TM-9-2815-224-34-P
T M
9 - 2 8 1 5 - 2 2 4 - 3 4 & P
DIRECT SUPPORT AND
GENERAL SUPPORT
MAINTENACE MANUAL
(INCLUDING REPAIR PARTS AND
SPECIAL TOOLS LIST)
ENGINE, DIESEL:
8-CYLINDER
TURBOCHARGED,
DETROIT DIESEL
CORPORATION
MODEL 8V92TA
NSN 2815-01-257-3879
Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
JANUARY 1988
TM9-2815-224-34&P
WARNING
CARBON MONOXIDE (EXHAUST GAS) CAN CAUSE DEATH.
Carbon monoxide is without color or smell, but can cause death, Breathing air
with carbon monoxide produces symptoms of headache, dizziness, loss of
muscular control, a sleepy feeling, and coma. Brain damage or death can result
from heavy exposure. Carbon monoxide occurs in the exhaust fumes of
fuel-burning heaters and internal combustion engines. Carbon monoxide can
become dangerously concentrated under conditions of no ventilation.
Precautions must be followed to ensure crew safety when the personnel heater
or engine of any vehicle is operated for any purpose.
1. DO NOT operate personnel heater or engine of vehicle in a closed place
without proper ventilation.
2. DO NOT drive any vehicle with inspection plates, cover plates, or engine
compartment covers removed unless necessary for maintenance purposes.
3. BE ALERT at all times during vehicle operation for exhaust odors and
exposure symptoms, If either are present, IMMEDIATELY VENTILATE
personnel compartments. If symptoms persist, remove affected crew to fresh
air and keep warm. DO NOT PERMIT PHYSICAL EXERCISE. If necessary, give
artificial respiration and get immediate medical attention. For artificial
respiration, refer to FM 21-11.
4. BE AWARE that the gas particulate filter unit or the field protection mask for
nuclear-biological-chemical protection WILL NOT offer safety from carbon
monoxide poisoning.
THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD
VENTILATION.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
WARNING
Never use the parking brake for normal braking or wheels will lock up causing
severe skid. Skidding vehicle could result in serious injury or death.
.
WARNING
Fuel is very flammable and can explode easily. TO avoid serious irjury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of vehicle.
WARNING
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry before
working around vehicle. Jewelry can catch on equipment and cause Injury, or
may short across an electrical circuit and cause severe burns or electrical shock.
a
TM9-2815-224-34&P
WARNING
The radiator is very hot and pressurized during vehicle operation. Let radiator
cool before removing cap. Failure to do so can result in serious burns.
WARNING
The exhaust pipe and muffler can become very hot during vehicle operation. Be
careful not to touch these parts with bare hands, or allow body to come in
contact with pipe or muffler. Exhaust system parts can become hot enough to
cause serious burns.
WARNING
Always use seatbelts when operating vehicle. Failure to use seatbelt can result in
serious injury in case of accident.
WARNING
When working inside the vehicle with power off, be sure to ground every
capacitor likely to hold a dangerous voltage potential.
Be careful when working on or with electrical equipment. Do not be misled by
the term "low voltage”. Voltages as low as 50 volts may cause death. For
artificial respiration, refer to FM 21-11.
WARNING
Be careful not to short out battery terminals. Do not smoke or use open flame
near batteries. Batteries may explode from a spark. Battery acid is harmful to
skin and eyes.
Starting fluid is toxic and flammable. Do not store in cab and do not breathe
fumes. Do not puncture or burn containers. Dispose of container following
manufacturer’s recommendations on the container.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment, goggles,
shield, and gloves.
WARNING
After Nuclear, Biological, or Chemical (NBC) exposure of vehicle, all air filters
shall be handled with extreme caution. Unprotected personnel can experience
injury or death if residual toxic agents or radioactive material are present. If
vehicle is exposed to chemical or biological agents, servicing personnel shall wear
protective mask, hood, protective overgarments, and chemical protective gloves
and boots in accordance with TM 10-277. All contaminated air filters shall be
placed in double-lined plastic bags and moved swiftly to a segregation area away
from the worksite. The same procedure applies for radioactive dust
contamination. The Company NBC team should measure the radiation prior to
filter removal to determine the extent of safety procedures required per the NBC
Annex to the unit Standard Operating Procedures (SOP). The segregation area in
which the contaminated air filters are temporarily stored shall be marked with
appropriate NBC placards. Final disposal of contaminated air filters shall be in
accordance with local SOP. Decontamination operation shall be in accordance
with TM 3-220 and local SOP.
b
TM 9-2815-224-34&P
C4
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 1 October, 2004
NO. 4
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE MANUAL
(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)
ENGINE, DIESEL: 8-CYLINDER, TURBOCHARGED,
DETROIT DIESEL CORPORATION
MODEL 8V92TA NSN 2815-01-257-3879
Approved for public release; distribution is unlimited.
TM 9-2815-224-34&P, January 1988, is changed as follows:
1. Remove old pages and insert new pages as indicated below.
2. New or changed material is indicated by a vertical bar in the margin of the page.
3. Minor changes to illustrations are indicated by a miniature pointing hand.
4. Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the
illustration.
Remove Pages
A and B
C/(D blank)
iii/(iv blank)
2-1 and 2-2
3-41 and 3-42
5-3 and 5-4
15-32.1 and 15-32.2
A-1 and A2/(B1 thru I-65 deleted)
C-3 and C-4
Insert Pages
A and B
C/(D blank)
iii/(iv blank)
2-1 and 2-2
3-41 and 3-42
5-3 and 5-4
15-32.1 and 15-32.2
A-1 and A2/(B1 thru B-65 deleted)
C-3 and C-4
File this change sheet in front of the publication for reference purposes.
1 of 2
By Order of the Secretary of the Army:
PETER J. SCHOOMAKER
General, United States Army
Chief of Staff
Official:
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
0422213
DISTRIBUTION: To be distributed in accordance with the Initial Distribution Number (IDN) 380415,
requirements for TM 9-2815-224-34&P.
2 of 2
TM 9-2815-224-34&P
C3
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 15 Febrary 2002
NO. 3
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE MANUAL
(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)
ENGINE, DIESEL: 8-CYLINDER, TURBOCHARGED,
DETROIT DIESEL CORPORATION
MODEL 8V92TA NSN 2815-01-257-3879
Approved for public release; distribution is unlimited.
TM 9-2815-224-34&P, January 1988, is changed as follows:
1. Remove old pages and insert new pages as indicated below.
2. New or changed material is indicated by a vertical bar in the margin of the page.
3. Minor changes to illustrations are indicated by a miniature pointing hand.
4. Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the
illustration.
5. Changes on cover are: Deleted destruction notice, changed distribution statement, deleted Appendix B
tab, changed title, and changed NSN.
Remove Pages
i -- ii
19-5 -- 19-8
Insert Pages
i -- ii
19-5 -- 19-8
File this change sheet in front of the publication for reference purposes.
1 of 1
By Order of the Secretary of the Army:
Official:
ERIC K. SHINSEKI
General, United States Army
Chief of Staff
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
0118704
DISTRIBUTION: To be distributed in accordance with the Initial Distribution Number (IDN) 380415,
requirements for TM 9-2815-224-34&P.
TM 9-2815-224-34&P
C2
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 2
Washington, D. C., 15 December 1998
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE MANUAL
(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)
ENGINE, DIESEL: 8-CYLINDER, TURBOCHARGED,
DETROIT DIESEL CORPORATION
MODEL 8V92TA NSN 2815-01-257-3879
Approved for public release; distribution is unlimited.
TM 9-2815-22434&P, 20 January 1988, is changed as follows:
1.
Remove old pages and insert new pages as indicated below.
2.
New or changed material is indicated by a vertical bar in the margin of the page.
3.
Minor changes to illustrations are indicated by a miniature pointing hand.
4.
Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the
illustration,
5.
Changes on cover are: Deleted destruction notice, changed distribution statement, deleted Appendix B
tab, changed title, and changed NSN.
Remove Pages
i thru iv
1-7 and 1-8
2-7 and 2-8
2-13 and 2-14
2-15/(2-16 blank)
3-3 and 3-4
3-11 and 3-12
3-23 thru 3-28
3-33 thru 3-54
4-3 thru 4-12
none
4-27 and 4-28
5-3 and 5-4
5-9 and 5-10
5-17 and 5-18
none
7-7 and 7-12
11-1 and 11-14
12-9 and 12-10
Insert Pages
i thru iii/iv blank)
1-7 and 1-8
2-7 and 2-8
2-13 and 2-14
2-15/(2-16 blank)
3-3 and 3-4
3-11 and 3-12
3-23 thru 3-28
3-33 thru 3-54
4-3 thru 4-12
4-26.1/(4-26.2 blank)
4-27 and 4-28
5-3 and 5-4
5-9 and 5-10
5-17 and 5-18
5-18.1 thru 5-18.4
7-7 and 7-12
11-1 and 11-14
12-9 and 12-10
1 of 2
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Insert Pages
12-15 thru 12-22
12-29 and 12-30
none
13-37/(12-38 blank)
14-1 and 14-2
none
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14-19 thru 14-24
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none
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19-19 thru 19-22
none
19-23 thru 19-26
19-31 and 19-32
C-3 and C-4
A-1 and A-2
D-1 and D-2
none
DA 2028 sample F & B
DA 2028 F & B
DA 2028 F & B
DA 2028 F & B
Cover
12-15 thru 12-22
12-29 and 12-30
12-30.1/(12-30.2 blank)
12-37 and 12-38
14-1 and 14-2
14-14.1/(14.2 blank)
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14-25 and 14-26
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14-35 and 14-36
14-36.1/(14.36.2 blank)
14-37 thru 14-55/(14-56 blank)
15-1 and 15-2
15-21 and 15-22
15-22.1 thru 15-22.5/(15-22.6 blank)
15-27 thru 15-32
15-32.1 and 15-32.2
15-35 thru 15-41/(15-42 blank)
16-1 thru 16-4
17-1 and 17-2
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18-1 thru 18-4
18-6.1/(18-6.2 blank)
18-7 and 18-8
18-11 and 18-12
19-1 thru 19-10
19-13 and 19-14
19-19 thru 19-22
19-22.1 thru 19-22.4
19-23 thru 19-26
19-31 and 19-32
C-3 and C-4
A-1 and A-2/(B-1 thru I-65 deleted)
D-1 and D-2
D-7 and D-8
DA 2028 sample F & B
DA 2028 F & B
DA 2028 F & B
DA 2028 F & B
Cover
File this change sheet in front of the publication for reference purposes.
2 of 2
By Order of the Secretary of the Army:
DENNIS J. RElMER
General, United States Army
Chief of Staff
Administrative Assistant to the
Secretary of the Army
05633
DISTRIBUTION: To be distributed in accordance with the Initial Distribution
Number (IDN) 380415, requirements for TM 9-2815-224-34&P.
TM 9-2815-224-34&P
C1
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 15 April 1989
CHANGE
NO.1
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE MANUAL
(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)
ENGINE, DIESEL: 8-CYLINDER, TURBOCHARGED,
DETROIT DIESEL ALLISON
MODEL 8V92TA NSN 2815-01-132-1417
TM 9-2815-224-34&P, 20 January 1988, is changed as follows:
1. Remove old pages and insert new pages as indicated below.
2. New or changed material is indicated by a vertical bar in the margin of the page.
3. Minor changes to illustrations are indicated by a miniature pointing hand,.
4. Illustrations that are new or that have major revisions are indicated by a
vertical bar adjacent to the illustration identification number.
Remove Pages
Insert Pages
iii and iv
iii and iv
7-45 and 7-46
7-45 and 7-46
7-49 and 7-50
7-49 and 7-50
19-5 and 19-6
19-5 and 19-6
19-23 and 19-24
19-23 and 19-24
19-29 and 19-30
19-29 and 19-30
D-1 and D-2
D-1 and D-2
D-5/(D-6 blank)
D-5 and D-6
File this change sheet in front of the publication for reference purposes.
By Order of the Secretary of the Army:
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
R.L. DILWORTH
Brigadier General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-38-R, Direct Support and General Support
maintenance requirements for Engine, Diesel, 8-Cylinder, Turbocharged, Detroit Allison Model
8V92T.
TM 9-2815-224-34&P
INSERT LATEST UPDATED PAGES/WORK PACKAGES, DESTROY SUPERSEDED DATE
LIST OF EFFECTIVE PAGES/WORK PACKAGES
NOTE:
The portion of text affected by the updates is indicated by a vertical line in the outer
margins of the page. Updates to illustrations are indicated by miniature pointing
hands. Updates to wiring diagrams are indicated by shaded areas.
Dates of issue for original and updated pages/work packages are:
Original . . . 0 . . . . . . . 20January 1988
Change . . . 1 . . . . . . . 15 April 1989
Change . . . 2 . . . . . . . 15 December 1998
Change . . . 3 . . . . . . . 15 February 2002
Change . . . 4 . . . . . . . 1 October 2004
TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 554
CONSISTING OF THE FOLLOWING:
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No.
*Change
No.
Page/WP
No.
*Change
No.
Page/WP
No.
*Change
No.
Cover
0
3-13 -- 3-22
0
4-4 -- 4-5
0
Blank
0
3-23
2
4-6 -- 4-7
2
a -- b
0
3-24
0
4-8
0
i
3
3-25 -- 3-28
2
4-9
2
ii
0
3-29 -- 3-33
0
4-10
0
iii
4
3-34 -- 3-35
2
4-11
2
iv Blank
4
3-36
0
4-12 -- 4-26
0
v
0
3-37 -- 3-38
2
4-26.1
2
vi Blank
0
3-39
0
4-26.2 Blank
2
1-1 -- 1-6
0
3-40
2
4-27
2
1-7 -- 1-8
2
3-41
4
4-28 -- 4-32
0
2-1
0
3-42
0
5-1 -- 5-2
0
2-2
4
3-43 -- 3-45
2
5-3
4
2-3 -- 2-6
0
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0
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3-48
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0
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2
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3-52
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3-12
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5-18
2
0
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2
3-53
2
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0
2
3-54 -- 3-62
0
7-1 -- 7-7
0
0
4-1 -- 4-2
0
7-8 -- 7-9
2
2
4-3
3
7-10
0
* Zero in this column indicates an original page.
A
TM 9-2815-224-34&P
INSERT LATEST UPDATED PAGES/WORK PACKAGES, DESTROY SUPERSEDED DATE
Page/WP
No.
*Change
No.
Page/WP
No.
*Change
No.
Page/WP
No.
*Change
No.
7-11
2
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2
15-35 -- 15-41
2
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1
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0
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2
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2
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0
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2
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4
19-20
0
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2
15-33 -- 15-34
0
19-21 -- 19-22
2
* Zero in this column indicates an original page.
B
TM 9-2815-224-34&P
INSERT LATEST UPDATED PAGES/WORK PACKAGES, DESTROY SUPERSEDED DATE
Page/WP
No.
*Change
No.
Page/WP
No.
*Change
No.
Page/WP
No.
*Change
No.
D-1
2
D-2 -- D-5
0
D-6 Blank
0
D-7 -- D-8
2
4
E-1 -- E-3
0
C-4
0
E-4 Blank
0
0
C-5
2
Index 1 -- Index 6
0
0
C-6 Blank
2
19-22.1 -- 19-22.4
2
A-2
4
19-23
0
19-24 -- 19-26
2
B-1 thru B-65
Deleted
2
19-27 -- 19-31
0
C-1
0
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2
C-2
0
C-3
19-33
0
19-34 Blank
A-1
* Zero in this column indicates an original page.
C/(D blank)
C
TM 9-2815-224-34&P
TECHNICAL MANUAL
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington, DC, 20 January 1988
No. 9-2815-224-34&P
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
ENGINE, DIESEL: 8-CYLINDER, TURBOCHARGED
DETROIT DIESEL CORPORATION MODEL 8V92TA
NSN 2815-01-257-3879
Approved for public release; distribution is unlimited.
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this publication. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment
Technical Publications), through the Internet, on the Army Electronic Product Support (AEPS) Web site.
The Internet address is http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACCESS
REQUEST FORM.” The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the
AEPS. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond
quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax, or e-mail
your letter or DA Form 2028 direct to: AMSTA--LC--CI/TECH PUBS, TACOM--RI, 1Rock Island Arsenal,
Rock Island, IL 61299-7630. The e-mail address is [email protected] The fax number
is DSN 793-0726 or Commercial (309) 782-0726.
M983 with crane and M985E1 without winch are no longer in the fleet. Ignore all references to these
vehicles. The M984E1 and M984A1 are the same vehicle. All references to M984E1 shall be interpreted as
the M984A1 model.
Repair Parts and Special Tools List for the engine, Diesel: 8-Cylinder, Turbocharged Detroit Diesel
Corporation Model 8V92TA (NSN 2815-01-257-3879) can be found in TM 9-2320-279-24P.
TABLE OF CONTENTS
CHAPTER 1
Section I
Section II
Section III
CHAPTER 2
Section I
Section II
Section III
Section IV
Section V
CHAPTER 3
Section I
Section II
Section III
Page
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii
INTRODUCTION
..........................................................
1-1
Equipment and Maintenance Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
Equipment Description
....................................................
1-3
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7
MAINTENANCE INSTRUCTIONS
..........................................
2-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Organization of Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-1
2-1
2-4
Troubleshooting
2-7
...........................................................
ENGINE BLOCK AND CYLINDER HEAD MAINTENANCE
..................
