ensine. Install the three bolts.
2. Connect the wires to starting motor and to

solenoid.
TYPICAL EXAMPLE
l14

AND MARINE ENGINES
AIR STARTER
REMOVE AIR STARTER
l.
11-1451
Turn the valve for.air supply to regulating

to ',OFF,, position.
valve
2. Remove the silencer (l) and elbow.

3. Remove the pressure regulating valve (2),
whistle valve (3), and oilei.
4, Install
1f2',_13 NC foreed
starter housing. Fasten a ho"ist

the three bolts that hold starter
housing. Remove the air starter.
Weight is
821b. (37 ke).
INSTALL AIR STARTER
l.
I
I
12-1451
Fasten a hoist and put air starter

in position
on engine. Install the three bolts.
2. Instatl
.the oiler, whistle valve, and pressure

regulating valve.
3. Install the elbow and silencer.

4. Turn the valve f,
supplv to regulating
varve to ',oN,,'"?irtXti
lt5
AIR STARTER
15-1451
DISASSEMBLE AI R STARTE R
A
Tools Needed
5F7465
1P232O
182716
Bolt ( 5" long)
484276
Washer
1P2852
Spanner Wrench
Puller
PullerAssembly
start by:
a) remove air starter
Put marks on parts to make alignment easier
during assembly.
2. Remove bolts (2) and remove the

housing
(l).
drive
Remove rine(4) and the screw (6).
Remove the drive assembly (5).
5.
Remove socket head screws (7) and remove

the cover (8).
6. Bend lockwasher (13) and remove nut (14)

with wrench (C).
7.
Remove the gear (12).
8. Remove retainer
(l l)
and push shaft (9) out
of bearing (10).
q
9. Push beainC
it
(10) out of cover (8).

MARINE ENGINES
AIR STARTER
10. Remove the bolts (17) and (18).
Remove
the gear housing ( I 9).
Remove cover (3..
12. Bend lockwasher and remove the nut with

wrench (C).
13. Remove plate assembly (16) and

bearing
( I 5) wirh tooling (A).
14.
5.
Remove ai motor housine.
Remove vanes (22) from rotor (24).
16. Bend lockwasher (21)

(23) with wrench (C).
and,
remove the nut
q
17. Remove the gear (26) wtthpuller (B).
18. Remove snap ring (20) and bearing (25).
117
D379, D398, D3gg INDUSTRIAL AND MARINE ENGINES
AIR STARTER
ASSEMBLE AIR STARTER
I
16-1451
Install bearing (7) and ring ( l).
2. Install
gear
3. Install
vanes
(6),lockwasher (2) andnut(4).

(3) into rotor (5).
NOTE: Assemble parts with marks in alignment.

See AIR STARTING MOTOR in TESTING AND
ADJUSTING for rotor clearance adiustment.
4. Install air motor housing (9).

5. Install
gear housing
6. Install
plate assembly (10) and bearing
(8).
(l l).
.7. Install lockwasher and nut.
8. Install the cover.
9.
Install bearing (14) in the cover (12).
10.
Install shaft (13) and retainer (15).
ll.
Install gear (16), lockwasher ( 17)

nut ( l8).
an<l
'*u!ti'.r
12. Install cover ( 12\ onthe gear housing (8).
13. Intall the drive assembly (19).

F
14. Install the drive housing.

end by:
a)
ilt
install air starter
the
FLYWH
REMOVE FLYWHEEL
Tools Needed
FTl094
FT524
1-1
156
A
Flywheel Lfting Bracket
Liftng Bracket
l.
Remove cover ( 1) from flywheel housing.

