Waukesha 570 and 884 Engine

⚠ Distributor must be retimed whenever points are removed or reset.

Tools: thin paper or cellophane

1. Turn engine until cylinder No. 1 is at TDC compression.
2. Align crankshaft pulley notch with timing pin.
3. Insert distributor with cap clamps and primary lead convenient.
4. Remove distributor cap.
5. Place thin paper between breaker points.
6. Turn distributor body counterclockwise until paper releases.
7. Lock in position.
8. Replace cap and connect wires per diagram.

⚠ Magnetos are not interchangeable between banks.

1. Turn engine until cylinder No. 1 is at TDC compression.
2. Align D.C. LEFT bank marking with timing pointer.
3. Insert lead wire into tower No. 1 of left magneto.
4. Turn left magneto drive shaft clockwise until spark occurs.
5. Hold position.
6. Insert left magneto into engine.
7. Connect remaining lead wires per wiring diagram.

⚠ Magnetos are not interchangeable between banks.

1. Turn engine until cylinder No. 2 is at TDC compression.
2. Align D.C. RIGHT bank marking with timing pointer.
3. Insert lead wire into tower No. 1 of right magneto.
4. Turn right magneto drive shaft counterclockwise until spark occurs.
5. Hold position.
6. Insert right magneto into crankcase cover hole.
7. Lock magneto with clamps and nuts.

⚠ Never adjust valve clearances without loosening and retightening the adjusting screw lock nut.

Tools: feeler gauge

1. Stop engine and allow to cool to room temperature.
2. Remove cylinder head cover.
3. Lubricate valve stems with light engine oil.
4. Rotate engine until No. 1 piston is at TDC compression.
5. Loosen rocker arm lock nut and adjust with feeler gauge.
6. Tighten lock nut and recheck clearance.
7. Follow firing order for remaining valves.

1. Drain system and measure water volume.
2. Replace half of measured volume with fresh water.
3. Boil other half and add washing soda until no more dissolves.
4. Add hot soda solution to cooling system.
5. Operate engine normally for 24 hours.
6. Drain, flush, refill with clean water plus soluble oil.

⚠ Replace all fan belts at the same time.

1. Loosen fan-hub nut behind fan-support bracket.
2. Lower fan-hub and pulley with fan adjustment screw.
3. Slip new belts over pulley.
4. Take up adjusting screw until belts have tension.
5. Retighten fan-hub retaining nut.

⚠ Thermostat damaged by corrosion is not repairable and must be replaced.

1. Remove by-pass line hose.
2. Remove radiator water inlet connection hose.
3. Remove capscrews securing thermostat housing.
4. Remove thermostat.

Tools: thermometer

1. Fill container with water to cover thermostat.
2. Suspend thermometer with bulb off bottom.
3. Heat water to 160°F range.
4. Observe start opening at 157°-162°F.
5. Check fully open about 182°F.
6. Lift into cooler air and check closing.

⚠ New bushings should be used whenever the pump is disassembled.

Tools: arbor press, feeler gauge, straight edge

1. Press pump gear on drive shaft with Woodruff key.
2. Lock pump gear with snap ring.
3. Insert drive shaft through pump body.
4. Check pump gear end clearance with feeler gauge and straight edge.
5. Press drive gear on with Woodruff key.
6. Check clearance between pump and drive gear.
7. Press roll pin through drive gear hub and drive shaft.
8. Install idler pump gear with oil holes toward drive gear end.

Tools: piston ring expander

1. Install oil control ring in bottom groove with sharp edge at bottom.
2. Install middle compression rings with side stamped TOP facing up.
3. Install top compression ring with side stamped TOP facing up.
4. Use piston ring expander to spread gap only enough to slide rings in place.

Tools: ring compressor, heat source

1. Heat piston to 165°F.
2. Locate piston arrow and connecting rod in original relative position.
3. Insert piston pin with palm push or very light tap.
4. Coat cylinder wall with clean engine oil.
5. Guide assembly into place using piston ring compressor.
6. Check connecting rod chamfer faces adjacent connecting rod.
7. Face piston arrow in direction of crankshaft rotation.

⚠ Use only specified cylinder head gaskets.

Tools: torque wrench

1. Replace valves, valve springs, and retaining washers or rotators.
2. Clean upper part of cylinder liner and remove carbon.
3. Place new cylinder head gasket on flange.
4. Replace head, push rods, and rocker arm shaft assembly.
5. Tighten cylinder head stud nuts finger tight.
6. Replace intake and exhaust manifold gaskets and manifolds.
7. Tighten manifold and cylinder head stud nuts to final torque in sequence.
8. Re-torque after first start and approximately 50 hours with engine warm.