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change 3
3-1
3-1
3-2
3-38
i
TM9-2815-224-34&P
Page
CHAPTER 4 CRANKSHAFT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-1
Section I Introduction ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4-1
Section II Crankshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . ., . . . . . . . . . . . . . . . . . . . ...4-1
CHAPTER 5 FLEXPLATE AND FLYWHEEL HOUSING MAINTENANCE . . . . . . . . . . . . . . . . . . . 5-1
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-1
Section II Flexplate and Flywheel Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHAPTER 6 PISTON AND CONNECTING ROD MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6-1
Section II Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-1
CHAPTER 7 VALVE MECHANISM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7-1
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7-1
Section II Valve Mechanisms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7-1
CHAPTER 8 0IL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8-1
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..8-1
Section II Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
CHAPTER 9 EXHAUST MANIFOLD MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9-1
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..9-1
Section II Exhaust Manifold Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9-1
CHAPTER 10 BLOWER AND WATER PUMP DRIVES MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 10-1
Section I Introduction . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . 10-1
Section II Blower Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10-1
Section III Water Pump Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..10-12
CHAPTER 11 ENGINE BRAKE RETARDER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..11-1
Section II Engine Brake Retarder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
CHAPTER 12 FUEL INJECTOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...12-1
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...12-1
Section II Fuel Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
CHAPTER 13 FUEL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...13-1
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..13-1
Section II Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..13-1
CHAPTER 14 BLOWER AND TURBOCHARGER MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...14-1
Section II Blower Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..14-1
Section III Turbocharger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...14-36
CHAPTER 15 ENGINE GOVERNOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...15-1
Section II Engine Governor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...15-1
ii
TM 9-2815-224-34&P
CHAPTER 16
Section I
Section II
CHAPTER 17
Section I
Section II
CHAPTER 18
Section I
Section II
CHAPTER 19
Section I
Section II
APPENDIXES
AFTERCOOLER MAINTENANCE
..........................................
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aftercooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN CLUTCH MAINTENANCE
............................................
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TUNE-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Tune-Up Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16-1
16-1
16-1
17-1
17-1
17-1
18-1
18-1
18-1
19-1
19-1
19-1
A
REFERENCES
A-1
B
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deleted
C
Section I
Section II
D
Section I
Section II
Section III
E
............................................................
EXPENDABLE SUPPLIES AND MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expendable Supplies and Materials List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ILLUSTRATED LIST OF MANUFACTURED ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufactured Items Part Number Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufactured Items Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-1
C-1
C-2
D-1
D-1
D-1
D-2
E-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 1
Figure
1-1
D-1
D-2
D-3
D-4
D-5
D-6
D-7
D-8
LIST OF ILLUSTRATIONS
Title
Page
Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Bearing Shell Remover (P/N 2BG623) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Lifting Eyes (P/N 2BH944) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Retaining Ring Pliers (P/N 2BH945) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Turbocharger Holding Fixture (P/N 2SK742) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
Hose (P/N 21021FX24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
Wire Assembly (P/N 25351FX7W) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
Wear Sleeve Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
Feeler Gage [0.004 in.(0.102 mm), 0.005 in. (0.127 mm), 0.017 in. (0.432 mm)] . . . . . . . . . . . D-9
Change 4
iii/(iv blank)
TM9-2815-224-34&P
HOW TO USE THIS MANUAL
This manual is designed to help maintain the M977 series 8V92TA Diesel Engine. Listed below are some of
the special features which have been put in to help locate and use needed information.
●
The front cover index provides a quick reference to chapters and sections that will be used often.
●
The appendixes are located at the end of the manual. They contain a reference guide to other
manuals, a list of expendable supplies and materials, a manufactured items list, and tables for torque
values.
●
Subject headings and certain other essential information are printed in bold type throughout the
manual to make them more visible.
●
The maintenance tasks describe what has to be done to the vehicle before starting the task, and
what must be done to return the vehicle to operating condition after the task is finished.
●
Instructions are provided in paragraph 2-8 for a complete teardown/buildup of the engine in
disassembly/reassembly sequence.
●
Certain parts with wear limitations may be checked by referring to the Cleaning/Inspection portion
of the task If the measurement falls within wear limits, it may ‘not be necessary to remove/replace.
The manual is divided into chapters containing direct support and general support maintenance
procedures. These procedures describe a number of things such as:
What will be needed to do the job.
If any assistance will be needed.
Important safety y precautions.
In addition to the text, there will be an exploded-view illustration of most steps. This illustration is keyed
to the text and shows how to take the part off and put it on. Cleaning and inspection procedures are also
included when required.
FOLLOW THESE GUIDELINES WHEN USING THIS MANUAL:
●
Become familiar with the entire maintenance procedure before beginning a maintenance task.
• Read all WARNINGS and CAUTIONS before performing any procedures.
v/(vi blank)
TM9-2815-224-34&P
CHAPTER 1
INTRODUCTION
Para
Contents
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Maintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Destruction of Army Material to Prevent Enemy Use...... . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Nomenclature Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Reporting Equipment Improvement Recommendations (EAR) . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Equipment Improvement Report and Maintenance Digest (EIR MD) and Equipment
Improvement Report and Maintenance Summary (EIR MS) . . . . . . . . . . . . . . . . . . . . . . . 1-7
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Metric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Equipment Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Location and Description of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Equipment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Section 1.
Page
1-1
1-1
1-1
1-2
1-2
1-2
1-2
1-2
1-2
1-3
1-3
1-7
1-7
EQUIPMENT AND MAINTENANCE REPORTS
Maintenance Information
11-1. SCOPE. ]The purpose of this chapter is to provide general information, equipment description, and
principles of operation for the M977 series 8V92TA diesel engine.
a. Type of Manual. Direct Support and General Support Maintenance Manual with Repair Partsand
Special Tools List (RPSTL) for the M977 series Heavy Expanded Mobility Tactical Truck (HEMTT) 8V92TA
diesel engine.
b. Model Number and Equipment Name. 8V92TA Diesel Engine.
C. Purpose of Equipnent. The 8V92TA engine powers the M977 series vehicles used bythe U.S.
Army.
d. Manual Content. Thismanual provides Direct Support and General Support Maintenance
instructions for the M977 series 8V92TA engine. These instructions include procedures for disassembly,
cleaning, repair, test, and adjustment as authorized by the Maintenance Allocation Chart. The procedures
covered are beyond the scope of tools, equipment, and supplies normally available to operators and
organizational maintenance personnel.
This manual also includes the Repair Parts and Special Tools List (RPSTL) for the M977 series 8V92TA
engine. Direct Support and General Support Maintenance personnel will request repair parts as necessary
from this RPSTL. The Source, Maintenance , and Recoverability (SMR) codes assigned to each part govern
the requisition and disposition of the part. In addition to repair parts, all special tools used in engine
maintenance are listed. These special tools are all tools required by the maintenance instructions which are
not in U.S. Army supply catalogs for shop equipment and tool sets.
1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS. Department of Army forms and
procedures used for equipment maintenance will be as specified in the latest edition of DA PAM 738-750,
The Army Maintenance Management System (TAMMS),
[ 1-3. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE. ICommand decision,
according to the tactical situation, will determine when the destruction of the M977 series 8V92TA engine
will be accomplished. A destruction plan will be prepared by the using organization unless one has been
prepared by a higher authority. For general destruction procedures for this equipment, refer to
TM 750-244-6, Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use (U.S.
Army Tank-Automotive Command).
1-1
TM9-2815-224-34&P
Maintenance Information (Cont)
I 1-4. PREPARATION FOR STORAGE OR SHIPMENT. Instructions for preparation for storage or
shipment are provided in TM 9-2320-279-20.
I 1-5. NOMENCLATURE CROSS-REFERENCE. ] Table 1-1 lists the nomenclature cross-references used
in this manual.
Table 1-1.
Nomenclature Cross-Reference
Common Name
Official Nomenclature
Snap ring
Engine coolant
Cold start system
Jake brake, Jacobs® brake
Retaining ring
Antifreeze, ethylene glycol mixture
Ether quick-start system
Engine retarder
1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS EIR. If any M977 series
8V92TA engine needs improvement, let us know. Send us an EIR. The user is the only one who can tell us
how the equipment might be improved. Let us know what is not liked about the design. Put it on an
SF 368 (Quality Deficiency Report). Mail it to: Commander, U.S. Army TAnk-Automotive Command, ATTN:
AMSTA-QRT, Warren, MI 48397-5000. We’ll send a reply.
1-7. EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE DIGEST (EIR MD) AND]
, EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE SUMMARY (EIR MS).] The
quarterly Equipment Improvement Report and Maintenance Digest, TB 43-0001-39 series, contains
valuable field information on the equipment covered in this manual. The information in the TB 43-0001-39
series is compiled from some of the Quality Deficiency Reports that have been prepared on the vehicles
covered in this manual. Many of these articles result from comments, suggestions, and improvement
recommendations that you submitted to the EIR program. The TB 43-0001-39 series contains information
on equipment improvements, minor alterations, proposed Modification Work Orders (MWO’S), warranties (if
applicable), actions taken on some of the DA Form 2028’s (Recommended Changes to Publications), and
advance information on proposed changes that may affect this manual. In addition, the more maintenance
significant articles, including minor alterations, field-fixes, etc., that have a more permanent and
continuing need in the field are republished in the Equipment Improvement Report and Maintenance
Summary (EIR MS) for TACOM Equipment (TM 43-1043). Refer to both of these publications
(TB 43-0001-39 series and TM 43-1043) periodically, especially the TB 43-0001-39 series, for the most
current and authoritative information on this equipment. The information will help to do a better job and
will advise to the latest changes to this manual. Also refer to DA Pam 310-1, Consolidated Index of Army
Publications and Blank Forms, and Appendix A, References, of this manual.
I 1-8. WARRANTY INFORMATION. I The M977 series 8V92TA engine is warranted by Oshkosh Truck
Corporation, for 18 months or 12,000 miles, (19 308 km), whichever comes first. For complete information
covering this warranty, refer to Warranty Technical Bulletin, TB 9-2300-295-15/19. Warranty starts on the
date found in block 23, DA form 2408-9, in the logbook. Report all defects in material or workmanship to
your supervisor who will take appropriate action.
1-9. METRIC SYSTEM. The equipment described herein contains metric components and requires
metric common and special tools; therefore, metric units in addition to English units will be used
throughout this manual. An English to metric conversion table is included as the last page of this manual
inside the back cover.
1-2
TM9-2815-224-34&P
Section II.
EQUIPMENT DESCRIPTION
Equipment Information
I 1-10. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES. The M977 series
8V92TA engine is an eight-cylinder, V-Type, two-cycle, turbocharged diesel engine. Refer to
TM 9-2320-279-10 for equipment characteristics, capabilities, and features.
I 1-11. LOCATION AND DESCRIPTION OF COMPONENTS. I
a. Turbocharger. (See fig. 1-1) Mounted on top of blower. Designed to increase overall efficiency of
engine by delivering high pressure air through engine blower to engine cylinders.
b. Governor. (See fig. l-l) Mounted on front end of blower and driven by one of blower rotors. Used
to control engine idle speed and limit maximum operating speed of engine.
e. Fan Clutch. (See fig. 1-1) Mounted on front of engine behind fan. Is controlled by temperature
valve and automatically engages fan to lower engine temperature.
d. Water Pump. (See fig. l-l) Mounted on front engine cover and driven by camshaft gear. It
circulates engine coolant through cylinder block, cylinder heads, radiator and oil cooler.
e. Oil Pan. (See fig. 1-1) Mounted on bottom of cylinder block. It provides a reservoir for engine oil,
f. Oil Filter. (See fig. 1-1) Mounted on lower right-hand side of cylinder block just behind oil cooler.
Filters out impurities as oil is forced through element.
g. Exhaust Manifold. (See fig. 1-1) Screwed to cylinder head. Routes by-product gases expelled from
engine to attached exhaust piping.
h. Valve Rocker Covers. (See fig. 1-1) Completely encloses valve and injector rocker arm
compartment at the top of cylinder head.
i. Fuel Pump. (See fig. 1-1) Attached to governor housing and driven off right-hand blower rotor. It
transfers fuel (diesel) from supply tank to fuel injectors.
j. Blower. (See fig. 1-1) Screwed to top of cylinder block. Provides continuous and uniform supply of
air to engine.
k. Engine Brake. (See fig. 1-1) Located on top of cylinder head, under valve rocker cover. Works to
slow engine speed to help slow truck.
I. cylinder Head. (See fig. 1-1) One screwed on each cylinder bank and contains exhaust valves, fuel
injectors and valve and injector operating mechanism.
m. Cylinder Block. (See fig. 1-1) Main structural part of engine. Provides rigidity and strength and
ensures alinement of block bores and bearings under load.
n. Oil Pump. (See fig. 1-1) Mounted on bottom of cylinder block, inside oil pan. Pumps oil from oil
pan into filter and various cavities and passages of engine to provide lubrication and cooling.
1-3
TM9-2815-224-34&P
Equipment Information (Cont)
[ 1-11.
LOCATION AND DESCRIPTION OF COMPONENTS (CONT). [
TA357823
Figure 1-1. Engine Components.
(Sheet 1 of 3)
1-4
TM9-2815-224-34&P
Equipment Information (Cont)
TA357065
Figure 1-1. En ine Components (Cent).
sheet 2 of 3)
1-5
TM9-2815-224-34&P
Equipment Information (Cont)
I 1-11.
LOCATION AND DESCRIPTION OF COMPONENTS (CONT). I
Figure 1-1. Engine Components (Cent).
(Sheet 3 of 3)
1-6
TM 9-2815-224-34&P
Equipment Information (Cont)
1-12. EQUIPMENT DATA.
GENERAL SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel, two-cycle
Detroit Diesel Corporation
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V92TA
Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8087-7899 (P/N 1768110) or 8083-7493 (P/N 3041219)
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Firing Order (RH Rotation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 1L-3R-3L-4R-4.L-2R-2L-1R
Total Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . ..............736 CU. m. (12.07 L)
4.84in.(123mm)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0in.(127mm)
5
Number of Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CompressionRatio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.0 to 1
Maximum Brake Horsepower (at 2100 rpm)
Model No. 8087-7899 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... SAE 445 (332 kw)
SAE 450 (336 kw)
Model No, 8083-7493 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Torque
Model No.8087-7899 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250 lb-ft (1695 N•m)
1330 lb-ft (1803 N•m)
Model No.8083-7493 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPEED RATINGS
Maximum Governed Speed, Full-Load . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .... . . . . . . . 2100 + 50 rpm
. . ± 25 rpm
Minimum Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
No-Load Governed Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 2250 ± 25 rpm
INTAKE
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Airesearch TV8101 with aftercooler
Blower . . . . . . . . . . . . Large bearing, gear driven, helical rotor blower with optional turbocharger mounting
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry element type
PISTONS AND CONNECTING RODS
Piston Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cross-head piston with crown and skirt
Number of Compression Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Number of Fire Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Number of Oil Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Type Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid core type with oil hole
Type Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid core type bushing
Type Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replaceable wet type, alloy cast iron
ENGINE LUBRICATING SYSTEM
. qt (26.5 L)
Crankcase Capacity ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 qt (28.4 L)
OilPressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 70 psi (344.7 to 482.6 kPa 1, 800 rpm)
Type System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure and spray circulation
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear type
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-flow, bolt-on type with by-pass valve
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plate-type, with by-pass valve
FUEL SYSTEM
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positive displacement, gear-type
Limiting Speed Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable speed, single-weight mechanical type
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model No. 9A90, needle valve type, valve opening pressure:
2200 to 3300 psi (15 169 to 22 753.5 kPa)
Fuel strainer, density-type element
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Fuel Water Separator
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. . Fuel filter, paper-type element
Secondary Fuel Filter
COOLING SYSTEM
Radiator Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 psi (48 kPa)
Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160°F to 185°F
Change 2
1-7
TM 9-2815-224-34&P
Section III.
1-13. PRINCIPLES OF OPERATION.
TM 9-2320-279-20.
1-8
Change 2
PRINCIPLES OF OPERATION
For principles of engine and related systems operation, refer to
TM9-2815-224-34&P
CHAPTER 2
MAINTENANCE INSTRUCTIONS
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left and Right Sides of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Organization of Removal, Installation, and Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . .
Engine Disassembly/Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Para
Page
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-1
2-1
2-1
2-1
2-1
2-4
2-4
2-4
2-7
2-7
Section 1. GENERAL INFORMATION
Parts and Tools
2-1. GENERAL. This chapter provides information on tools, general maintenance, and troubleshooting
required to maintain the engine.
Section II.
REPAIR PARTS AND SPECIAL TOOLS
2-2. COMMON TOOLS AND EQUIPMENT. These are common tools and general mechanics tool sets
required for maintenance of the engine. For authorized common tools and equipment, refer to the
Modified Table of Organization and Equipment (MTOE) applicable to your unit.
2-3. SPECIAL TOOLS. special tools for Direct Support/General Support Maintenance are listed in
Appendix B.
REPAIR PARTS
Appendix B.
[ Repair parts authorized for use at Direct Support/General Support are listed in
Section Ill. GENERAL MAINTENANCE PRACTICES
2-5. GENERAL MAINTENANCE INSTRUCTIONS. [
a. Follow these maintenance practices when working on engine.
(1) When unpacking items, remove all packing material, barrier paper, tape, plastic bags, protective
caps, and protective grease coating.
(2) Cap or tape over engine inlets and exhaust ducts to prevent foreign objects from getting inside
engine. Keep dust, dirt and other objects out of internal parts of engine.
(3) Cap or tape over all open tubes, hoses, fittings, and engine component openings as soon as parts
are removed.
CAUTION
Do not use tape to close off fuel or oil openings. Sticky surface of tape can mix
with fuel and oil and cause engine malfunctions.
(4) Use suitable containers to catch oil, fuel, or coolant when removing hoses and fittings.
2-1
TM 9-2815-224-34&P
Engine Maintenance
2-5. GENERAL MAINTENANCE INSTRUCTIONS (CONT).
(5)
(6)
(6.1)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
2-2
Handle and store removed engine components carefully.
Inspect parts as removed for breaks, dents, cracks, surface defects or other obvious damage. Turn in
bad parts. Set aside good parts for later use.
When fastener tightening requirements are not given in maintenance task, tighten screws and nuts
in accordance with Appendix E, TORQUE LIMITS.
Replace all gaskets, packings, and seals removed during repair work. Replace all lockwires,
lockwashers, cotter pins, etc., at time of reassembly.
Remove burrs from gear teeth with a fine-cut file.
Remove residue from bearing races with crocus cloth.
Welding and brazing processes may be used to repair cracks in external steel parts, such as brackets,
panels, and light framework. Because of time required and the chance of subsequent failure, such
repairs should be attempted only when replacement parts are not available. Welding and brazing of
castings and running parts or parts under great stress will only be done in emergencies.
When installing studs in engine block use a proper driver. A worn stud driver may damage the end
thread. Then a chasing die must be used before a nut can be screwed on. This procedure will
remove cadmium plating and allow corrosion. Before installing a stud, inspect hole for chips. Blow
out foreign matter, and start stud by hand. Before final insertion, coat thread with a film of
antiseize compound. Install stud to proper “setting height”, which is the total projection length.