Remove pointer from tlywheel housing.
2.
Remove two bolts (2) that hold flywheel in

position on crankshaft. Install two j 18,,-14
NF 8 in. long bolts as a guide, on D379 &
D398. On D399 only. use two l"-14 NF x
10 in. long bolts as a guide.
3. Install tooling (A) on the flywheel. Remove

the remainder of the bolts that hold flvwheel to crankshaft.
4.
gl
Remove the flywheel. For D379 and D398,

weight of the flywheel is 450 Ib. (204 kg.
For D399 only, weight of flywheel is 550
tb. (249 ks).
EE
..r';1,
FLYWHEEL
12-1156
INSTALL FLYWHEEL
.:,'
Tools Needed
FTl094
Ff524
Flywheel Lfting Bracket
Liftng Bracket
1. For D379 and D398, install two 718"-14

NF x 8 in. long bolts (1) as a guide, in the
crankshaft. On D399 only, install two
l"-14 NF x 10 in. long bolts as a guide.
2. Use a hoist and toolinC (A) to put

flywheel in position on crankshaft.
the
3. Install the bolts that hold flywheel to crankshaft. Tighten bolts on D379, D398 to a
torque of 450 1 30 lb.ft. (62.2 x 4.1 mkg).
On D399 only, tighten bolts to a torque of
'
670
4.
Remove tooling (A) from flywheel.
50
lb.ft. (92.7
6.9 mkg).
5. Install pointer (2) in flywheel

stall cover on flywheel housing.
t:0
housing. In-
D379, Ds98, D399 tNDUSTRI#AnDMAR|NE

ENGTNES
CRANKSHAFT REAR SEAL RING AND THROWER

REMOVE CRANKSHAFT REAR SEAL
RING
AND THROWER
11_1161
start by:
a) remove flywheel
l.
Remove twelve bolts

flywheel housing.
(l)
thathold baffle to
Remove the baffle (2) from housing.
Remove
thrower.
5.
the seal ring and spring
from
Remove the ring from flywheel housing.
1*
121
CRANKSHAFT REAR SEAL RING AND THROWER

INSTALL CRANKSHAFT REAR SEAL RING
AND THROWER
12-1161
Tools
FT105
T603
9H 1031
Needed
Plate
Bolt
Washer
Push
A
1
2
2
1. Put 8M8060 Quick Cure Primer and 953265

Retaining Compound on ring. Install the
ring in flywheel housing.
2. Heat the thrower in oil to a maximum temperature of 300'F (149'C). Install thrower
on crankshaft. Use tooling (A) to install
thrower in correct location on crankshaft.
CAUTION: Do not use an old oil thrower, seal ring
or spring.
3. Put clean engine oil on spring and ring. Install spring and ring ( l) on thrower.
NOTE: The work "OLIT" on ring must be installed

away from crankshaft. Put the gap of the ring to
the top of crankshaft when installed.
4. Put clean engine oil on inside diameter of

baffle (2). Install the baffle (2) on the
flywheel housing.
end by:
a) install flvwheel
!t
D379, D398, D399
tN
Rt L AND MARTNE
ENGTNES
DISASSEMBLY AND
ASSEMBLY
FLYWHEEL HOUSING
REMOVE FLYWHEEL
l.
HOUSING
11_1157
start by:
a) remove aftercooler housins
b) remove flywheel
c.) remove starters
Loosen bolts (4) that hold cylinder block to
oil pan base. Remove oil prssure regulating
valve (5).
2. Remove the four bolts that hold flange for

oil pump to oil pan base..
4.
Remove thE biffle seal ring and spring from

tne throweri-.
t.
6.
,
/gt'_ll
NC bolts 6,, long as a

two 3/9,'_16 NC forged eye_
.t:'
en a hoist.
: r.'
7. Refirov the bolts that hold lifting eye to

cylinder block and to the flywtreeiiousing.
8. Remove bolts that hold governor
drive
housing to flywheel housing.
9.
_Remove flywheel housing