Replace all broken, worn, or burned electrical wiring. Wires with broken strands must be replaced.
Replace all broken, frayed, crimped, or soft flexible hoses. Replace stripped or damaged fittings.
Replace entire flexible hose if fittings are damaged. Hose clamp should not crimp hoses.
Replace any screw, nut, or fitting with damaged threads. Inspect tapped holes for thread damage.
If cross-threading is evident retap the hole for the next oversize screw or stud. If retapping will
weaken the part, or if the cost of the part makes retapping impractical, replace the part. Chasing
the threads with proper size tap or die may be adequate.
Reshape elongated mounting holes to round and drill to receive bushing with required inner
diameter. Stake bushing in place with center punch.
Remove protective grease coatings from new parts before installation.
To replace a preformed packing, first clean groove, then stretch packing,and place into position.
Place component on flat surface and uniformly press packing into position.
Use nonhardening pipe-joint compound or Teflon tape to join piping.
Coat both sides of gasket with sealant. Remove all traces of previous gasket and sealant before
installing new gasket.
Coat oil seals evenly with oil or grease before installing. Install oil seals with seal lip facing in,
applying an even force to outer edge of seal. If oil seals are to be installed over keyed or splined
shafts, use a guide to prevent sharp edge of the keyway of splines from cutting the leather or
neoprene seal. Construct guides of very thin gage sheet metal and shape to the required diameter.
Make certain guide edges are not sharp and are bent slightly inward so they do not cut the seal.
When mounting bearings on shafts always apply force to the inner races. When mounting bearings
into housing always apply the force to the outer race.
Lubricate all preformed packings with a thin coat of light mineral oil before installation.
Lubricate bearings before assembly with lubricant used in the related housing or container to
provide the first run-in until lubricant from the system can reach the bearings.
To ease assembly and installation, tag and mark shims, connectors, wires, and mating ends of lines
before disconnecting them. Identify similar parts to ensure correct assembly.
Use a chain hoist, jack, or other aid when lifting the heavier components.
Change 4
TM9-2815-224-34&P
Engine Maintenance (Cont)
b.
Follow these cleaning instructions when working on the engine.
WARNING
●
Dry cleaning solvent, PD-680 Type II is flammable and toxic. Skin and eye
protection is required. Good ventilation is required. Keep away from open
flame or sparks.
●
Compressed air used for cleaning and drying purposes will be reduced to 30 psi
(207 kPa) and used only with adequate chip guarding and personal protection
equipment.
(1) Soak parts in dry cleaning solvent, and wash away deposits by sloshing or spraying. When
necessary, brush with a soft bristle brush (not wire) moistened in dry cleaning solvent. Use a jet
of dry compressed air to dry parts, except bearings, after cleaning. Bearings must drip and air
dry.
(2) Do not use wire brushes, abrasive wheels, or compounds to clean parts, unless specifically
approved in the detailed instructions. Dimensional characteristics ‘of machined surfaces can be
altered, and may weaken a highly stressed part.
(3) Do not clean rubber parts in dry cleaning solvent. Wipe clean with a clean, dry, lint-free cloth.
WARNING
Trichloroethylene is toxic to skin, eyes, and respiratory tract. Avoid all exposure.
Skin and eye protection, and exhaust hood are required. Contact safety officer
for local procedure regulations concerning the use of trichloroethylene before
using.
(4) A decreasing tub may be used to remove heavy grease and oil from metal parts.
Trichloroethylene is used as a decreasing agent.
CAUTION
To prevent corrosion, parts should be dipped in rust preventive (Item 24,
Appendix C) within two hours of decreasing.
(5) Remove parts from decreasing machine, and check all oil passages and cavities for cleanliness
and freedom from obstructions before coating with rust preventive. Run a thin, flexible wire
through oil passages to make sure they are not clogged. Use a pressure spray gun and dry
cleaning solvent to clean dirty passages.
(6) Parts soaked in carbon removal solution should be rinsed with dry cleaning solvent. Rinse in a
solvent spray booth equipped with a filter and hand spray gun, then use a soft bristle brush to
remove carbon deposits. A cloth buffing wheel may also be used.
(7) Electrical parts, such as coils, junction blocks, and switches, should not be soaked or sprayed
with cleaning solutions. Clean-these parts with a clean lint-free cloth moistened with dry
cleaning solvent.
C . Follow these inspection instructions when working on the engine.
(1) Inspect all surfaces in contact with gaskets, packings, or seals for nicks and burrs which might
damage the new seal upon assembly. If any defect is found, remove it before assembly.
NOTE
Defects which may cause bearing binding or misalinement are cause for rejection.
Nicks or gouges outside race load areas are not cause for rejection.
(2) Inspect bearings for rusted or pitted balls, races, or separators. Inspect balls and races for
abrasion and serious discoloration.
2-3
TM9-2815-224-34&P
Engine Maintenance (Cont)
[ 2-5.
GENERAL MAINTENANCE INSTRUCTIONS (CONT). [
(3) Cuts or grooves parallel to ball or roller rotation, fatigue pits (not minor machine marks or
scratches and cracks found during magnetic part icle inspection) are causes for bearing rejection.
(4) Remove drain plugs from engine system components and inspect the sediment sticking to the
plug. Grit or fine metal particles may indicate actual or potential component failure. A few fine
particles are normal. This inspect ion will help to show defective parts before internal inspection
of the component.
(5) Guidelines for rejection of gears by visual inspection are not listed because of varying conditions
for gear application. The following descriptions of wear conditions may help to determine when
parts are defective.
(a) Initial pitting may occur when gears are first started in service. When pitting reduces local high
spots so there is still enough contact area to carry load without further impairment, initial
pitting is not serious.
(b) Destructive pitting continues to progress after initial pitting. If there is not enough contact area
remaining to carry the load, rapid destruction may occur from continued operation.
(c) Abrasive wear is surface damage caused by fine particles carried in lubricant or particles
imbedded in tooth surfaces. Particles may be metal, sand or scale, or other impurities in oil or
surrounding atmosphere.
(6) Inspect all hose surfaces for broken or frayed fabric. Check for breaks caused by sharp kinks or
contact with other parts of the truck. Inspect the fitting threads for damage. Replace any
defective part. After assembly and during initial vehicle operation period, check for leaks.
(7) Inspect all wiring harnesses for chafed or burned insulation. Inspect all terminal connectors for
loose connections and broken parts.
(8) Visually inspect all castings and weldments for cracks.
] 2-6. LEFT AND RIGHT SIDES OF ENGINE. The left and right sides of the engine are determined by
standing at the rear of the engine.
Section IV. ORGANIZATION OF MAINTENANCE PROCEDURES
Maintenance Procedures
] 2-7. ORGANIZATION OF REMOVAL, INSTALLATION, AND REPAIR PROCEDURES. Some
procedures have repair procedures combined with the removal and installation, while others have a
separate paragraph for repair of components. Components that are removed, repaired, and installed at the
same level of maintenance, DS or GS, will have the repair procedure integrated into the same primary
paragraph.
Components which are removed and installed at one level of maintenance but are repaired at a different
level of maintenance, will have the removal and installation in one primary paragraph and the repair in
another. Components which are removed and installed (but not repaired) at one level of maintenance will
be sent to the next designated level of maintenance.
2-8. ENGINE DISASSEMBLY/REASSEMBLY SEQUENCE. The procedures in this manual are
organized in accordance with the functional group codes (FGC) used in the Maintenance Allocation Chart
(MAC). However, should you have to disassemble the engine completely, table 2-1 is provided as a guide to
help you do so. The table gives the paragraphs (tasks), the technical manuals in which they are found, and
the recommended sequence in which the tasks should be performed in order to completely disassemble the
engine. Table 2-1 can also be used as a guide to reassemble an engine by following the sequence numbers
and tasks in the reverse order.
2-4
TM9-2815-224-34&P
Maintenance Procedures (Cont)
Table 2-1.
Engine Diaassembly/Reassembly Sequence Guide
NOTE
Steps 1 through 9 must be done before mounting engine on engine stand,
Sequence No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
TM No.
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2320-279-20
TM 9-2320-279-34
TM 9-2320-279-20
TM 9-2320-279-20
TM 9-2320-279-20
TM 9-2320-279-34
TM 9-2320-279-20
TM 9-2320-279-20
TM 9-2320-279-20
TM 9-2320-279-20
TM 9-2815-224-34&P
TM 9-2320-279-20
TM 9-2320-279-20
TM 9-2815-224-34&P
TM 9-2320-279-20
TM 9-2320-279-20
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2320-279-20
TM 9-2320-279-34
TM 9-2320-279-20
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-281 5-224-34&P
TM 9-2320-279-20
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-28 15-224-34&P
TM 9-281 5-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-281 5-224-34&P
TM 9-2815-224-34&P
Para No.
9-2
3-5
3-6
7-8
6-4
3-2
7-17
6-13
3-4
6-11
6-15
6-17
6-12
18-2
4-6
4-11
15-10
6-8
6-9
17-2
7-12
10-5
7-2
6-2
7-4
4-2
4-3
8-3
8-7
8-6
8-4
8-5
4-6
4-4
14-6
14-7
14-5
3-3
15-6
15-8
15-4
15-7
14-2
14-3
14-4
16-2
15-2
15-3
13-2
Description
Exhaust Manifold
Air Box Covers
Air Box Drains
Starting Motor
Starter Motor Repair
Engine Block Coolant System Draincock
Sender Mounting Bracket
Fan Clutch to Engine Block Hose
Dipstick Tube
Fan
Alternator Belts
Fan Belts
Fan Clutch
Fan Clutch Repair
Fuel Lines
Secondary Fuel Filter
Engine Stop Solenoid
Left Thermostat Housing
Right Thermostat Housing
Water Pump
Front Balance Cover
Water Pump Drive Gear
Alternator
Alternator Repair
Alternator Support and Adjusting Strap
Crankshaft Pulley
Vibration Damper
Oil Pan
oil Pressure Regulator Valve
Oil Pressure Relief Valve
Oil Pump
Oil Pump Repair
Crankshaft Cover
Oil Pump Drive Gear
Turbocharger
Turbocharger Repair
Air Inlet Adapter
Rocker Covers
Variable Low Speed Limiting Governor
Throttle Air Cylinder
Governor Cover
Buffer Screw Switch
Tachometer Drive
Blower
Blower Repair
Aftercooler
Governor Housing
Governor Repair
Fuel Pump
2-5
TM9-2815-224-34&P
Maintenance Procedures (Cent)
2-8. ENGINE DISASSEMBLY/REASSEMBLY SEQUENCE (CONT). I
Table 2-1.
Sequence No.
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
2-6
Engine Disassembly/Reassembly Sequence Guide (Cent]
TM No.
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224 -348&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-28 15-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2320-279-20
TM 9-2320-279-20
TM 9-2320-279-34
TM 9-2320-279-34
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815 -224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2320-279-20
TM 9-2320-279-20
TM 9-2320-279-20
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
TM 9-2815-224-34&P
Para No.
13-2
12-5
3-7
11-4
11-2
11-3
15-5
7-5
7-8
7-6
7-7
12-2
12-4
12-3
7-4
7-3
3-10
3-9
3-11
7-2
3-8
15-9
11-37
11-38
11-9
12-8
5-2
5-3
10-2
7-9
7-10
7-11
3-4
3-3
3-6
3-4
3-7
6-2
6-3
4-5
8-2
3-2
Description
Fuel Pump Repair
Injector Control Tube
Cylinder Head
Engine Brake Wire Harness
Engine Brake Retarder
Engine Brake Retarder Repair
Throttle Delay
Rocker Arm
Exhaust Valve Bridge
Cam Follower
Cam Follower Repair
Fuel Injector
Fuel Injector Testing
Fuel Injector Repair
Exhaust Valves
Valve Guide
Valve Seat Insert
Injector Tube
Water Nozzle
Valve Bridge Guides
Cylinder Head Repair
Throttle Control Solenoid
Air Governor
Air Compressor
Air Compressor Repair
Steering Pump
Flexplate
Flywheel Housing & Rear Oil Seal
Blower Drive Support
Camshaft
Camshaft End Bearing and Bushing
Idler Gear
Rear End Plate
Front End Plate
Oil Cooler Inlet Elbow & Flange Elbow
Oil Filter
Oil Cooler Housing
Piston Connecting Rod & Liner
Piston Repair
Main Bearing and Crankshaft
Engine Block Breather Tube
Engine Block Repair
TM 9-2815-224-34&P
Section V. TROUBLESHOOTING
2-9. TROUBLESHOOTING INTRODUCTION This section contains step by step procedures for identifying,
locating, isolating, and repairing equipment malfunctions.
2-10. TROUBLESHOOTING INSTRUCTIONS
The troubleshooting system symptom index Table 2-2 lists
common malfunctions which could be found during maintenance of the M977 series engine or its components.
Each malfunction is followed by a list of tests or inspections which will help to determine corrective action to be
taken (Table 2-3).
a. This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective
actions. If a malfunction is not listed or is not corrected by listed corrective actions, notify your
supervisor.
b. Table 2-3 lists malfunctions which can occur during operation or maintenance of the M977 series
engine or its components. Perform tests, inspections, and corrective actions in the order listed.
Operation of a deadline vehicle without a preliminary examination can cause further damage to a
disabled component and possible injury to personnel. By careful inspection and troubleshooting, such
damage and injury can be avoided. In addition, cause of faulty operation of a vehicle or component can
often be determined without extensive disassembly.
Table 2-2. System Symptom Index
Troubleshooting
Procedure
Page
ENGINE
1.
2.
3.
4.
5.
6.
7.
8.
Fails to crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cranks - will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hard to start/stalls at idle speed/does not run smoothly . . . . . . . . . . . . . . . . . . . . . . . . .
Fails to develop full power . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High crankcase pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8
2-9
2-11
2-12
2-12
2-13
2-14
2-15
Change 2
2-7
TM 9-2815-224-34&P
Troubleshooting Malfunctions
2-10. TROUBLESHOOTlNG INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting
Malfunction
Test or Inspection
Corrective Action
ENGINE
1. FAILS TO CRANK.
TA357651
Step 1.
Check if engine is internally seized. Try to rotate crankshaft by turning pulley (1) clockwise.
If engine does not turn. engine is seized.
Remove engine (TM 9-2320-279-34), and repair (para 3-3).
2-8
TM9-2815-224-34&P
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting
(Cont)
Malfunction
Test or Inspection
Corrective Action
ENGINE (CONT)
2. CRANKS - WILL NOT START.
Step 1. Check fuel pump operation. Disconnect fuel line at inlet side of fuel filter and crank engine.
If no fuel flows from fuel line, remove fuel pump (para 13-2),
Step 2. Check injectors for free fuel flow. Remove
fuel pipe (1) between return manifold
connector (2) and injector (3). Crank engine
to pump fuel through injector. If fuel does not
flow freely, tag injector (3), replace fuel
pipe (l), and check each injector same way.
Remove tagged injectors (para 12-2).
Test and repair injectors (paras 12-3
and 12-4).
2-9
TM9-2815-224-34&P
Troubleshooting Malfunctions (Cont)
2-1O. TROUBLESHOOTING INSTRUCTIONS (CONT)
Table “2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ENGINE (CONT)
2. CRANKS – WILL NOT START (CONT).
Step 3. Check for damaged or broken compression rings. Remove air box covers (para 3-5). Inspect
three compression rings (1) through ports in cylinder liners (2).
Replace damaged or broken compression rings (para 6-3).
2-10
TM9-2815-224-34&P
Troubleshooting Malfunctions (Cent)
Table 2-3. Troubleshoothg
(Cont)
Malfunction
Test or Inspection
Corrective Action
ENGINE (CONT)
3. HARD TO START/STALLS AT IDLE SPEED/DOES NOT RUN SMOOTHLY.
Step 1. Check adjustment of exhaust valve clearances (para 19-2).
Adjust exhaust valve clearances (para 19-2).
TA357650
Step 2. Check for misfiring cylinders. Start engine. Hold injector follower (1) down with a
screwdriver to prevent operation of injector. If cylinder has been firing properly, cylinder
will miss with a noticeable change in sound and engine operation. If cylinder has been
misfiring, there will be no noticeable change. Check all cylinders and tag misfiring ones.
Remove tagged injectors (para 12-2).
Test and repair injectors (paras 12-3 and 12-4).
Step 3. Repeat check for misfiring cylinder(s).
If cylinder(s) still misfire, perform engine tune-up (para 19-2 through 19-9).
Step 4. Check engine compression (para 19-1 1). If compression values are not within allowable
limits, remove air box covers (para 3-5). Inspect compression rings through ports of cylinder
liners.
Replace damaged or broken compression rings (para 6-2 and 6-3).
2-11
TM9-2815-224-34&P
Troubleshooting Malfunctions (Cont)
TROUBLESHOOTING INSTRUCTIONS (CONT).
12-10.
Table 2-3. Troubleshooting (Cont)
MaIfunction
Test or Inspection
Corrective Action
ENGINE (CONT)
FAILS TO DEVELOP FULL POWER.
Step 1.
Perform engine tune-up (para 19-2 through 19-9).
Step 2. Check exhaust manifold for leaks.
Tighten loose connections (para 9-2).
Replace damaged exhaust manifold gaskets (para 9-2).
Replace damaged exhaust manifolds (para 9-2).
Step 3. Check if cylinder liner ports are clogged. Remove air box covers (para 3-5).
Check and clean cylinder ports if clogged (para 6-2).
Step 4. Inspect turbocharger for free movement.
Replace defective turbocharger (para 14-6).
OVERHEATS.
Step 1, Check freeze plugs (1) (four on each side of engine) for coolant leaks.
Replace defective freeze plugs (cup plugs) (para 3-2).
2-12
TM 9-2815-224-34&P
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ENGINE (CONT)
5.
OVERHEATS (CONT)
Step 2. Check water pump impeller for looseness. Drain coolant below level of water pump
(TM 9-2320-279-20), remove retaining ring (1), pump cover (2) and preformed packing (3).
Try to move impeller in and out to detect play indicating worn bearings, gears, or seal.
Remove damaged water pump (para 17-2).
Repair water pump (para 17-2).
Step 3.
Inspect engine aftercooler for leaks.
Remove aftercooler from engine (para 16-2).
Replace aftercooler if leaks are detected (para 16-2).
6.
LOW OIL PRESSURE.
Step 1.
Check for clogging of oil pump inlet screens. Remove oil pan (para 8-3).
Remove and clean oil pump inlet screens (para 8-4).
Replace damaged screens (para 8-4).
Step 2. Inspect oil pressure regulator valve for clogging or damage.
Remove and clean oil pressure regulator valve (para 8-7).
Inspect valve, valve seat, and valve spring for damage.
Replace damaged parts (para 8-7).
2-13
TM 9-2815-224-34&P
Troubleshooting Malfunctions (Cont)
2-10. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting
(Cont)
Malfunction
Test or Inspection
Corrective Action
ENGINE SYSTEM
6. LOW OIL PRESSURE (CONT).
Step 3.
Inspect oil pressure relief valve for clogging or damage.
Remove and clean oil pressure relief valve (para 8-6).
Inspect valve, valve seat, and valve spring for damage.
Replace damaged parts (para 8-6).
Step 4.
Inspect oil pump for damaged parts.
Remove and clean oil pump (para 8-4).
Inspect oil pump for worn, scored, or damaged parts.
Replace worn or damaged parts (para 8-5).
7. HIGH OIL CONSUMPTION.
Step 1.
Check if oil breather tube assemblies are clogged or damaged.
Remove and clean breather tube assembly (para 8-2).
Step 2.
Check for low air box pressure (para 3-6).
If pressure is low, do steps 3 and 4.
Step 3.
Check if blower-to-block gasket is damaged (para 14-3).
Replace damaged gasket (para 14-3).
Step 4.
Check if front end plate gasket is leaking (para 3-3).
Replace leaking front end plate gasket (para 3-3).
Step 5.
Check for head gasket leaks by performing engine compression check (para19-11).
Replace leaking gaskets (para 3-7).
Step 6.
Check turborcharger oil seals for wear or damage (para 14-7).
Replace defective seals (para 14-7).
Step 7.
Remove air inlet adapter (para 14-5), start engine (TM 9-2320-279-10), and check if blower
oil senl leaks.
Repair blower (para 14-4).
Step 8.
Check for damaged or broken piston rings and pistons or liners (para 6-2).
Replace damaged or broken piston rings, pistons, or liners (para 6-2).
2-14
Change 2
TM 9-2815-224-34&P
Troubleshooting Malfunctions (Cont)
Tab/e 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ENGINE SYSTEM (CONT)
7.
HIGH OIL CONSUMPTION (CONT).
Step 9.
Check crankcase pressure. Place manometer (J7333-6) on vehicle so that meter is visible
during test. Remove oil dipstick and place hose (J8639-2) of manometer at dipstick tube.
Open bleeder valve on manometer to level out manometer fluid. Adjust manometer so that
zero is placed along top position of fluid line. Start engine and check crankcase pressure.
Crankcase pressure shall be 3.1 in. of water at 1800 rpm, 3.3 in. at 1950 rpm, and 3.5 in.a t
2100 rpm.
If crankcase pressure is high, refer to Malfunction 8. HIGH CRANKCASE PRESSURE
8. HIGH CRANKCASE PRESSURE.
Step 1.
Check for head gasket leaks by performing engine compression check (para 19-11).
Replace leaking gaskets (para 3-7).
Step 2.
Check for damaged or broken piston rings and pistons or liners (para 6-2).
Replace damaged or broken piston rings, pistons, or liners (para 6-2).
Step 3.
Check for damaged blower-to-block gasket (para 14-3).
Replace damaged gasket (para 14-3).
Step 4.
Check for damaged cylinder block and plate gaskets (para 3-3 or 3-4).
Replace damaged gasket (para 3-3 or 3-4).
Change 2
2-15/(2-16 blank)
TM9-2815-224-34&P
CHAPTER 3
ENGINE BLOCK AND CYLINDER HEAD MAINTENANCE
‘Contents
Para
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
Engine Block Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Front End Plate Removal/Installation . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . ..... ... .... . . . 3-3
Rear End Plate Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . . . . . 3-4
Air Box Covers Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . . . 3-5
Air Box Drains Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 3-6
Cylinder Head Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Injector Tube Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Valve Seat Insert Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Water Nozzle Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Section 1.
Page
3-1
3-2
3-23
3-26
3-29
3-31
3-34
3-44
3-53
3-58
3-60
INTRODUCTION
3-1. GENERAL. This chapter covers repair and replacement of the engine block, end plates, air box
drains, front covers, and cylinder head assemblies. The subassemblies and parts which must be removed
before these items can be removed will be referenced to other paragraphs or chapters of this manual,
TM 9-2320-279-10, TM 9-2320-279-20, or TM 9-2320-279-34.
3-1
TM9-2815-224-34&P
Section II.
ENGINE BLOCK ASSEMBLY
Engine Block Maintenance Instructions
3-2. ENGINE BLOCK REPAIR.
This
a.
b.
c.
task covers:
Disassembly
Cleaning/Inspection
Assembly
d. Testing
e. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Remover/installer, core plug J23019
Remover/installer, water inlet adapter,
aftercooler J25275
Gage, cylinder checking J5347-01
Gage, cylinder liner depth J24898
Engine block pressure testing kit 2SK737
supplies
Oil, lubricating, Item 48, Appendix C
Compound, sealing, lubricating, Item 31,
Appendix C
Compound, sealing, pipe thread, Item 32,
Appendix C
Antifreeze, permanent, Item 7, Appendix C
Compound, International, No. 2, Item 26,
Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
3-2
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Engine circuit breaker
bracket removed.
TM 9-2320-279-20 Flange elbow removed.
TM 9-2320-279-20 Starter removed.
TM 9-2320-279-20 Oil cooler removed.
TM 9-2320-279-34 Engine mounted on engine
stand.
Para 16-2
Aftercooler removed.
Para 3-3
Front end plate removed.
Rear end plate removed.
Para 3-4
Air box covers removed.
Para 3-5
Para 3-6
Air box drains removed.
Engine block breather pipe
Para 8-2
removed.
Crankshaft removed.
Para 4-5
Para 3-7
Cylinder head removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
a.
Removal.
(1)
(2)
(3)
Remove oil galley plugs (1, 2, and 3)
from front of engine block (4).
Remove drain cock (5).
Remove plugs (6 and 7).
NOTE
Some engines have a connector. Others have
an elbow.
(4)
Remove connector (8) or elbow (8.1).
(5)
Remove oil galley plug (9) from rear end
of engine block (4).
Remove oil galley plug (10).
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Remove two plugs (11) from
right side of engine block (4).
Remove drain cock (12).
Remove compressor oil supply
elbow (13) and fitting (14).
Remove oil galley plugs (15 and
16).
Remove elbow (17), fitting (18),
and reducer bushing (19).
Remove plug (20).
Change 2
3-3
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
13-2. ENGINE BLOCK REPAIR (CONT).
(13) Remove two plugs (21) from
left side of engine block (4).
(14) Remove reducer bushing (22)
and ether starting aid
thermostat (23).
(15) Remove two plugs (24).
(16) Remove reducing bushing (25
and elbow (26) from engine
block (4).
(17) Remove oil plug (27).
(18) Remove drain cock (28).
(19) Remove elbow (29). reducing
bushing (30), and fitting (31).
(20) Remove two screws (32)
lockwashers (33),
washers (34), and starter
motor bracket (35).
(21) Remove core plug (36) and gasket (37) from top of engine block (4) using core plug remover.
(22) Remove aftercooler water inlet adapter (38) and gasket (39), using aftercooler water inlet
adapter remover.
(23) Remove oil galley plugs (40).
3-4
TM9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
(24) Remove four screws (4 1),
washers (42), cover
plate (43), and gasket (44)
from left side of engine
block (4).
TA357772
NOTE
Remove the following plugs and dowels only if damaged. Do not remove just to
clean engine block.
(25) Remove two dowels (45) from top of engine block (4).
(26) Remove 14 plugs (46) from bottom of cylinder head screw holes (47).
3-5
TM9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
3-2.
ENGINE BLOCK REPAIR (CONT). I
Remove two dowels (48) from front
engine block (4).
Remove three plugs (49) and two
plugs (50).
(29) Remove two dowels (5) ) from rear of engine block (4).
(30) Remove cup plug (52) from bottom of engine block (4).
(31) Remove four cup plugs (53) from both
right and left sides of engine block (4).
3-6
TM9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
b. Cleaning/lnspection.
(1) Scrape gasket material and sealant off
engine block (1) surfaces.
WARNING
High pressure steam can blow particles into eyes, can cause severe burns, and
creates hazardous noise levels. Eye, skin, and hearing protection is required.
(2) Steam clean engine block (1). Make sure oil and water galleries are cleaned thoroughly.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and persona] protective equipment
(goggles/shield, gloves, etc.).
(3) Dry engine block (1) with compressed air.
(4) Inspect grooves (2) and lands (3) for pitting and erosion.
3-7
TM 9-281 5-224-34&P
Engine Block Maintenance Instructions (Cent)
3-2. ENGINE BLOCK REPAIR (CONT).
NOTE
All eight cylinders are measured the same. Follow steps (5) through (9).
(5) Make two cylinder bore (4) measurements (5 and 6) with cylinder bore gage in steps (6) to (9).
(6) Measure cylinder bore (4) at position A. Measurement cannot be greater than 5.3625-in.
(136.2075 mm).
(7) Measure cylinder bore (4) at position B. Measurement cannot be greater than 5.3390-in.
(135.6106 mm).
(8) Measure cylinder bore (4) at position C. Measurement cannot be greater than 5.2180-in.
(132.5372 mm).
(9) Measure cylinder bore (4) at position D. Measurement cannot be greater than 5.2180-in.
(132.5372 mm).
(10) Replace engine block (1) if any cylinder bore (4) is beyond limits listed.
(11) Use straight edge and feeler gage
to measure flatness of engine
block (1) crosswise, between all
cylinders (7).
(12) If block (1) varies more than
0.003-in. (0.076 mm), replace
engine block (1).
(13) Using a straight edge and feeler
gage, measure flatness of engine
block contact surface (1)
lengthwise. If block (1) varies
more than 0.007-in. (O. 178 mm),
replace engine block (1).
TA357779
3-8
TM9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
NOTE
Cylinders may be counterbored
to either of two depths.
(14) Using counterbore depth gage,
measure depth of counterbore (8).
If depth is not between ‘ ‘
0.4755-in. (12. 13 mm) and
0.477-in. (12.12 mm) or
between 0.4905-in.
(12.46 mm) and 0.4920-in.
(12.50 mm) and cannot be
brought into limits by
installing cylinder liner insert,
replace engine block (1).
(15) If counterbore (8) varies more than 0.0015-in. (0.04 mm) around edge of cylinder, replace engine
block (l).
NOTE
If two adjacent cylinders are in different counterbore depth ranges measured in
step (14) above, step (16) does not apply.
(16) If difference between any one adjacent cylinder counterbores (8) measured at their closest
point (9) is more than 0.0015-in. (0.04 mm), replace engine block (l).
NOTE
Main bearing caps must be installed in proper
positions in engine block, as marked during
removal (para 4-5). Make sure caps are firmly
seated in engine block and main bearing shells
are removed.
(17) Install five main bearing caps (10) and ten
screws (11 ).
(18) Tighten screws (11) up snug.
(19) Strike caps (10) with soft-face hammer to seat
them.
(20) Tighten screws (11) to 50 lb-ft (68 NŽm).
(21) Tighten screws (11) to 110 Ib-ft (149 N•m).
(22) Tighten screws (11) to 250 to 260 lb-ft (339 to
352 N•m).
3-9
TM9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
3-2.
ENGINE BLOCK REPAIR (CONT). I
(23) Use bore gage to measure each main bearing bore (12) diameter. If main bearing bore diameter is
less than 4.812-in. (122.22 mm) or is greater than 4.813-in. (1 22.25 mm), replace engine
block ( 1).
(24) Remove five main bearing caps ( 10) and screws (11).
(25) Inspect dowel holes in engine
block (1) for oversize holes or damage.
Replace engine block if damaged or
oversize.
(26) Inspect threaded holes for stripped or
crossed threads. Use a tap to clean up
threads.
(27) Inspect machined surfaces for
flatness, burrs, and scratches. If
surfaces cannot be cleaned up by
lapping, replace engine block (1).
3-10
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
c. Assembly.
WARNING
Adhesives, solvents, and sealing
compounds can burn easily, can
give off harmful vapors, and are
harmful to skin and clothing. To
avoid injury or death, keep away
from open fire and use in
well-ventilated area. If adhesive,
solvent, or sealing compound gets
on skin or clothing, wash
immediately with soap and water.
Coat threads of all serviceable
plugs, fittings, and draincocks with
pipe thread sealing compound and
transfer to new engine block.
(1) Install core pIug (1) and gasket (2) inside air box (3). Tighten plug to 230 to 270 lb-ft (312 to
366 N•m).
(2) Install two 1/4-in. oil galley plugs (4) in top of engine block (5); Tighten plugs to 14 to 16 lb-ft
(19 to 22 N•m).
If no pressure test (Section d. Testing) is to be
performed, do next step, otherwise go on to
Step (4).
(3) Install aftercooler water inlet adapter (6)
and gasket (7) using aftercooler water inlet
adapter installer. Tighten aftercooler water
inlet adapter to 230 to 270 lb-ft (312 to
366 N•m).
TA357785
3-11
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions
3-2. ENGINE BLOCK REPAIR (CONT).
NOTE
Front face of engine block is shown.
(4)
(5)
(6)
(7)
(8)
(9)
Install 3/4-in. oil galley plug (8) in
front of engine block (5). Tighten
plug to 33 to 37 lb-ft (45 to 50 N•m).
Install 1/2-in. oil galley plug (9).
Tighten plug to 23 to 27 lb-ft (31 to
37 N•m).
Install 1/4-in. oil galley plug (10).
Tighten plug to 14 to 16 lb-ft (19 to
22 N•m).
Install 3/8-in. drain cock (11).
Install 1/4-in. water jacket plug (12).
Tighten plug to 14 to 16 lb-ft (19 to
22 N•m).
Install 1-1/4-in. water core plug (13). Tighten plug to 95 to 105 lb-ft (129 to 143 N•m).
NOTE
Some engines have a connector. Others have an elbow. Refer to TM 9-2320-279-24P.
(10)
Install connector (14) or elbow (14.1).
NOTE
Rear face of engine block is shown.
(11) Install 1/2-in. oil galley plug (15) in rear end of engine block (5). Tighten plug to 23 to 27 lb-ft
(31 to 37 N•m).
(12) Install 3/4-in. oil galley plug (16). Tighten plug to 33 to 37 lb-ft (45 to 50 N•m).
3-12
Change 2
TM 9-281 5-224-34&P
Engine Block Maintenance Instructions (Cont)
(13) Install
right s
Tighte
(19 to
(14) Install
(15) Install
(16) Install
fitting
(17) Install
plug to 75 to 85-lb-ft (102 to
115 NŽm).
(18) Install reducer bushing (22).
Install fitting (23) and
elbow (24).
(19) Install 1/8-in. oil galley
plug (25). Tighten plug to
10 to 12 lb-ft (14 to 16 N•m).
(20) Install 3/4-in. oil galley plug (26). Tighten plug to 33 to 37 lb-ft (45 to 50 N•m).
(21) Install two l-in. plugs (27) in
left side of engine block (5).
Tighten plugs to 75 to 85 Ib-ft
(102 to 115 N•m).
(22) Install 3/4 x 3/8-in. reducer
bushing (28).
(23) Install ether starting aid
thermostat (29) in reducer
bushing (28).
(24) Install l/4-in. plugs (30).
Tighten plugs to 14 to 16 lb-ft
(19 to 22 N•m).
(25) Install l/8-in. oil plug (31).
Tighten plug to 10 to 12 lb-ft
(14 to 16 N•m).
(26) Install reducer bushing (32)
and elbow (33).
(2?’) Install drain cock (34).
(28) Install fitting (35), reducer
bushing (36), and elbow (37).
(29) Install starter motor
bracket (38), two
washers (39), two
lockwashers (40), and two
screws (41 ).
3-13
TM9-2815-224-34&P
Engine Block Maintenance
13-2.
ENGINE BLOCK REPAIR (CONT). I
(30) Install gasket (42), cover
plate (43), four screws (44), and
washers (45) on left front side of
engine block (5).
NOTE
If dowel pins were removed, do step (31).
(31) Install two dowel pins (46) in top of engine
block (5) until they are flush with surface of
engine block.
3-14
Instructions (Cont)
TM9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
NOTE
●
●
There are 14 plugs, seven in each cylinder bank. Apply small quantity of
sealing and lubricating compound to thread area above plug. Do not let sealant
get onto threads of cylinder head screws, allow sealant to set for 12 hours
before performing pressure check section d. Testing
Top of plugs must be 1.960-in. (50 mm) below surface of block when installed.
(32) Coat threads of 1 1/16-in. plugs (47) with sealing and lubricating compound and install in cylinder
head screw holes (48). Tighten to 50 to 60 lb-ft (68 to 81 N•m).
(33) Install two dowels [49) in front of engine
block (5) until they-stick out 3/8-in. (9.5 mm)
(34) Install three p] ugs (50) and two plugs (51 ).
TA357794
(35) Install two dowels (52) in rear of engine block (5) until they stick out 3/8-in. (9.5 mm).
(36) Install cup plug (53) in bottom of engine block (5).
3-15
TM9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
3-2. ENGINE
BLOCK REPAIR (CONT). I
(37) Install four cup plugs (54) in both right
and left side of engine block (5).
TA357795
d. Testing.
(1)
(2)
(3)
(4)
3-16
Coat two seal rings (1) with lubricating oil.
Install two seal rings (1) in grooves (2) of each cylinder of engine block (3).
Install cylinder liner inserts (4) into each cylinder recess.
Install eight cylinder liners (5) into engine block (3).
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
(5) Install eight compression gaskets (6) in cylinders (7).
(6) Install oil hole seals (8) and water hole seals (9) in 34 counterbored holes (10) of each side of
engine block (3).
(7) Install four shims (11 ) one at each end of the cylinder head contact surface of each side of engine
block (3).
(8) Install gasket (12) and water inlet cover plate on right front side of engine block (3) with two
screws (13), nuts (14), and four lockwashers (15).
3-17
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
3-2. ENGINE BLOCK REPAIR (CONT).