Weight is 450 lb. (204 ke).
from
engine.
\h,
123
]]
FLYWHEEL HOUSING
INSTALL FLYWHEEL
l.
HOUSING
12_1157
Put 7M7260 Liquid Gasket Material on top

surface of housing that makes contact with
governor drive housing.
2. Install two 5/8"-11 NC bolts 6" long as a

guide in the cylinder block. Install two
318"-16 NC forged eyebolts and fasten a
hoist. Put the flywheel housing on the cylin-
der block. Install the bolts that hold flywheel housing.
3. Install bolts that hold governor drive to

flywheel housing.
4. Install bolts that hold lifting
eye.
5.. Install spring, ring, and baffle on thrower.
NOTE: The word "OIJT" on ring must be installed

away from crankshaft. Put gap of ring to top of
crankshaft when installed. Install bolts that hold
baffle to flywheel housing.
6. Fasten a hoist to engine. Lift the
engine
enough to remove the spacers (1).
7. Install oil pressure
regulating valve (2).
8. Install the four bolts (3) that hold
flange for
oil pump to oil pan base.
9. Tighten bolts (4) that hold cylinder block
ll4
to oil pan base.

end by:
a) install flywheel
b) install aftercooler housing
c) install starters
D379, D398, D399INDUSTRIAL AND MARINE

ENGTNES
REAR TIMING GEARS

REMOVE REAR TIMING GEARS 11-D-12O6
Tools Needed
'1P2321
PullerAssemblv
FT884
Leg
887561
8F3672
887548
887550
Step Ptate
3
1
Puller Ptate
Push Puiler
Les
8H684
484280
Washer
L1329
Botr
l.
Ratchet Wrench
start by:
a) remove flywheel housing
Be sure the No. I piston is at top center on
the compression stroke. See TIlflNG THE
CAMSHAFT FOR THE FUEL INJECTIO\J
PUMPS in TESTING AND ADJUSTING.
. 2. Remove the pins. bolts (l)
and locks that

hold large camshaft gear to small camshaft
gear. Remove the large camsh aft gear (2).
CAUTION: Do not turn the crankshaft with laree

camshaft gear removed and the camshaft instaile.
3. Remove bolts and locks that hold thrust

washer to the cylinder block. Remove
thrust washer. Remove bolts and retainer.
4. Use tooling (B) to remove the small cam_

shaft gear (3) from camshaft.
5. On D379
on|y, remove the thrower (5) with

tooling (A). Remove bolts, lock and retainer
that hold balancer gear on its shaft. Remove
rear balancer gear (4). Remove bearins from
balancer gear.
INSTALL
REAR TIMING GEARS

REAR TIMING GEARS 12.D.12O6
Tools Needed
1P529
1P473
1P478
FT105
Push Plate
T603
1031
Bolt
Washer
9H
Handle
Drve Plate
Drive Plate
1
,|
- l. On D379 only, use tooling (A) to install
the
bearing in balancer gear.
NOTE: Be sure No. I piston is at top center on the

compression stroke. See TIMING THE CAMSHAFT FOR THE FUEL INJECTION PUMPS iN
TESTING AND ADUSTING.
2. Install small camshaft gear (2), thrust

washer (3), lock and bolts. Install retainer
' (6). Tighten bolts (l) to a torque of 60 to
'
70 lb.ft. (8.3 to 9.7 mkg).
3.
Put a mark with chalk on the camshaft gear

at the location of timing mark "C". Put a
mark with chalk on the tooth of crankshaft
gear with punch marks. The back of gears
can be marked so the marks can be seen
with a mirror (7) after installation.
Install the large camshaft gear (5). Be suie

the "C" mark on gear is in alignment with
punch mark on crankshaft gear. On D379
only, move large camshaft gear out enough
to turn the balancer gear until "4" marks
are in alignment.
gear in position on the
dowel on small camshaft gear. Install locks,
bolts, and pin (4).
5. Put large camshaft
6. On D379, heat the thrower in oil to a maximum temperature of 300'F ( 149'C). Install
thrower on crankshaft. Use tooling (B) to
install thrower in correct location on crankshaft.
C-\L-TIO\: Do not
or spnng.
use an old oil thrower, seal ring