(9) Install engine block pressure
test core plug (16) and gasket
in hole for aftercooler water
inlet adapter using core plug
remover/installer. Tighten plug
to 230 to 270 lb-ft (312 to
366 N-m).
(10) Pour one gallon of antifreeze into engine block water jacket through fitting (17) and fill with
water.
(11) Connect an air line to fitting (17). Route air line from above engine block to prevent antifreeze
solution from draining into hose.
3-18
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
(12) Install two plates (18) from engine block
test kit on right and left cylinder banks of
engine block (3) with 20 head screws (19)
and spacers (20).
(13) Tighten screws (19) to 50 lb-ft (67.80 N-m)
then to 110 lb-ft (149.16 N-m).
WARNING
Be careful when using high air pressure.
Make sure connections and seals are tight
before applying pressure. High air pressure
can blow out parts, hoses, or debris with
force. Explosive force can damage equipment
and cause injury.
(14) Apply 40 psi (276 kPa) pressure to engine
block (3). Maintain this pressure for at least
two hours.
(15) After test period, inspect engine block (3)
for leaking antifreeze. If leaks are found in engine block, engine block must be replaced.
(16) Relieve 40 psi (276 kPa) pressure from engine block (3).
(1 7’) Disconnect air line from fitting (17).
(18) Remove 20 screws (19), spacers (20), and
two plates (18) from engine block (3).
3-19
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
3-2. ENGINE BLOCK REPAIR (CONT).
(19) Remove engine block
pressure test core plug and
gasket from aftercooler
water inlet adapter
hole (16) using core plug
remover.
(20) Install aftercooler water inlet adapter (21) and gasket (22) using aftercooler water inlet adapter
installer. Tighten adapter to 230 to 250 lb-ft (339 N•m).
3-20
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
(21) Remove two screws (13),
nuts (14), four lockwashers (15),
water inlet cover plate and
gasket (12), from right side of
engine block (3).
(22) Remove eight compression gaskets (6) from cylinders (7).
(23) Remove oil hole seals (8) and water hole seals (9) from 34 counterbored holes (10) of each side of
engine block (3).
(24) Remove four shims (11) from each end of cylinder head contact surface of each side of engine
block (3).
3-21
TM
9-2815-24-34&P
Engine Block Maintenance Instructions (Cont)
3-2. ENGINE BLOCK REPAIR (CONT).
(25) Remove eight cylinder
liners (5) from engine
block (3). Coat liners with
lubricating oil.
(26) Remove cylinder liner
inserts (4) from each
cylinder recess.
(27) Remove two seal rings (1)
from grooves (2) of each
cylinder of engine block (3).
WARNING
Compressed air used for
cleaning purposes will not
exceed 30 psi (207 kPa). Use
only with effective chip
guarding and personal
protective equipment
(goggles/shield, gloves, etc.).
(28) Dry engine block (3) with
compressed air.
(29) Coat engine block machined
surfaces with lubricating oil
to prevent rust.
e. Follow-on Maintenance.
(1) Install right side air box drains (para 3-6).
(2) Install crankshaft (para 4-5).
(3) Install right side air box covers (para 3-5).
(4) Install engine block breather pipe (para 8-2).
(5) Install rear end plate (para 3-4).
(6) Install front end plate (para 3-3).
(7) Install aftercooler (para 16-2).
(8) Install cylinder head (para 3-7).
(9) Install oil cooler (TM 9-2320-279-20).
(10) Install starter (TM 9-2320-279-34).
(11) Install flange elbow (TM 9-2320-279-20).
(12) Install engine circuit breaker bracket (TM 9-2320-279-34).
(13) Remove engine from stand (TM 9-2320-279-34).
END OF TASK
3-22
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
FRONT END PLATE REMOVAL/INSTALLATION.
3-3.
This task covers:
c. Follow-on Maintenance
a. Removal
b. Installation
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-34 Engine mounted on
engine stand.
Camshafts removed.
Para 7-9
Special Tools
None
Supplies
Grease, automotive and artillery,
Item 36 Appendix C
Personnel Required
MOS 63S, Wheel vehicle repairer
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
a.
Removal.
NOTE
Some engines have five screws and
lockwashers. Others have flanged head
screws and no lockwashers.
(1)
(2)
Remove live
lockwashers
Remove two
lockwashers
screws (1) and
(2) from front end plate (3).
screws (4) and
(5) from front end plate (3).
Change 2
3-23
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
3-3. FRONT END PLATE REMOVAL/lNSTALlATlON (CONT).
(3) Remove front end plate (3) and gaskets (6 and 7) from engine block (8).
CAUTION
Support front end plate on flat, even surface when removing screw insert to
prevent warping or bending end plate
(4) Remove screw insert (9) from front end plate (3).
b. Installation.
CAUTION
Support front end plate on flat, even surface when
installing screw insert to prevent wraping or bending
end plate.
(1) Support front end plate (1).
(2) Press screw insert (2) into front end, plate (1) until
head seats on end plate surface.
3-24
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
(3)
Coat end plate gaskets (3 and 4) with
grease and install on engine block (5).
NOTE
Some engines have five screws and
lockwashers. Others have flanged head
screws and no lockwashers.
(4)
Install front end plate (1), five screws (6),
lockwashers (7), two screws (8) and
lockwashers (9). Tighten screws (6 and 8)
finger tight.
NOTE
Smaller right hand camshaft end bearing
will be used as a pilot when alining front
end plate on engine block.
(5)
Install two camshaft end bearings (10)
into the front end plate (1).
(6)
Tighten five screws (6) to 35 lb-ft
(47 N•m).
Tighten two screws (8) to 75 lb-ft
(102 N•m).
Remove end bearings (10).
(7)
(8)
c . Follow-on Maintenance. Install camshafts
(para 7-9).
END OF TASK
Change 2
3-25
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
3-4. REAR END PLATE REMOVAL/INSTALlATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Grease, automotive and artillery,
Item 36, Appendix C
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-34 Engine mounted on
engine stand.
Para 7-9
Camshaft removed.
Para 10-2
Blower drive support
removed.
Para 7-11
Idler gear removed.
Personnel Required
MOS 63W, Wheel vehicle repairer
Special Environmental Conditions
None
General Safety Instructions
None
References
None
Level of Maintenance
General Support
a.
Removal.
NOTE
Note direction of special washer during
removal to aid in correct installation.
(1)
(2)
Remove screw (1), special washer (2),
and dummy hub (3) from end plate (4)
Remove screw (5) and lockwasher (6)
from end plate (4).
NOTE
Some engines have four screws and
lockwashers. Others have flanged head
screws and no lockwashers.
(3)
3-28
Remove four screws (7) and
lockwashers (8) from end plate (4).
Change 2
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
(4) Remove end plate (4).
(5) Remove gasket (9) from end plate (4) and
engine block (10).
CAUTION
Support rear end plate on flat,
even surface when removing screw
inserts to prevent warping or
bending end plate.
(6) Remove two screw inserts (11)
from end plate (4).
(7) Remove eight screw inserts (12)
from end plate (4).
b. Installation.
CAUTION
Support rear end plate on flat,
even surface when installing screw
inserts to prevent warping or
bending end plate.
(1) Press eight screw inserts (1) into
back of end plate (2).
(2) Press two screw inserts (3) into
front of end plate (2).
3-27
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
3-4. REAR END PLATE REMOVAL/INSTALLATION (CONT).
(3) Coat gasket (4) with grease and install
over dowel pins (5) onto engine
block (6).
(4) Install end plate (2) on dowel pins (5).
(5) Install four screws (7) and lockwashers (8).
Tighten screws finger tight.
(6) Install screw (9) and lockwasher (10).
Tighten screw finger tight.
NOTE
Special washer is installed in same direction
as noted during removal.
(7’) Install special washer (11 ) on screw (12)
with grooved side facing head of screw.
(8) Install dummy hub (13), special
washer (11 ), and screw (12). Tighten screw
finger tight.
(9) Insert two right hand camshaft end
bearings (14) into end plate (2).
Tighten four screws (7) to 35 lb-ft (47 N•m).
Tighten screw (9) to 110 lb-ft (149 N•m).
Tighten screw (12) to 90 lb-ft (122 N-m).
Remove end bearings (14).
c. Follow-on Maintenance.
(1) Install camshafts (para 7-9).
(2) Install blower drive support (para 10-2).
(3) Install idler gear (para 7-1 1).
(lo)
(11)
(12)
(13)
END OF TASK
3-28
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
3-5. AIR BOX COVERS REMOVAL/lNSTALIATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
Equipment Condition
All
TM or Para
Test Equipment
Condition Description
TM 9-2320-279-10 Engine off.
TM 9-2320-279-10 Parking brake on.
Engine cool.
None
Special Tools
Special Environmental Conditions
None
None
supplies
Adhesive-sealant, silicone, Item 6, Appendix C General Safety Instruction
None
Personnel Required
MOS 63W, Wheel vehicle repairer
References
Level of Maintenance
Direct Support
None
a. Removal.
NOTE
Right and left air box covers are removed and installed the same way.
(1) Remove seven screws (1) from air box covers (2, 3, and 4).
3-29
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
3-5. AIR BOX COVERS REMOVAL/INSTALLATION (CONT).
(2) Remove three air box covers (2, 3, and 4), two gaskets (5), and gasket (6).
b. Installation.
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing. To
avoid injury or death, keep away from open
fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets
on skin or clothing, wash immediately with
soap and water.
(1) Coat two gaskets (1) and gasket (2) with
adhesive-sealant and install on engine
block (3).
(2) Install three air box covers (4, 5, and 6) on
engine block (3) with seven screws (7).
Tighten screws to 96 to 144 lb-in (11 to
16 N•m).
c. Follow-on Maintenance. None.
END OF TASK
3-30
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
3-6. AIR BOX DRAINS REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Testing Air Flow
d. Follow-on Maintenance
INITIAL SETUP
Models
All
Equipment Condition
Test Equipment
Air pressure gage, O to 30 psi (O to 210 kPa)
Special Tools
None
Supplies
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
None
Condition Description
Engine off.
Parking brake on.
Spare tire removed.
Batteries disconnected.
Engine cool.
9-2320-279-10
9-2320-279-10
9-2320-279-10
9-2320-279-20
Special Environmental Conditions
Compound, sealing, pipe thread, Item 32,
Appendix C
References
TM or Para
TM
TM
TM
TM
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
NOTE
Right and left air box drains are removed the same way.
(1) Remove screw (l), and lockwasher (2), and washer (3).
(2) Remove fitting (4) and hose (5) from check valve (6).
(3) Remove clamp (7).
3-31
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
3-6. AIR BOX DRAINS REMOVAL/INSTALLATION (CONT).
(4) Remove check valve (6) from tee (8).
(5) Remove tee (8) and fitting (9) from engine block (10).
(6) Remove plug (1 1).
b. Installation.
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful to
skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and water.
NOTE
Right and left air box drains are installed the same way.
(1) Coat threads of fitting (1) with pipe thread sealant
(2) Install fitting (1) and tee (2) in engine block (3).
(3) Install plug (4).
3-32
TM 9-2815-224-34&P
Engine Block Maintenance Instructions (Cont)
(4) Install check valve (5) on tee (2).
(5) Install fitting (6) and hose (7) on check
valve (5).
(6) Install clamp (8) with screw (9),
lockwasher (10), and washer (11).
c. Testing Air Flow.
WARNING
Do not stand in front of vehicle when testing airbox
pressure. Brake could release and vehicle could jump
forward causing personal injury or death.
CAUTION
Do not operate vehicle with transmission engaged and at
maximum rpm for more than 15 seconds at a time.
Transmission oil heats up quickly and could cause
transmission to fail.
(1) Remove plug (1) and install air pressure gage.
(2) Chock wheels, set parking brake and foot brake (TM 9-2320-279-10).
Low airbox pressure can be caused by an obstruction in the air inlet system, dirty
or damaged air cleaners, damaged blower rotors, or an air leak from the airbox
(such as leaking end plate gaskets). High airbox pressure reading can be caused
by partially plugged cylinder liner ports.
(3) When told by Soldier A, Soldier B starts engine (TM 9-2320-279-10), warms up engine for
5 minutes, then shifts transmission into Drive (D).
(4) Check airbox pressure. Pressure shall be 9 psi (62 kPa) at 1200 rpm, 16 psi (110 kPa) at 1800 rpm
and 20 psi (138 kPa) at 1950 psi.
d. Follow-on Maintenance.
(1) Stow spare tire (TM 9-2320-279-10).
(2) Connect batteries (TM 9-2320-279-20).
END OF TASK
3-33
TM 9-2815-224-34&P
Section III.
CYLINDER HEAD ASSEMBLY
Cylinder Head Maintenance Instructions
3-7. CYLINDER HEAD REMOVAL/INSTALLATION
This task covers:
a. Removal
b. Cleaning and Inspection
c. Installation
d. Follow-on Maintenance
INITIAL SETUP
Models
Equipment Condition (cont)
TM or Para
Condition Description
All
Test Equipment
None
Special Tools
Stud, guide, cylinder head J24748-1
Fixture, lifting J22062-01
Wrench, fuel line J8932-01
Supplies
Compound, International, No. 2, Item 26,
Appendix C
Connector, electrical, butt, Item 34,
Appendix C
Solvent, drycleaning, Item 60, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
Referernces
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-10 Engine off,
TM 9-2320-279-10 Engine cover open.
TM 9-2320-279-20 Batteries disconnected.
3-34
Change 2
TM 9-2320-279-20 Engine cooling system
drained.
TM 9-2320-279-10 Spare tire removed.
TM 9-2320-279-20 Muffler exhaust pipe
removed.
TM 9-2320-279-20 Air cleaner air hoses
removed.
TM 9-2320-279-20 Thermostat hoses
removed.
TM 9-2320-279-20 Thermostat housing
removed.
TM 9-2320-279-20 Rocker cover removed.
Para 15-4
Governor cover removed.
Para 9-2
Exhaust manifold removed.
Para 12-5
Injector control tube
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions
a. Removal.
NOTE
Left and right banks are
different. Left bank has
three screws. Right bank
has only two screws.
Bracket shown being
removed from left bank.
(1) Remove two
screws (1),
lockwashers (2),
and washers (3).
NOTE
Some engines have a fuel
modulator air supply hose
on the left bank. For
engines with fuel modulator
air supply hose, perform
steps (1.1) and (2.2). For
engines without fuel
modulator or for right
bank, perform step (2).
(1.1)
(1.2)
(2)
(3)
(4)
Disconnect hose (3.1) from elbow (3.2).
Remove screw (4), lockwasher (5), hose (3.1), clamp (3.3), and bracket (6).
Remove screw (4), lockwasher (5), and bracket (6).
Remove two screws (7), lockwashers (8), and hose clamp (9).
Remove engine lifting bracket (10).
(5)
Remove two screws (11) and
washers (12) from crossover
tube (13) at rear of engine (14).
NOTE
.
Tag wire before cutting or
disconnecting.
.
Some brake retarder wires must
be cut at butt connector. Others
can be disconnected and do not
need to be cut.
(6)
Disconnect brake retarder
wire (15) from cylinder head
(31) or cut wire at butt
connector.
Change 2
3-35
TM 9-2815-224-34&P
Cylinder Head Maintanance Instructions (Cont)
3-7. CYLINDER HEAD REMOVAL/INSTALLATION (CONT).
(7) Loosen two hose clamps (16) and slide
hose (17) up to clear cover tube (18).
NOTE
Fuel rod is removed through cylinder head. Left and right bank fuel rods are
removed differently. Step (8) covers left bank and step (9) covers right bank.
(8) Lift connecting pin (19) 3/4-in. (19 mm) and remove left bank fuel rod (20) from control link
operating lever (21).
(9) Remove screw (22) and right bank fuel rod (23) from control link operating lever (21).
3-36
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions
NOTE
Fuel pipes have changed from flare style
to preformed packing style pipes and
connectors. Use new style pipes and
connectors to replace old style pipes and
connectors. Refer to TM 9-2320-279-24P
for parts identification.
Flare and preformed packing style pipes
and connectors are not interchangeable.
When replacing one flare type pipe or
connector, all pipes and connectors must
be replaced with new preformed packing
style pipes and connectors.
Tag eight fuel tubes (24), loosen sixteen
fuel tube nuts (25), and remove eight
fuel tubes.
(10.1) Remove and discard sixteen preformed packings (25.1).
NOTE
Checking tightness of cylinder head screws may show cause of cylinder head
failure.
(11)
(12)
(13)
(14)
(15)
(16)
Check and record tightness on 10 cylinder head screws (26). Tightness must be between 260 to
270 lb-ft (353 to 366 N•m).
NOTE
Leave in two screws at top right and left of head.
Remove eight screws (26) and washers (27).
Install lifting fixture over three studs (28).
Secure with three nuts (29) and washers (30).
Remove two screws (26) and washers (27).
Using a suitable lifting device lift cylinder head (31).
Change 2
3-37
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions
3-7. CYLINDER HEAD REMOVAL/INSTALLATION (CONT).
NOTE
Compression gaskets are color coded. Be sure
to note color for replacement.
(17)
(18)
Remove seal strip gasket (32), two
support shims (33), seventeen water
seals (34), oil seal (35), and four
compression gaskets (36).
Remove gasket (37) from crossover
tube (13).
b. Cleaning and Inspection.
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors
and are harmful to skin and clothing. To
avoid injury or death, keep away from open
fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets
on skin or clothing, wash immediately with
soap and water.
(1)
Clean cylinder head (1) with
drycleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi. Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves,
etc.)
(2)
(3)
3-38
Dry cylinder head (1) with compressed air.
Inspect cylinder head mounting surface to be sure it is clean and free from burrs.
Change 2
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
(4) Inspect push rod ends (2) to be sure they are
threaded into clevis (3) until end of push rod
projects through clevis.
(5) Clean cylinder block head gasket surface with
dry cleaning solvent.
(6) Dry cylinder block head gasket surface with
compressed air.
TA474889
(7) Inspect piston crowns (1) to he sure they are clean and free of foreign material.
(8) Inspect head gasket surface, counterbores (5). and seal grooves (6) to be sure they are clean and
free of foreign material.
(9) Inspect counterbores (5) for burrs or sharp edges.
(10) Inspect screw holes for accumulation of water or foreign material.
3-39
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions
3-7. CYLINDER HEAD REMOVAL/INSTALLATION (CONT).
c.
Installation.
CAUTION
Never install used compression gaskets;
they will cause compression leaks.
(1)
(2)
(3)
Install four compression
gaskets (1), seventeen water
seals (2), oil seal (3), and seal
strip gasket (4).
Remove paper covering from
back of two support shims (5)
and install glued side down.
Install two cylinder head guide
studs into two bottom corners of
cylinder block (6).
Soldier A alines cylinder
head (7) with guide studs while
Soldier B operates suitable
lifting device.
(5) Lower cylinder head (7) on
cylinder block (6).
Remove three nuts (8),
(6)
washers (9), and lifting fixture
from studs (10).
(6.1) Apply international compound
No. 2 to threads and under
heads of ten cylinder head
screws (11).
(7) Install eight cylinder head
screws (11) and washers (12).
Remove two guide studs and
install two remaining cylinder
head screws and washers.
(7.1) Tighten ten cylinder head
screws (11) in the sequence
shown until cylinder head (7) is
seated on the compression
gaskets (1) and is parallel to the
cylinder block (6) face.
(4)
3-40
Change 2
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions
(8)
Gradually tighten ten cylinder
head screws (11), in 50 lb-ft (68
NSm) increments, to 150 lb-ft (204
NSm) in the sequence shown.
Hold the wrench at this torque for
2 to 3 seconds to allow bolts to
turn while the compression seals
yield to their crushed thickness.
CAUTION
While performing step (8.1) do
not loosen more than one bolt at
a time. Failure to comply may
cause damage to equipment.
NOTE
For ease in carrying out the procedure below, it may be convenient to premark a
socket with four marks 90 degrees apart. At the start of each turn, mark the head
with a grease pencil at one mark on the socket and turn to the next mark.
(8.1) After completing step (8) perform the following in the same sequence, beginning with cylinder
head screw #1 and continuing one cylinder head screw at a time. Back off cylinder head screw
until loose (at least one-half turn.) Retighten to 100 lb-ft (136 NSm), plus a turn of an additional
90 degrees. Try to turn the cylinder head screw in a single arc with one pull of the wrench.
Then proceed with cylinder head screw #2, etc.
NOTE
O-rings must be installed dry. Do not apply oil.
(9)
Install eight fuel tubes (13 and 14) and
sixteen O-rings (14.1).
(10)
Tighten 16 nuts (15) to 160 lb-in (18.1
NSm) using fuel line nut wrench.
•
•
NOTE
Fuel rod is installed through cylinder
head.
Left and right bank fuel rods are installed
differently. Step (11) covers installation of
left bank; step (12) covers installation of
right bank.
(11) Lift connecting pin (16) 3/4-in. (19 mm).
Install left bank fuel rod (17) to control
link operating lever (18).
(12) Install right bank fuel rod (19) to control
link operating lever (18). Install
screw (20).
Change 4
3-41
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
3-7. CYLINDER HEAD REMOVAL/INSTALLATION (CONT).
TA474896
(13) Connect brake retarder wire (21) to cut wire end with butt connector.
(14) Install gasket (22) and crossover tube (23) with two screws (24) and washers (25).
(15) Slide hose (26) into position over
cover tube (27). Tighten two
clamps (28).
3-42
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions
(16) Install engine
lifting
bracket (29).
NOTE
Left and right banks are
different. Left bank has
three screws. Right bank
has only two screws.
Bracket shown being
installed on left bank.
(17)
Install two
screws (30),
lockwashers (31),
and hose
clamp (32).
Tighten screws to
20 to 25 lb-ft (27 to
34 N•m).
NOTE
Some engines have a fuel modulator air supply hose on the left bank. For engines
with fuel modulator air supply hose, perform steps (17.1) and (17.2). For engines
without fuel modulator or for right bank, perform step (18).
(17.1)
(17.2)
(18)
(19)
d.
Connect hose (32.1) to elbow (32.2).
Install hose (32.1), clamp (32.3), bracket (33), lockwasher (35), and screw (34).
Install bracket (33), screw (34), and lockwasher (35).
Install two screws (36), lockwashers (37), and washers (38). Tighten screws to 20to 25 lbs-ft (27
to 34 N•m).
Follow-on Maintenance.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Install injector control tube (para 12-5).
Install exhaust manifold (para 9-2).
Install governor cover (para 15-4).
Install rocker cover (TM 9-2320-279-20).
Install thermostat housing (TM 9-2320-279-20).
Install thermostat hoses (TM 9-2320-279-20).
Install air cleaner air hoses (TM 9-2320-279-20).
Install muffler exhaust pipe (TM 9-2320-279-20).
Stow spare tire (TM 9-2320-279-10).
Fill engine cooling system (TM 9-2320-279-20).
Connect batteries (TM 9-2320-279-20).
Close engine cover (TM 9-2320-279-10).
END OF TASK
Change 2
3-43
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions
3-8. CYLINDER HEAD REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Testing
d. Assembly
e. Follow-on Maintenance
INlTlAL SETUP
Models
All
Test Equipment
None
Special Tools
Fixture, test, head J28454
Supplies
Solvent, drycleaning, Item 60, Appendix C
Compound, sealing, pipe thread, Item 32,
Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
Equipment Condition
Condition Description
TM or Para
Cylinder head on clean
work surface
Rocker arms removed.
Para 7-5
Para 7-8
Exhaust valve bridges
removed.
Fuel injectors removed.
Para 12-2
Para 7-4
Exhaust valves removed.
Engine brake retarders
Para 11-2
removed.
Para 7-6
Cam followers removed.
Para 15-5.1
Fuel modulator and tube
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
a. Disassembly.
NOTE
Fuel adapters have changed to a preformed packing style adapter instead of a
flared style adapter. Replace all old style flared adapters with new style
preformed packing adapters as required. Refer to TM 9-2320-279-24P.
(1)
3-44
Remove eight fuel adapters (1) and washers (2) from cylinder head (3).
Change 2
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
NOTE
Fuel adapters have changed to a preformed packing style adapter instead of a
flared style adapter. Replace all old style flared adapters with new style
preformed packing adapters as required. Refer to TM 9-2320-279-24P.
(1.3) Remove eight fuel adapters (1) and washers (2) from cylinder head (3).
RIGHT FRONT BANK
LEFT FRONT BANK
NOTE
It may be necessary to drill plugs and remove with an easy out.
(2)
(3)
(4)
(5)
Remove
Remove
Remove
Remove
two plugs (4), plug (5), and plug (6).
elbow (7), elbow (8), connector (9), and tee (10).
three plugs (11), plug (12), and plug (13).
two elbows (14).
Change 2
3-45
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
3-8. CYLINDER HEAD REPAIR (CONT).
(6)
(7)
(8)
(9)
(10)
Remove five plugs (15), two plugs (16), and plug (17).
Remove plug (18) and gasket (19).
Remove four plugs (20), plug (21), and plug (22).
Remove fitting (23).
Remove plug (24) and gasket (25).
(11) Remove four screws (26),
lockwashers (27), two cover
plates (28), and two gaskets (29)
from water inlet ports (30).
(12) Remove eight screws (31), copper
washers (32). four covers (33), and
gaskets (34).
3-46
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
(13) Remove nine pipe plugs (3.5)
from cylinder head (3).
b. Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Clean stripped cylinder head wash dry cleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(2) Dry cylinder head with compressed air.
5
4
3
2
1
(3) Aline straightedge along
lines 1, 2, 3, 4, and 5 on
cylinder head (1). Measure for
warp with feeler gage at
points where lines 6, 7, 8, 9,
10, and 11 intersect
straightedge.
(4) If warp measurement exceeds
0.004-in. (0.1 mm), cylinder
head (1) must be replaced.
(5) Aline straight edge along
lines 6, 7, 8, 9, 10, and 11 on
cylinder head (1). Measure al
points where lines 1, 2, 3, 4.
and 5 intersect straightedge.
(5) If warp measurement exceeds 0.008-in. (0.2 mm), cylinder head (1) must be replaced.
3-47
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
3-8. CYLINDER HEAD REPAIR (CONT).
c.
Testing.
NOTE
The cylinder head must be pressuretested following cylinder head repair.
(1)
(2)
(3)
Using injectors removed in
paragraph 12-2, install four
injectors (1) into injector
tubes (2).
Install four gaskets (3).
Install four covers (4) with
eight screws (5).
HOLD DOWN SCREWS
(4)
(5)
3-48
Aline test fixture on top of bottom face of cylinder head (6) so rubber stoppers cover water
inlets (7).
Install and tighten 10 holddown screws until rubber stoppers start to flatten out.
Change 2
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
(6)
(7)
(8)
(9)
(10)
(11)
Install end plate onto thermostat end of cylinder head (7).
Install rear plug (9) and pipe plug (10) into rear of cylinder head (7).
Install air hose to end plate and apply 40 psi (275.8 kPa) to cylinder head (7).
Put cylinder head (7) in water for 20 minutes and check for leaks.
If cylinder head (7) does not leak, remove from water.
If leak is found in cylinder head (7), remove from water and check test assembly for proper
seating. Repeat steps (9) and (10).
(12) If cylinder head (7) leaks when steps (9) and (10) are repeated, replace cylinder head.
(23) Relieve air pressure.
(14) Remove test fixture, pipe plug (10), and end plate from cylinder head (7).
3-49
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
3-8. CYLINDER HEAD REPAIR (CONT).
(15)
Remove four injectors (1) from injector
holes (2).
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing. To
avoid injury or death, keep away from open
fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets
on skin or clothing, wash immediately with
soap and water.
(16)
Clean cylinder head with drycleaning
solvent.
WARNING
Compressed air used for cleaning purposes
will not exceed 30 psi (207 kPa). Use only
with effective chip guarding and personal
protective equipment (goggles/shield, gloves,
etc.).
(17)
Dry cylinder head with compressed air.
d. Assembly.
3-50
Change 2
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
WARNING
Adhesives, solvents, and sealing compound can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
NOTE
Coat threads of plugs with pipe thread sealing compound before installation.
Fuel adapters have changed to a preformed packing style adapter instead of a flared
style adapter. Replace all old style flared adapters with new style preformed packing
adapters. Refer to TM 9-2320-279-24P.
RIGHT FRONT BANK
(1)
(2)
(3)
(4)
(5)
Install eight washers (1) and fuel adapters (2) into cylinder head (3). Tighten adapters to 40 to
45 lb-ft (102 to 115 N•m).
Install two plugs (4), plug (5), and plug (6) flush with end of cylinder head (3).
Install elbow (7), elbow (8), tee (9), and connector (10).
Install three plugs (11), plug (12), and plug (13).
Install two elbows (14).
Change 2
3-51
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
3-8. CYLINDER HEAD REPAIR (CONT).
LEFT REAR BANK
(6)
(7)
(8)
(9)
Install
Install
Install
Install
plug (15) and gasket (16).
five plugs (17), two plugs (18), and plug (19).
four plugs (20), plug (21), and plug (22).
plug (23), fitting (24), and gasket (25).
(10) Install two water manifold
gaskets (26), two cover plates (27),
four lockwashers (28), and screws (29)
into water inlet ports (30).
3-52
RIGHT REAR BANK
TA474920
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
(11)
e.
Install nine pipe plugs (31).
Follow-on Maintenance.
(I)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Install
Clean
Install
Install
Install
Install
Install
Install
valves (para 7-4).
and test injectors (para 12-3).
fuel injectors (para 12-2).
exhaust valve bridges (para 7-8).
rocker arms (para 7-5).
engine brake retarder (para 11-2).
cylinder head (para 3-7).
fuel modulator, tube, and fittings (para 15-5.1).
END OF TASK
3-9. INJECTOR TUBE REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Reconditioning set J22525
Gage, sled J22273
Gage, injector J25521
Supplies
Solvent, drycleaning, Item 60, Appendix C
Oil, lubricating, Item 54, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
Equipment Condition
Condition Description
TM or Para
Engine brake retarder
Para 11-2
removed.
Rocker arms removed.
Para 7-5
Exhaust valve bridges
Para 7-8
removed.
Fuel injectors removed.
Para 12-2
Exhaust valves
Para 7-4
removed.
Cam followers and push
Para 7-6
rods removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
Change 2
3-53
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
3-9. INJECTOR TUBE REMOVAL/lNSTALLATlON (CONT).
INJECTOR TUBE
TA474912
NOTE
All injector tubes are removed the same way.
Insert injector tube installer into injector tube (1).
Install pilot into injector
tube installer through
bottom of cylinder head (2).
Tap pilot to loosen injector
tube (1).
Remove injector tube (1),
preformed packing (3),
pilot, and installer from
cylinder head (2).
3-54
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
b. Installation.
●
NOTE
Injector tube must be reamed before injectors can be installed.
●
All injector tubes are installed the same way.
(1) Clean dirt from injectors tube (1) and hole.
(2) Install preformed packing (2) into cylinder head counterbore (3).
(3) Tap injector tube (1) into injector tube hole using installer until bottom rim of installer is flush
with cylinder head (4).
(4) Set cylinder head (4) upside
down on two wood blocks.
(5) Seat injector tube (1) using
upsetting die. Tighten to
30 lb-ft (40 N•m) and
remove die.
3-55
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
3-9. INJECTOR TUBE REMOVAL/INSTALLATION (CONT).
(6) Set cylinder head (4) right side up on work surface on wood blocks.
Turn reamer clockwise only, counterclockwise will ruin reamer and injector tube.
(7) Lubricate reamer blades with lubricating oil.
(8) Ream injector tube (1) with first operation reamer.
(9) Clean metal filings from injector tube (1).
(10)) Repeat steps (7) and (8) until shoulder of reamer touches top of injector tube (l).
(11) Set cylinder head (4) on side.
(12) Remove excess material from tip of injector
tube (1) with tube tip refinisher until finisher
contacts bottom of cylinder head.
(13) Clean out inside of injector tube (1).
3-56
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
(14) Measure depth of gage in injector tube (1) beneath face
of cylinder head (4) using sled gage.
(15) Measurement must be 0 ± 0.014 in, (0.36 mm). If
measurement is within tolerance, do steps (22) and (23).
If measurement is more than 0.014 above 0 reading,
replace tube (1) and do steps (16) through (21).
(16) Set cylinder head (4) right side up on
work surface.
WARNING
Adhesives, solvents, and sealing
compounds can burn easily, can give off
harmful vapors, and are harmful to skin
and clothing. To avoid injury or death,
keep away from open fire and use in
well-ventilated area. If adhesive,
solvent, or sealing compound gets on
skin or clothing, wash immediately with
soap and water.
(1 ?“ Wash injector tube (1) with dry
cleaning solvent.
(18) Lubricate reamer blades while
reaming injector tubes.
CAUTION
Counterclockwise reaming will damage
reamer blades and injector tube.
(19)
(20)
(21)
(22)
Ream injector tube (1) clockwise.
Clean filings from injector tube (l).
Repeat steps (17) through (20) until protrusion gage is flush ± 0.014 in. (0.36 mm).
Clean injector tube (1) with dry cleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(23) Dry with compressed air.
3-57
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
3-9. INJECTOR TUBE REMOVAL/INSTALLATION (CONT).
c. Follow-on Maintenance.
(1) Install exhaust valves (para 7-4).
(2) Install fuel injectors (para 12-2).
(3) Install exhaust valve bridges (para 7-8).
(4) Install rocker arms (para 7-5).
(5) Install brake retarder (para 11-2).
(6) Install cam followers and push rods (para 7-6).
END OF TASK
3-10. VALVE SEAT INSERT REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Installing tool J24357
Puller assembly, J23479-15
Collet, valve seat J23479-13
Set, dial indicator J7872
Equipment Condition
TM or Para
Condition Description
Para 7-5
Para 7-6
Rocker arms removed.
Cam followers and push rods
removed.
Exhaust valve bridges
removed.
Fuel injectors removed.
Exhaust valves removed.
Engine brake retarders
removed.
Para 7-8
Para 12-2
Para 7-4
Para 11-2
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
3-58
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
a. Removal.
NOTE
There are 16 valve seat inserts on a cylinder head. All valve seat inserts are
removed in same manner.
(1) Support cylinder head (l), bottom side up, on two thick wooden blocks.
(2) Remove valve seat insert (2) out of cylinder head (1) using valve seat collet and puller assembly.
b. Installation.
NOTE
New valve seat inserts are pre-ground and need
not be ground after installation. All inserts are
installed in same manner.
(1) Put cylinder head (1) in water heated to a
temperature of 180 to 200°F (82 to 93°C) for
not less than 30 minutes.
WARNING
Be sure to wear protective gloves and clothing to
prevent personal injury when handling heated
part.
(2) Place cylinder head (l), bottom side up, on wooden blocks and place valve seat insert (2), seat
side up, in counterbore.
(3) Drive valve seat insert (2) into place until seated solidly in cylinder head using valve seat insert
installer.
(4) Set dial indicator on cylinder head and check roundness of each valve seat insert relative to
valve guide. Total runout must not exceed 0.002-in. (0.05 mm).
(5) If runout exceeds 0.002-in. (0.05 mm), check for damaged or worn valve guide.
3-59
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
3-10. VALVE SEAT INSERT REMOVAL/INSTALLATION (CONT).
c. Follow-on Maintenance.
(1) Install engine brake retarders (para 11-2).
(2) Install cam followers and push rods (para 7-6).
(3) Install exhaust valves (para 3-8).
(4) Install fuel injectors (para 12-2).
(5) Install exhaust valve bridges (para 7-8).
(6) Install rocker arms (para 7-5).
END OF TASK
3-11. WATER NOZZLE REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Installer, water nozzle J24857-A
Supplies
Equipment Condition
TM or Para
Condition Description
Para 7-5
Para 7-8
Rocker arms removed.
Exhaust valve bridges
removed.
Fuel injectors removed.
Exhaust valves removed.
Cam followers and push rods
removed.
Para 12-2
Para 7-4
Para 7-6
None
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
3-60
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
a. Removal.
NOTE
Repeat steps (1) through (3) for removing all water nozzles.
(1) Install 1/2-in. tap into water nozzle (1) of cylinder head (2).
(2) Tap water nozzle (1) 1/2-in. (12.7 mm) deep.
(3) Remove water nozzle (1) from cylinder head (2).