ENGINES
CAMSHAFT
)
REMOVE CAMSHAFT
11-1210
start by:
a) remove fuel injection pump housing,
safety shutoff, governor, and gover_
nor drive as a unit
b) remove flywheel housing
c) remove vibration damper (D399
only)
l. Loosen the adjustment screws for valves to
get maximum clearance.
2. Remove
3.
the push rods.
Disconnect the
brackets (3).
oil lines (l) from lifter
a magnet and pull the lifters (2) up

enough to put rubber bands or wire on
them. This will hold lifters awav from cam-
4. Use
shaft.
for vibration damper. if

Remove powe takeofl, if
5.
ousing
so
so
'(
6. Remove
the service meter and tachometer

drive from front of engine. Install the alienment tool (A).
7.
Remove the large camshaft gear (4).
8.
Remove the bolts and locks thathold thust

washer (5). Remove the camshaft and small
camshaft gear (6). Weight for a D379 is 60
lb. (27 kg); for a D398 is 85 lb. (39 kg); for
a D399 is I 00 lb. (45 kg) .
9.
Remove the plate, small camshaft gear, and

key from camshaft.
127
D379. D3S, D399 INDUSTRIAL AND MARINE ENGINES
CAMSHAFT
12-1210
INSTALL CAMSHAFT
Tools
FT751
l.
Needed
Camshaft Alignment
Tool
A
1
Put the key and small camshaft gear on the

camshaft. Put clean engine oil on camshaft.
NOTE: On SAE standard rotation
engines,
(counterclockwise as viewed from flywheel end) install the small camshaft gear on the end opposite
the F-mark on camshaft. For SAE opposite rotation engines (clockwise as viewed from flywheel
end) install this gear on end with the F-mark.
2. Install the plate, lock, and bolts that hold

small gear on camshaft. Tighten bolts to 60
to 70 lb.ft. (8.3 to 9.1 mkg). Install alignment tool (A) on end of camshaft. Install
camshaft in engine.
the thrust washer. locks. and bolts

' 3. that hold
small camshaft sear in cvlinder
, block.
Install
NOTE: Be sure the crankshaft is in position with

No. I piston at top center on compression stroke.
4. Put a mark with chalk on "C" mark of gear

(2) and tooth of crankshaft gear with punch
marks. Put a mark on back of gears so they
can be checked with a mirror after installation. Put the large gear (1) on small camshaft gear. Be sure "C" mark and punch
mark of crankshaft gear are in alignment.
On D379, move gear ( 1) out enough to turn
balancer gear to make "A." marks in alignment.

AND MARINE ENGINES
CAMSHAFT
6.
Remove rubbe bands or wires from lifters.

Install the push rods (4). Connect the oil
lines (3) for rocker shaft assemblies.
7. Make adjustment of valve clearance.
The
end by:
a) install flywheel housing

b) install fuel injection pump
c)
housing,
safety shutoff, governor, and gover_

nor drive as a unit
install vibration damper (D399 only)
D379. D3S, D399INDUSTRIAL AND MARINE ENGINES
CAMSHAFT BEAR INGS

REMOVE CAMSHAFT BEAR INGS
Tools
85224'l
Needed
CamshaftBearinglnstallation
Group
Ratchet Wrencn
Puller Plate
Spacer
Extension
and Bemoval
8H684
5P1666
5P1667
858292
start by:
a) remove camshaft
b) remove valve lifters
1.
776lXl
Remove the camshaft bearings with tooling