3-61
TM 9-2815-224-34&P
Cylinder Head Maintenance Instructions (Cont)
3-11. WATER NOZZLE REMOVAL/INSTALLATION (CONT).
b. Installation.
CAUTION
Water nozzles must be installed so holes are pointed toward cylinder for proper
cooling water flow to prevent engine overheating.
NOTE
Repeat steps (1) and (2) to install all water nozzles.
(1) Gently tap water nozzle (1) into water nozzle hole using water nozzle installer.
(2) Make sure nozzle (1) is recessed 0.004-in. (0. 1 mm) into face of cylinder head (2).
(3) Pressure test cylinder head (para 3-8).
co Follow-on Maintenance.
(1) Install cam followers and push rods (para 7-6).
(2) Install exhaust valves (para 7-4).
(3) Install fuel injectors (para 12-2).
(4) Install exhaust valve bridges (para 7-8).
(5) Install rocker arms (para 7-5).
END OF TASK
3-62
TM 9-2815-224-34&P
CHAPTER 4
CRANKSHAFT MAINTENANCE
Para Page
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Crankshaft Pulley Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Vibration Damper Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Oil Pump Drive Gear Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Main Bearing and Crankshaft Removal/Repair/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Crankshaft Cover, Trunnion, and Front Oil Seal Removal/Installation . . . . . . . . . . . . . . . . . . 4-6
4-1
4-1
4-4
4-8
4-10
4-28
Section 1. INTRODUCTION
4-1. GENERAL. This chapter covers removal, installation, and repair of the crank shaft. The
subassemblies and parts which must be removed before the crankshaft components can be removed will be
referenced to other paragraphs or chapters of this manual, TM 9-2320-279-10, TM 9-2320-279-20, or
TM 9-2320-279-34.
Section Il.
CRANKSHAFT ASSEMBLY
Crankshaft Maintenance Instructions
4-2. CRANKSHAFT PULLEY REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Oil, lubricating, Item 48, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
Equipment Condition
TM or Para
Condition Description
TM
TM
TM
TM
Alternator belts removed.
Fan belts removed.
Radiator removed.
Fan removed.
9-2320-279-20
9-2320-279-20
9-2320-279-20
9-2320-279-20
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
4-1
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4-2. CRANKSHAFT PULLEY REMOVAL/INSTALLATION (CONT).
a. Removal.
(1) Remove three screws (1), lockwashers (2), support plate (3), and pulley (4).
(2) Remove screw (5) and retainer (6) from crankshaft pulley (7).
4-2
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
CAUTION
Use care when removing crankshaft pulley.
Do not pry on vibration damper or damage can
occur.
(3)
(4)
Remove crankshaft pulley (7).
Remove two keys (8).
b. Installation
(1)
(2)
(3)
(4)
(5)
(6)
Lubricate end of crankshaft (1) with
lubricating oil.
Install two keys (2) in end of
crankshaft (1).
Install crankshaft pulley (3) on
crankshaft (1).
Install screw (4) and retainer (5).
Tighten screw (4) to 180 lb-ft (224 N•m).
Strike head of screw (4) with soft face
hammer.
NOTE
Some models of crankshafts have a Grade 8
screw. Skip steps (7) and (8) and do steps(8.1)
and (8.2) for those models.
Tighten screw (4) to 300
and strike screw again.
(8) Tighten screw (4) to 300
(8.1) Tighten screw (4) to 450
and strike screw again.
(8.2) Tighten screw (4) to 450
(7)
lb-ft (407 N•m)
lb-ft (407 N•m).
lb-ft (610 N•m)
lb-ft (610 N•m).
Change
2
4-3
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4 - 2 . CRANKSHAFT PULLEY REMOVAL/INSTALLATlON (CONT).
(9) Install support plate (6) and
accessory pulley (7) to
crankshaft pulley (3).
(10) Install three screws (8) and
Lockwashers (9).
(11) Tighten three screws (8) to
25 to 30 lb-ft (33 to
40 N•m).
c. Follow-on Maintenance.
(1) Install radiator (TM 9-2320-279-20).
(2) Install fan belts (TM 9-2320-279-20).
(3) Install alternator belts (TM 9-2320-279-20).
(4) Install fan (TM 9-2320-279-20).
END OF TASK
4-3. VIBRATION DAMPER REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
None
Supplies
Oil, lubricating, Item 48. Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
4-4
TM or Para
Para 4-2
Condition Description
Crankshaft pulley removed
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
a. Removal.
CAUTION
Use care when removing vibration damper, Pounding or prying can den and
cause damage.
(1) Install screw (1) in end of crankshaft (2). Loosen vibration damper (3).
(2) Remove screw (1) and sleeve spacer (4) from crankshaft (2).
4-5
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4-3. VIBRATION DAMPER REMOVAL/INSTALLATION (CONT).
(3)
(4)
Remove vibration damper (3).
Turn cone (5) clockwise and remove from
crankshaft (2) inside trunnion support (6).
NOTE
Some engine models contain a cone with a
preformed packing to provide better oil seal
capability. Replace all cones with cone and
preformed packing combinations. Perform
step (4.1) for those models. Refer to
TM 9-2320-279-24P
(4.1) Remove preformed packing (4.1) from
cone (5).
(5)
(6)
(7)
Position damper (3) in soft jaw vise.
Remove eight screws (7), scuff plate (8),
and hub (9) from vibration damper (3).
Remove two pins (10) from hub (9).
b. Installation.
(1)
(2)
Install two pins (1) in unthreaded bores
in hub (2).
Press two pins (1) through hub (2) until
pins stick out from hub 3/8 in. (9.5 mm).
(3) Install eight screws (3), scuff plate (4),
and hub (2) in vibration damper (5).
(4) Tighten eight screws (3) to 75 to 85 lb-ft
(102 to 115 N•m).
4-8
Change 2
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
NOTE
Some engine models contain a cone with a
preformed packing. Replace all cones with
cone and preformed packing combinations.
Perform step (4.1) for all installations. Refer
to TM 9-2320-279-24P.
(4.1) Lubricate preformed packing (5.1) with
lubricating oil and install in groove on
inner diameter of cone (6).
(5) Apply lubricating oil to cone (6) and
crankshaft (7).
(6) Turn cone (6) clockwise and install tapered
end pointing out on crankshaft (7).
CAUTION
Use care when installing vibration damper.
Pounding or hammering vibration damper can
cause damage.
(7)
(8)
c.
Install vibration damper (5) on
crankshaft (7).
Install sleeve spacer (8) on crankshaft (7)
with tapered end pointing toward
vibration damper (5).
Follow-on Maintenance. Install crankshaft pulley (para 4-2).
END OF TASK
Change
2
4-7
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4-4. OIL PUMP DRIVE GEAR REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INlTlAL SETUP
Models
All
Test Equipment
None
Equipment Condition
TM or Para
Para 4-6
Condition Description
Crankshaft cover and front
oil seal removed.
Special Tools
None
Special Environmental Conditions
None
Supplies
Compound retaining, Item 30, Appendix C
General Safety Instructions
None
Personnel Required
MOS 63W, Wheel vehicle repairer
Level of Maintenance
Direct Support
References
None
NOTE
Some crankshafts will have a split pin in oil
pump drive gear.
a . Removal. Remove oil pump drive gear (1),
spacer (2), woodruff key (3), and split pin (4).
4-8
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
b. Installation.
NOTE
If crankshaft has split pin, do step (1) then step (3). If no split pin, go to step (2).
(1)
Install split pin (1).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
NOTE
There are two models of crankshafts. Model B crankshaft, used in engines with
Serial No. 8VF-098597 and later, has a different machined diameter for the oil
pump drive gear. The oil pump drive gear has not changed but must be pressed on,
without adhesive, for Model B crankshaft. Skip step (2) for Model B crankshafts.
(2)
(3)
(4)
(5)
c.
Apply retaining compound to crankshaft (2).
Install woodruff key (3).
Install spacer (4), finished side facing away from engine (5).
Install oil pump drive gear (6), flat side of hub facing away from engine (5) and beveled side of
hub facing towards engine.
Follow-on Maintenance. Install crankshaft cover and front oil seal (para 4-6).
END OF TASK
Change
2
4-9
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4-5. MAIN BEARING AND CRANKSHAFT REMOVAL, REPAIR, AND INSTALLATION.
This task covers:
a.
b.
c.
Removal
Disassembly
Cleaning/Inspection
d.
e.
f.
Assembly
Installation
Follow-on Maintenance
INITIAL SETUP
Models
All
Equipment Condition
TM or Para
Test Equipment
None
Special Tools
Set, Dial Indicator J7872
Fabricated Tools
Bearing shell remover 2BG623
Supplies
Compound. International No. 2, Item 26.
Appendix C
Oil, fuel, diesel, Item 44, Appendix C
Tags, identification, Item 61, Appendix C
Oil, lubricating, Item 48, Appendix C
Cloth, crocus, abrasive, Item 17, Appendix C
Cloth, cleaning, low-lint, Item 16, Appendix C
Gage. plastic. Item 35, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
None
a. Removal.
(1) Soldier A installs dial indicator on
engine block (1). Soldier B pushes
crankshaft (2) towards gage with pry
bar while Soldier A adjusts dial
indicator to zero.
(2) Soldier A notes end play while
Soldier B removes pry bar and forces
crankshaft (2) in opposite direction.
4-10
Para 8-4
Para 4-6
Para 5-3
Para 7-11
Para 6-2
Para 4-4
Condition Description
Engine turned upside down
on engine stand.
Oil pump removed.
Crankshaft cover and front
seal removed.
Flywheel housing and rear
oil seal removed.
Idler gear removed.
Pistons, connecting rods, and
liners removed.
Oil pump drive gear
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
(3)
Remove six screws (3) and timing gear (4) from crankshaft (2).
NOTE
There are two models of crankshafts and timing gears. Model B crankshaft, used in
engines with Serial No. 8VF-098597 and later, has a roll pin to locate the timing gear.
Model B timing gear, used in the same engines,has a groove to accept the roll pin.
Model A and B parts are interchangeable with the following exception: do not use roll
pin with Model B timing gear and Model A crankshaft, or Model A timing gear and
Model B crankshaft.
Perform step (3.1) for Model B crankshaft and timing gear only.
(3.1)
(4)
(5)
(6)
Remove
Remove
Remove
Remove
roll pin (4.1) from crankshaft (2).
seven screws (5) and washers (6).
ten screws (7).
four bearing cap stabilizers (8 and 9).
Change 2
4-11
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
14-5. MAIN BEARING AND CRANKSHAFT REMOVAL, REPAIR, AND INSTALLATION (CONT).
(7) Install two screws (7) in front main
bearing cap (10) and rear main
bearing cap (11).
(8) Tighten four screws (7) to 50 lb-ft
(5.65 N•m).
(9) Strike front main bearing cap (10)
and rear main bearing cap (11) with
soft-face hammer.
(10) Tighten four screws (7) to 110 lb-ft
(12.43 N•m).
(11) Strike front main bearing cap (10)
and rear main bearing cap (11) with
soft-face hammer.
(12) Tighten four screws (7) to 250 to
260 lb-ft (28.25 to 29.38 N•m).
(13) Install spacer (12) and
screw (13) on front of
crankshaft-(2).
NOTE
Bearing caps are numbered from
1 to 5 for later installation.
(14) Remove three center bearing
caps (14).
NOTE
If bearing shells will be reused, tag and mark them for installation.
(15) Remove lower bearing shells (15) from three center bearing caps (14).
4-12
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
(16) Push upper bearing shell (16) out from under crankshaft main bearing journal No. 2 (17) with
bearing shell remover.
NOTE
Turn crankshaft to aid in removing bearing shell from under bearing journal.
(1 7’) Soldier A removes upper bearing shell (16) while Soldier B turns screw (13) to turn
crankshaft (2).
(18) Repeat steps (16) and (17) for crankshaft main bearing journals No. 3 (18) and No. 4 (19).
(19) Soldier A tells Soldier B to
turn screw (13) to turn
crankshaft (2), while
Soldier A reads runout of
main bearing journals (17,
18, and 19) with dial
indicator.
NOTE
If crankshaft has too much
runout, do steps (21) to (27) to
remove crankshaft, do
steps (28) to (39) to see if bad
bearing shell caused
crankshaft runout. If runout is
within limits only do steps (21)
to (27).
(20) Maximum allowable runout for journals (17 and 19) is 0.002 in. (0.05 mm). Maximum allowable
runout for journal (18) is 0.004 in. (0.10 mm).
4-13
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4-5. MAIN BEARING AND CRANKSHAFT REMOVAL, REPAIR, AND INSTALLATION (CONT). ]
(21) Remove four screws (7) and two bearing caps (10) and (11).
(22) Remove lower bearing shells (15) from bearing caps (10 and 11).
NOTE
Tag and mark thrust washers before removal.
(23) Remove thrust washers (20) from bearing cap (11).
4-14
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
Crankshaft may be bent if stored on side. Store crankshaft on end.
(24) Attach suitable lifting device to crankshaft (2).
(25) Soldier A guides crankshaft (2) while Soldier B operates lifting device to remove crankshaft.
(26) Remove two remaining upper bearing shells (16) from bearing surfaces (21) at front and rear of
engine block (22).
(27) Remove two thrust washers (23) from rear bearing surface (21).
4-15
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
[ 4-5. MAIN BEARING AND CRANKSHAFT REMOVAL, REPAIR, AND INSTALLATION (CONT).
(28) Aline tab (24) on new upper bearing shell (16)
with slot (25) on engine block rear bearing
surface (21).
(29) Install new bearing shell (16). Make sure both
ends of bearing shell are flush with bearing
cap mounting surfaces (26). Install another
new bearing shell on front bearing surface.
(30) Aline tabs (27) with slots (28) and install new bearing shells (29) making sure both ends of
bearing shells are flush with bearing cap mounting surfaces (30).
(31) Install two new thrust washers (31) on rear bearing cap (11) so that grooved sides of thrust
washers point away from bearing cap.
4-16
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
(32) Apply oil to crankshaft front and
rear main bearing journals (32).
(33) Attach suitable lifting device to
crankshaft (2).
(34) Soldier A guides crankshaft (2)
while Soldier B operates lifting
device to install crankshaft.
(35) Push crankshaft (2) to front and
install thrust washer (33). Push
crankshaft to rear and install
other thrust washer.
(36) Install two bearing caps (10
and 11).
(37)) Do steps (7) to (12).
(38) Do steps (19) and (20) but disregard
1note between steps. If crankshaft
1runout is still too high replace
( crankshaft (2).
(39) 1 Do steps (21) to (27).
b. Disassembly.
(1) Remove screw (1) and
spacer (2) from
4-17
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4-5. MAIN BEARING AND CRANKSHAFT REMOVAL, REPAIR, AND INSTALLATION (CONT).
NOTE
Following steps will be done only to
remove loose or broken plugs, studs, and
dowels. Steps (2) through (4) are not
necessary for ordinary cleaning and
inspection.
(2) Remove four studs (4 and 5) from two.
front bearing caps (6).
(3) Remove four dowel pins (7) from rear
bearing cap (8).
(4) Remove four plugs (9) from
crankshaft (3).
c. Cleaning/Inspection.
Fuel is very flammable and can explode
easily. lb avoid serious injury or death,
keep fuel away from open fire and keep
fire extinguisher within easy reach
when working with fuel. Do not work
on fuel system when engine is hot. Fuel
can be ignited by hot engine. Smoking is
prohibited while working with fuel.
(1) Clean crankshaft (1) and bearing
caps (2) with clean diesel fuel and a
lint free cloth.
(2) Flush oil passages (3) in
crankshaft (1).
(3) Visually inspect crankshaft (1) for
signs of burning or overheating.
4-18
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
(4) Inspect crankshaft connecting rod
journals (4) and main bearing journals (5) for deep scratches.
Replace crankshaft (1) if damaged.
(5) Inspect connecting rod journals (4)
and main bearing journals (5) for
signs of cracks at connecting rod
journal oil holes (6) or at joining
points (7) of connecting rod journal
and main bearing journals. Replace
crankshaft (1) if damaged,
(6) Inspect crankshaft keyways (8) for cracks or damage. Replace crankshaft (1) if damaged.
(7) Inspect rear oil seal (9) contact surface for deep scratching. If scratches cannot be smoothed out
with crocus cloth, replace crankshaft (1).
(8) Inspect crankshaft thrust surfaces (10) for grooving. Replace crankshaft (1) if deep grooves have
been scratched in thrust surfaces.
(9) Inspect timing gear (11) for chipped teeth. Replace if damaged.
(10) Measure and note thickness of two thrustwashers (12).
4-19
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4-5. MAIN BEARING AND CRANKSHAFT REMOVAL, REPAIR, AND INSTALLATION (CONT). I -
Table 4-1. Main Bearing and Connecting Rod Journal Diameter Specifications
Minimum Diameter (Main Bearing Journals) (13, 14, 15, 16, and 17) . . . . . . . . . . . 4.498 in. (114.25 mm)
(Connecting Rod Journals) (18) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.998 in. (76.15 mm)
Maximum Journal Out of Round (All Journals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0005 in. (0.013 mm) —
Maximum Taper(All Journals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0004in. (0.010 mm)
Table 4-2. Main Bearing and Connecting Rod Journal Width Specifications
Maximum Width (Main Bearing Journals) (13, 15, 16, and 17) . . . . . . . . . . . . . . . . . . 1.505 in. (38.23 mm)
(Main Bearing Journal) (14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.501 in. (38.12 mm)
(Connecting Rod Journals). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.652 in. (67.36 mm)
Table 4-3. Crankshaft End Play Specifications
Crankshaft end play found in step (18)
Less than 0.016 in. (0.41 mm)
0.017 to 0.026 in. (0.43 to 0.66 mm)
0.027 to 0.036 in. (0.69 to 0.91 mm)
More than 0.36 in. (0.91 mm)
Use this size thrust washer
Standard 0.122 in. (3.1 mm)
Oversized 0.127 in. (3.23 mm)
Oversized 0.132 in. (3.35 mm)
Replace crankshaft
NOTE
Refer to Table 4-1 for steps (11) to
(13). Refer to Table 4-2 for steps (14)
and (15). Refer to Table 4-3 for
steps (16) to (19).
(11) Measure diameter of main bearing
journals (13, 14, 15, 16, and 17) at
several different spots on each.
(12) Measure diameter of connecting rod
journals (18) at several different
spots on each.