Use the extensions as needed.
(A).
INSTALL CAMSHAFT BEARINGS

Tools
Needed
452241
CamshaftBearinglnstallation
8H684
5P1666
5P1667
858292
Batchet
Grouo
Wrench
Puller Plate
Spacer
Extension
and Removal
t.
12-1230
A
Put the bearings in the cylinder block with

tooling (A). Put clean engine oil on
bearings.
NOTE: Be sure the oil holes (1) in the bearings are

in alignment with oil holes in cylinder block.
end by:
a) install camshaft
b) install valve lifters
Itr
_=_=
11-1230
D379,D398, D399 INDUSTRIAL AND MARINE ENGINES
CRANKSHAFT
REMOVE CRANKSHAFT
Tools Needed
8F2550
Engine
Tilting
Group
11-1202
A
1
start by:
a) remove flywheel housing
b) remove accessory drive housing
c) remove intake manifolds
d) remove crankshaft front seal ring and
thrower
e) remove crankshaft rear seal ring and
thrower
O remove engine oil cooler
WARNING: Never use the engine tilting
group unless the base of engine is fastened
safely to its foundation.
Remove the inspection covers from both

of engine. Install 58l l8l Turnbuckles
(5) with left-hand threads to top of engine.
Put FT73l Left and FT735 Right Support
Beams (9) and FT734 Supports (10) on
their respective sides of engine. D398 and
D379 Engines use FTI l3A and FTl l3 Support Beams.
sides
Install 8F4239 Blocks (l) and 8F4226

Yokes (7) on support beams (9). Tighten
the 8F4230 Studs (6) 14.5 in. (368.3 mm)
long into the 8F4226 yokes (7). Use the
nuts on studs as shown.
3. Turn the 58l l8l Turnbuckles (5) on'studs
(6). Turn 8F4231 Studs (4)9in.(229mm)
long into the turnbuckles.
2.
CAUTION: The turnbuckles and studs must carry

the engine evenly and must be turned evenly or
restriction will be caused. If either turnbuckle is
extra hard to turn, correct the restriction before
proceeding. Turning with a force will cause damage
to threads.
4. Turn the top of 8F4231 Studs in 8F4226

Yokes (3) and install 8F4239 Yoke, block
(l), and FT736 Bracket (2) to the cylinder
heads.
(ll), (six for D398

and D399 Engines and four for D379 Engtnes) in place of bolts used to hold cylinder
block to oil pan base.
6. Install steel plates or steel pipes as a support
under the support beams (9).
5. Install 8F4225 Bolts
UT'g. D3S, D3gg INDUSTRIAL AND MARINE ENGINES
CRAN KSHAFT
t-
Lift the engine four inches ( 102 mm) with
the turnbuckles and install 8F4228 Hinge
Yokes (12) and 8F4233 Hinge Blocks.
WARNING: The engine must be kept level

while it is being lifted from base. If an extra amount of effort is needed to turn one
tumbuckle, or hinge block and holes do not have
alignment, check the opening around the base with
a scale. Make adjustments to keep the distance
equal between cylinder block and base.
8. Install 8F4228 Hinge Yokes and 8F4233
Hinge Blocks between block and oil pan
base. Use L1178 Bolts between yokes and
base. Use bolts removed to hold hinge
blocks to the block.
9. Remove the 8F4225 Bolts used as a guide in
Step 5.
10. Begin tilting the engine by turning the turn. buckles on both sides of engine. When the
ends of studs are even with inside base of
'
turnbuckles, replace the 8F4230 Studs with
FTl l l-A studs 20.5 in. (521 mm) long.
Replace studs one at a time.
WARNING: Having the ends of studs extended farther than even with inside base
of turnbuckles can cause damage to threads
of studs and in turnbuckles. If damage is caused to
threads the engine can fall.
ll Tilt the engine until studs are extended
the
permissible distance. Remove 8F4231 Studs
and replace with FT733-5 Studs 11.5 in.

(292 mm) long. Remove the FTl11-A Studs
and replace with FT733-10 Studs (18) 23.5
in. (597 mm) long. These replacements are
on the side being opened. Before tilting the
engine farther, remove 8F4230 Studs from
side of engine with hinges. Replace them
with FTl l I Studs lO in. (254 mm) long.
t2. Keep tilting engine until studs are again extended the permissible distance. Remove
FT733-5 Studs and replace with FT733-7
Studs 18.5 in. (47O mm) long.
Tilt engine again until studs are extended
the permissible distance. Remove the
F-1733-7 Studs and replace with FT733-9
Studs ( 16) 21.5 in. (546 mm) long. Move to
side of engine with hinges and remove the
FTlll Studs and replace with FT733-2
Studs (14) 8 in. (203 mm) long. Remove
the 8F 4231 S tud s and rePlace with
FT733-l Studs ( l3) 6 in. (152 mm) long.

ENGINES
CRAN KSHAFT
14. Tilt the engine until there js l7 in. (432
mm) clearance. Install Lifting Channels ( I 5)

on cylinder heads.
I 5. Put a clean cover (20) on the oil pan
base to
lower crankshaft on.
16. Install pins or bolts as a guide (19) on each
end of crankshaft. Fasten a ratchet hoist to
each guide.
17. Remove the bearing caps from connecting

rods and push the pistons and rods to top oi
their stroke.Use wire or rope to hold rodi on
side of engine that has bien lifted so rods
will not drop.
CAUTION: Do not cause damage to piston cooling
tubes.
18. Remove main bearing caps and bearings.

Put tape on threads of ituds to prevent
damage to them during removal. Lower the
crankshaft with two hoists ( 17) on cover
(20) and emove. Weight of crankshaft for
D379 is 650 tb. (295 kg); D398 is 890 lb.
(404 k;D399 is I 100 tb. (499 ks).
CRAN KSHAFT
INSTALL CRANKSHAFT
Tools Needed
8F2550
852328
581161
Engine Tiltng Group
Dial Test Indicator Group
12-1202
A
Wire
t. Fasten hoists and put the crankshaft in position under the cylinder block.
2. Install new upper halves (with oil holes) of
main bearings in cylinder block. Install the
upper halves of connecting rod bearings. Put
clean engine oil on all bearings.
3. Lift the crankshaft in to position in the cylinder block. Remove the tape from threads
of studs.
NOTE: Be sure the timing marks are in alignment.
SEe CAMSHAFT AND TIMING GEARS AND
FRONT ACCESSORY DRIVE in TESTING AND
AD.JUSTING.
. 4. Put new bearings in main bearing
caps. Use
wire (C) to check bearing clearance. Install

caps and tighten both nuts to 200 t 10
lb.ft. (31.1 r l 4 mkg). Put a mark on nuts
and end of studs. Tighten nuts 120' from
the mark. Remove caps and check thickness
of wire (C) to find bearing clearance.
Bearing clearance must be .005 to .008 in.
(0.127 to 0.203 mm) for new parts. Maximum permissible clearance for used parts is
.015 in. (0.38 mm).
NOTE: Main bearing caps are numbered as to their
location in cylinder block. Install bearing caps so
the number on cap is the same as number on
cylinder block. Both numbers must be on same
side of cylinder block.
5. Put clean engine oil on threads of studs and

seat for nut. Install main bearing caps and
nuts. Install the thrust plates on dowels on
rear cap. The dowels must not be extended
more than .160 in. (4.064 mm) from
counterbore face of bearing cap. Tighten
the nuts to 200 I l0 lb.ft. (37.7 1.4 mkg).
Put a mark on nuts and ends of studs and
tighten nuts an extra 120' from mark.
CRAN KSHAFT
6. Put the connecting rods on the crankshaft.
Install lowe half of new rod bearings in
caps. Put clean engine
oil on bearings.
Use tool group (B) to check crankshaft end

play as controlled by thrust plates. End play
must be .005 to .021 in. (0.127 to 0.533
mm). Maximum permissible end play is .035
in. (0.889 mm).
8 Lower the engine by replacing the studs in
tool group (A) in turnbuckles as required.
Replace studs one at a time.
7
WARNING: The turnbuckles and studs

must carry the engine evenly and must be
turned evenly or restriction will be caused.
If either
tra hard to turn, correct
the restri
ceeding. Turning with a
force
will
threads.
9. When engine is lowered to 4 in. ( 102 mm)

with turnbuckles and studs, remove the
8F4228 Hinge Yokes (2) and 9F4233 Hinge
Blocks.
10. Install 8F4225 Bolts (l) as a guide. Install a

new gasket on the oil pan base.
I l Lower the engine on the base with the turn_
buckles and necessary studs. Install the
bolts that hold cylinder block to oil pan
base.
12. Install the inspection covers on each side of

engine.
13. Remove the beams, supports, turnbuckles,

yokes, block, brackets, and studs of tool
goup (A).
end by:
a) install crankshaft front seal rine
and
thrower
b) install accessory drive housing
c) install engine oil coole
d) install intake manifolds
e) install flywheel housir_s
f) install crankshaft rea seal rine and
thower
TYPICAL EXAMPLE
D379, D3S, D399INDUSTRIAL AND MARINE ENGINES
GENERATOR REMOVAL
REMOVE GENERATOR FROM
ENGINE
l.
114450
Remove adapter screen (l) and cover from

the generator by removing two bolts on the
right side of the screen for the generator '
2. Remove bolts (4) that fasten the plates to

the flywheel.
3. Remove bolts (3) that fasten the
generator
to the flywheel housing.
4. Fasten a hoist to the generator. Remove

bolts (2) that hold the generator to the
mount or rails.
generator with a hoist. Weight

(1905
kg) for theD379 engine;
is 4200 lb.
(2313
for the D398 engine;
kg)
5100 lb.
'7560
(3429
for the D399 enkg)
lb.
and
5. Remove the
eine.
GEN E RATOR INSTALLATION

INSTALL GENERATOR ON
124450
ENGINE
1. Install the shims and plates in the following

step sequence:
Step
Step 2
a)
Make sure the crankshaft is in

the most forward postion. Measure dimension (A) from the
face of the flywheel where the
coupling plate fastens to the rear
face of the flywheel housing.
If the face of the flywheel is inside the rear face of the flywheel
housing add .587 in. (14.91
mm) to dimension (A). Then
subtract the thickness of plate
(l).
b) If the face of the flywheel is

outside the rear face of the
flywheel housing subtract di-
mension (A) from.587 in.

Step
(14.91 mm). Then subtract the

thickness of plate ( l).
Install the number of shims (3)
needed to get the measured
thickness to the nearest .015 in.
(.38 mm). Tighten bolts (4) to a
torque of 370 t 35 lb.ft. (51.2
4.8 mkg).
s8760xr
Install a guide bolt (5) in the flywheel for

alignment.
3.
Put generato into position on engine with a

hoist. Install the bolts holding the plates to
the flywheel.
4.
Install the bolts that hold the generator to

the flywheel housing. Install the adapter
screen and cover for the fan.
5. Install the
four bolts that hold the generator

to the mount or rail.
r37
MARINE GEAR REMOVAL

REMOVE MARINE GEAR
1-3300
l.
Remove oil from marine gear housing.
2.
Remove the coolant from the ensine.
3. Remove the water lines
from marine gear oil
cooler.
4. Remove the output shaft from
5.
flange.
Disconnect the oil line (l) for sump pump

from bottom of marine sear.
the boltb (4) that hold marine gear

to flywheel housing. Fasten a hoist to marine gear. Remove water lines (2) and (3).
6. Remove
bolts (5) and shims that fasten marine gear to support rails.
7. Remove
NOTE: Keep the shims with their respective location for installation.
8. Move
the marine gear from flywheel hous-
ing until drive spider is away from drive

ring. Remove the marine gear. Weight is
from 4100 lb.(1860 kg) for D379,to 60001b.
(2722 kg) on D398 and D399.
9.
Remove bolts
that hold drive ring
to
flywheel and remove drive ring (6).
DlSASSEMBLY AND ASSEMBLYF
MARIN E GEAR INSTAL LATION

INSTALL MARINE GEAR
12-3300
(l)
l.
Install the drive ring
2.
Fasten a hoist and install marine gear in

alignment with engine. Be sure the rubber
blocks (2) are on the drive spider.
a
J.
Move the marine gear to the engine. Make

the drive spider in alignment with drive ring.
on the flywheel.
NOTE: The cover on top of marine gear can

if necessary.
be
removed to check alignment
4. Install the bolts that hold marine gear to

flywheel housing.
Install original shims between mane
gear
brackets and support rails. Install bolts and
lockwashers. See LUBRICATION AND

MAINTENANCE.
Install the oil lines to marine gear oil cooler

and sump pump.
7. Fill marine gear with lubricant as neeJ::

Fill engine with coolant to correct ier':,
't."

Desmontaje y Montaje D 379398 y 399

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Desmontaje y Montaje D 379398 y 399

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SERVICE MANUAL

DISASSEM BLY AN D ASSEM BLY

D379, D39EI A, DSs|s|

D379: 688254O-UP AND 6981227-UP

D379, D398, D399 INDUSTRIAL AND MARINE ENGINES

DISASSEMBLY AND ASSEMBLY

Fuel Injection Pump Housing, Safety Shutoff, Governor,

Governor, Disassemble &Assemble

Crankshaft Front Seal Ring and Thrower

Oil Filter Housing

Oil Pressure Regulatng Valve ..

AITD MARINE ENGINES

Safety Shutoff, Disassemble & Assemble

Sea Water Purnp

rurbocharier r-uu'""ii "j;; ::::::.::::.::::

D379, D398, D399 INDUSTRIAL AND MARINE ENGINES

Fuel Transfer Pump

Fuel Transfer Pump, Disassemble &

Fuel Priming Pump

Fuel Priming Pump, Disassemble &

Water Temperature Regulators

Fuel Filter Housing

Oil Filter Housing

Sea Water Pumo

Sea Water Pump, Disassemble

Vibration Damper (D398 & D399 Enginesl

Crankshaft Front Seal Ring and Thrower

Accessory Drive Housing

Accessory Drive Gears

Oil Pressure Regulating Valve

Oil Pressure Regulating Valve, Disassemble &

OTHER NEEDED OPERATIONS

Oil Pump, Disassemble & Assemble

Engine Oil Cooler

Fresh Water PumD

Fresh Water Pump, Disassemble & Assemble

Prelubrication Oil Pump (D399 Engine)

Prelubrication Oil Pump (D399 Enginel,

Connecting Rod Bearings

Crankshaft Main Bearings

Piston Cooling Tubes

Oil Pan Base

Fuel Ratio Control with Override

Fuel Ratio Control with Override,

Governor, Disassemble & Assemble

Safety Shutoff. Diassemble & Assemble

Fuel Injection Pumps

Fuel Injection Lines

Exhaust Manifolds (lndstrial Enginesl

Exhaust Manifolds (Marine Enginesl

Fuel Injection Pump Housing, Safety

Disassemble & Assemble

AND MARTNE ENGTNEs

Fuel Injection Pump Housing, Disassemble

Governor Drive Housing, Disassemble &

Fuel Injection Valves

Rocker Shafts and Push Rods

Flocker Shafts, Disassemble & Assemble

OTHER NEEDED OPERATIONS

t'rstons, Dsassemble & Assemble

urbocharger Lubrication Valve

Turbocharger Lubrcation Valve,

Air Cleaner Housings

Turbocharger Heat Shietd