(13) Replace crankshaft (1) if journals (13, 14, 15, 16, 17, and 18) are outside limits shown on
Table 4-1.
(14) Measure width of main bearing journals (13, 14, 15, 16, 17) and connecting rod journals (18).
(15) Replace crankshaft if journals (13, 14, 15, 16, 17, and 18) are outside limits shown on Table 4-2.
(16) Add together thickness of two bottom thrust washers measured in step (10).
(17) Subtract total in step (16) from 0.244 in. (6.20 mm).
(18) Subtract result in step (17) from crankshaft end play measured in section a. step (3).
(19) Find amount of crankshaft end play from step (18) on Table 4-3 and read what size thrust
washers to use.
4-20
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cent)
d. Assembly.
NOTE
Do steps (1) to (4) only if the studs, dowels,
and plugs have been removed.
(1) Install two longer studs (1) in front bearing
cap (2).
(2) Install two shorter studs (3) in second
bearing cap (4).
(3) Install four dowel pins (5) in rear bearing
cap (6).
(4) Install four plugs (7) in
crankshaft (8).
e. Installation.
CAUTION
Do not handle bearing shells and thrust
washers more than necessary for
installation. Sweat from hands can damage
bearing shells and thrust washers.
NOTE
Bearing surfaces are numbered 1 to 5 from
front to rear of engine block. Repeat
steps (1) and (2) for four other bearing
surfaces.
(1) Aline tab (1) on upper bearing shell (2)
with slot (3) on engine block bearing
surface (4).
(2) Install shell (2). Make sure both ends of
shell are flush with bearing cap
mounting surfaces (5).
(3) Apply oil to bearing shells (2) after installation.
4-21
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4-5. MAIN BEARING AND CRANKSHAFT REMOVAL, REPAIR, AND INSTALLATION (CONT).
(4) Apply oil to five crankshaft main
bearing journals (6).
(5) Attach suitable lifting device to
crankshaft (7).
(6) Soldier A operates lifting device
while Soldier B installs
crankshaft (7).
(7) Push crankshaft (7) to front and
install thrust washer (8). Push
crankshaft (7) to rear and install
other thrust washer.
(8) Aline tab (9) with slot (10) and install bearing shell (1 1),
making sure both ends of bearing shell are flush with bearing
cap (12) mounting surfaces.
(9) Install four bearing shells (9) on other bearing caps (12).
(10) Install two thrust washers (13) on rear bearing cap (12) so
that grooved sides of thrust washers point away from bearing
cap.
NOTE
Wipe oil from bearing shells and
crankshaft main bearing journals
before doing steps (11) to (13).
(11) Place strip of plastic gage across
width of bearing shell (11)l/4-in.
(6 mm) from center (14).
(12) Do step (11) for four bearing
caps (12).
4-22
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cent)
(13) Install five bearing caps (12).
(14) Strike bearing caps (12) with
soft-face hammer.
CAUTION
When installing bearing cap screws on
engines built prior to Serial No. 8VF085 187
replace all ten flanged head screws
with new 12-point screws with
captured washers. If engine has new
type screws, individual screws may be
replaced. Mixing of old type and new
type screws may cause damage to
engine.
(15) Install ten screws (15).
(16)
(17)
(18)
(19)
Tighten ten screws (15) to 50 lb-ft (68 N-m).
Strike bearing caps (12) with soft-face hammer.
Tighten ten screws (15) to 110 lb-ft (149 N-m).
Tighten ten screws (15) to 230 to 240 lb-ft (312 to 325 N-m).
4-23
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4-5. MAIN BEARING AND CRANKSHAFT REMOVAL, REPAIR, AND INSTALLATION (CONT).
(20) Remove ten screws (15) and five bearing caps (12).
(21) Measure width of plastic gage with measuring strip. Width must be no more than 0.006-in.
(0.15 mm). If greater, replace bearing shells (11).
(22) Wipe plastic gage from five main bearing journals (6) or bearing shells (11) and apply lubricating
oil to those surfaces.
4-24
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
(23) Install five bearing caps (12).
(24) Strike bearing caps (12) with soft-face hammer.
(25) Install four bearing cap stabilizers (16 and 17).
4-25
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4-5. MAIN BEARING AND CRANKSHAFT REMOVAL, REPAIR, AND INSTALLATION (CONT).
(26) Install seven screws (18) and
washers (19). Tighten screws finger
tight.
WARNING
Adhesives, solvents, and sealing
compounds can burn easily, can give
off harmful vapors, and are harmful
to skin and clothing. To avoid injury
or death, keep away from open fire
and use in well-ventilated area. If
adhesive, solvent, or sealing
compound gets on skin or clothing,
wash immediately with soap and
water.
(27) Apply small amount of compound No. 2 to threads of ten screws (15) and surfaces of
stabilizers (16 and 17).
(28) Install ten screws (15).
(29) Strike bearing caps (12) with soft-face hammer.
(30) Tighten eight screws (15) on four front bearing caps (12) to 50 lb-ft (68 N-m) starting with the
middle two caps.
(31) Strike bearing caps (12) with soft-face hammer and tighten eight screws (15) to 110 lb-ft
(149 N-m).
(32) Strike bearing caps (12) with soft-face hammer and tighten eight screws (15) to 230 to 240 lb-ft
(312 to 325 N-om).
4-26
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
Tighten two screws (15) on rear bearing cap (12) to 50 lb-ft (68 N•m).
Strike both ends of crankshaft (7) two or three blows with soft-face hammer.
Strike rear bearing cap (12) with soft-face hammer.
Tighten two screws (15) on rear bearing cap (12) to 110 lb-ft (149 N•m).
Strike rear bearing cap (12) with soft hammer.
Tighten two screws (15) on rear bearing cap (12) 230 to 240 lb-ft (312 to 325 N•m).
Tighten seven screws (18) to 75 lb-ft (102 N•m).
NOTE
There are two models of crankshafts and timing gears. Model B crankshaft, used with
serial No. 8VF-098597 and later, has a roll pin to locate the timing gear. Model B
timing gear, used in the same engines, has a groove to accept the roll pin.
Mode1 A and B parts are interchangeable with the following exception: do not use roll
pin with Mode1 B timing gear and Model A crankshaft, or Mode1 A timing gear and
Mode1 B crankshaft.
Perform step (39.1) for Mode1 B crankshaft and timing gear only.
(39.1)
(40)
(41)
(42)
(43)
Install roll pin (19.1) in crankshaft (7).
Install timing gear (20) and six screws (21).
Install spacer (22) and screw (23) on end of crankshaft (7).
Soldier A holds front end of crankshaft (7) while Soldier B tightens six screws (21) to 40 lb-ft.
(54 Nom).
Remove screw (23) and spacer (22) from crankshaft (7).
Change 2
4-26.1/(4-26.2 blank)
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
(44)
(45)
f.
Soldier A installs dial indicator on
engine block (24). Soldier B pushes
crankshaft (7) towards gage with pry
bar while Soldier A adjusts dial
indicator to zero.
Soldier A reads end play while Soldier B
removes pry bar and forces crankshaft
in opposite direction. Minimum end play
is 0.004 in. (0.10 mm) and maximum
end play is 0.018 in. (0.46 mm). If end
play is outside limits, replace
crankshaft (7).
Follow-on Maintenance.
(1)
(2)
(3)
(4)
(5)
(6)
Install pistons, connecting rods, and
liners (para 6-2).
Install oil pump drive gear (para 4-4).
Install idler gear (para 7-11).
Install flywheel housing and rear oil seal
(para 5-3).
Install crankshaft cover and front oil
seal (para 4-6).
Install oil pump (para 8-4).
END OF TASK
Change 2
4-27
TM 9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4-6. CRANKSHAFT COVER AND FRONT SEAL REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Oil, lubricating, Item 48, Appendix C
Grease, automotive and artillery, Item 36,
Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Alternator support and
adjusting strap removed.
Para 4-3
Vibration damper removed.
Para 8-3
Oil pan removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
References
None
a. Removal.
(1) Support engine with a suitable lifting device.
(2) Remove two screws (1) six washers (2) and two locknuts (3) from support (4).
4-28
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cent)
(3) Remove two screws (5) and
lockwashers (6) from support (4).
(4) Remove support (4) and ring (7) --
-
(5) Remove four screws (9) and lockwashers (10)
from trunnion (8).
(6) Remove two screws (11 ) and
lockwashers (12).
(7) Remove two screws (13) and
lockwashers (14).
(8) Remove trunnion (8) from crankshaft
cover (15).
(9) Remove two screws (16) and lockwashers (17) from inside crankshaft cover (15).
(10) Remove crankshaft cover (15) and gasket (18).
(11) Remove old sealant from crankshaft cover (15) and engine block (19).
4-29
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cent)
4-6. CRANKSHAFT COVER AND FRONT SEAL REMOVALI/INSTALLATION (CONT). I
Support crankshaft cover (15) outer face on two
wooden blocks.
(13) Drive front seal (20) out front side of crankshaft
cover (15).
(12)
b. Installation.
NOTE
Do not remove lubricant or plastic coating on outer
surface of new front seal.
(1) Coat sealing lip of front seal ( 1 ) with grease.
(2) Position front seal (1) in crankshaft cover (2) with
sealing lip of front seal against inner face of (’crankshaft
cover.
(3) Drive front seal (1) into crankshaft cover (2).
Coat gasket (3) with grease and
install on engine block (4).
(5) Install crankshaft cover (2) on
dowels (5) and engine block (4)
while sliding oil seal (1) over
crankshaft (6).
(4)
4-30
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cent)
(6) Install two screws (7) and lockwashers (8) in
crankshaft cover (2).
(7) Tighten two screws (7) to 80 to 90 lb-ft (108 to
122 N-m).
(8) Position trunnion (9) against crankshaft
cover (2).
(9) Install four screws (10) and lockwashers(11)
in trunnion (9).
(10) Install two screws (12) and lockwashers (13).
(11) Install two screws (14) and lockwashers (15).
(12) Tighten screws (12 and 14) to 30 to 35 lb-ft
(41 to 47 N-m).
(13) Tighten screws (10) to 70 to 75 lb-ft (94 to
102 N-m).
(14) Coat ring (16) with light coat of grease and slide over trunnion (9).
4-31
TM9-2815-224-34&P
Crankshaft Maintenance Instructions (Cont)
4-6.
CRANKSHAFT COVER AND FRONT SEAL REMOVAL/iNSTALLATION (CONT). ]
(15) Install bottom half of support (17) on engine support
bracket (18).
(16) Install two screws (19), six washers (20), and two
locknuts (21) in support (17).
(17) Install top half of support (17).
(18) Install two screws (22) and lockwashers (23) to support (17).
(19) Tighten screws (22) to 45 to 50 lb-ft (61 to 67 N-m).
(20) Remove lifting device from engine.
c. Follow-on Maintenance.
(1) Install oil pan (para 8-3).
(2) Install vibration damper (para 4-3).
(3) Install alternator bracket (TM 9-2320-279-20).
END OF TASK
4-32
TM9-2815-224-34&P
CHAPTER 5
FLEXPLATE AND FLYWHEEL HOUSING MAINTENANCE
Para Page
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
FlexplateRemoval/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:2
Flywheel Housing and Rear Oil Seal Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Section I.
5-1
5-1
5-3
INTRODUCTION
5-1. GENERAL. This chapter includes removal, installation, and repair of the flexplate and flywheel
housing. The subassemblies and parts which must be removed before the flexplate and the flywheel
housing components can be removed will be referenced to other paragraphs or chapters of this manual,
TM 9-2320-279-10, TM 9-2320-279-20, or TM 9-2320-279-34.
Section
Il.
FLEXPLATE AND FLYWHEEL HOUSING
Flexplate and Flywheel Housing Maintenance Instructions
5-2. FLEXPLATE REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
References
All
None
Test Equipment
None
Special Tools
None
Supplies
Compound, international, No. 2, Item 26,
Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-34 Transmission removed from
engine.
Special Environmental Condition
None
General Safety Instructions
None
Level of Maintenance
Direct Support
5-1
TM9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cent)
5-2. FLEXPLATE REMOVAL/INSTALLATION (CONT). ]
a. Removal.
(1) Remove 12 screws (1) and plate (2), from flywheel housing (3).
Mark flexplate disks for proper installation.
(2) Remove five disks (4) from flywheel housing (3).
(3) Remove 12 screws (5), plate (6), and hub (7) from crankshaft (8).
b. Installation.
(1) Aline screw holes in hub (7) with crankshaft (8) in flywheel housing (3).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(2) Apply international No. 2 compound to 12 screws (5).
(3) With rough side toward engine, install hub (7), plate (6), and 12 screws (5). Tighten screws to
50 lb-ft (67 N-m) and an additional 1/4 turn.
(4) Apply international No. 2 compound to 12 screws (l).
(5) Aline screw holes in five disks (4) and plate (2) with hub (7).
(6) Install five disks (4), plate (2), and 12 screws (l). Tighten screws to 100 lb-ft (135 N-m).
c. Follow-on Maintenance. Install transmission (TM 9-2320-279-34).
END OF TASK
5-2
TM 9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
5-3. FLYWHEEL HOUSING AND REAR OIL SEAL REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Stud set, alinement J1927--01
Stud set, alinement J25002
Installer, seal J21112-B
Expander, seal J4239
Handle J3154-1
Tool set, seal and wear sleeve J35686
Fabricated Tools
Lifting eyes 2BH944
Supplies
Oil, lubricating, Item 48, Appendix C
Grease, automotive and artillery, Item 36,
Appendix C
Compound, sealing, pipe thread, Item 32,
Appendix C
Compound, sealing, lubricating, Item 31,
Appendix C
Compound, sealing, Item 30.1, Appendix C
Tags, identification, Item 61, Appendix C
Cloth, crocus, abrasive, Item 17, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Air compressor removed.
TM 9-2320-279-20 Starting motor removed.
TM 9-2320-279-34 Steering hydraulic pump
removed.
TM 9-2320-279-34 Engine removed.
Para 8-3
Oil pan removed.
Para 5-2
Flexplate removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Change 4
5-3
TM 9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
5-3. FLYWHEEL HOUSING AND REAR OIL SEAL REMOVAL/INSTALLATION (CONT).
a.
Removal.
(1)
(2)
(3)
(4)
Install two lifting eyes,
support flywheel housing (1) with suitable lifting device.
Remove three screws (2), lockwashers (3), washers (4), and left bank bracket (5)
Remove three screws (6), lockwashers (7), washers (8), and right bank bracket (9).
NOTE
Tag and mark screws (10), (12), (14),
and (16).
(5) Remove six screws (10) and
washers (11) from flywheel
housing (1).
(6) Remove six screws (12) and
lockwashers (13) from
flywheel housing (1).
(7) Remove four screws (14)
and washers (15) from
flywheel housing (1).
(8)
Remove three screws (16)
and washers (17) from
flywheel housing (1).
NOTE
Screws (18), (21), (26), (29), (31),
(34), and (37) and washers (19), (22),
(27), (36), (32), (35), and (38) must
not De reused.
5-4
Change 2
TM9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
(9) Remove five screws (18)
and lockwashers (19) from
access cover (20).
(10) Remove screw (21) and
copper washer (22).
(11) Remove access cover (20)
and gasket (23).
(12) Remove three nuts (24),
lockwashers (25), screws (26), and
washers (27) from access cover (28).
(13) Remove two screws (29) and lockwashers (30).
5-5
TM9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
5-3. FLYWHEEL HOUSING AND REAR OIL SEAL REMOVAL/INSTALLATION (CONT). I
(14) Remove screw (31) and washer (32),
(15) Remove access cover (28) and gasket (33).
(16) Remove two screws (34) and lockwashers (35) from
access plate (36).
(17) Remove three screws (37) and lockwashers (38) from
access plate (36).
5-6
TM9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
NOTE
Copper washer must not be reused.
(18) Remove screw (39), copper washer (40),
and nut (41 ).
(19) Remove access plate (36) and
gasket (42).
(20) Remove two screws (43) and
lockwashers (44).
(21) Remove screw (45) and washer (46) from air
box drain retaining clip (47).
5-7
TM9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
5-3. FLYWHEEL HOUSING AND REAR OIL SEAL REMOVAL/INSTALLATION (CONT). [
CAUTION
Screw inside access hole must
be removed. Failure to remove
screw may cause flywheel
housing to crack when hoisted
from engine.
NOTE
Screw must not be reused.
(22) Remove screw (48) from
access hole,
(23) Install four alining studs
from alinement stud set in
engine block (49).
WARNING
Make sure lifting device is
secured. Keep hands and feet
out from under flywheel
housing when removing from
engine. Falling parts may
cause serious personal injury.
(24) Remove flywheel
housing (1) from rear end of
engine block (49).
(25) Remove pipe plug (50) from
bottom of flywheel
housing (1).
(26) Remove pipe plug (51 ) from
back side of flywheel
housing (1).
5-8
TM 9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
(27)
Remove crankshaft rear oil seal (52)
from flywheel housing (1).
CAUTION
Use care not to damage crankshaft when
removing crankshaft rear oil sleeve.
NOTE
Rear oil sleeve may not be present on
crankshaft.
(27.1) Remove sleeve (52.1) by splitting with a
chisel and hammer.
(28) Remove gasket (53) from engine block rear
end plate (54) and flywheel housing (1).
CAUTION
Crankshaft must be clean and smooth or oil
seal lip will be damaged when flywheel
housing is installed.
NOTE
Polishing motion should be clockwise around
end of crankshaft.
(29)
(30)
(31)
(32)
Polish end of crankshaft (55) with
crocus cloth wet with lubricating oil.
Lubricate gear train teeth (56) with
lubricating oil.
Remove four alining studs from engine
block (49).
Remove lifting eyes.
Change
2
5-9
TM 9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance instructions (Cont)
5-3. FLYWHEEL HOUSING AND REAR OIL SEAL REMOVAL/INSTALLATION(CONT).
a. Installation.
(1) Install two lifting eyes.
(2) Set flywheel housing (1), engine side
down, on flat surface.
(3) Deleted.
LIFTING EYES
(4)
(5)
(6)
Apply grease to engine side of flywheel
housing (1).
Install gasket (3) on engine side of
flywheel housing (1).
Apply grease to gasket (3).
5-10 Change 2
TM9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
WARNING
Adhesives, solvents, and
sealing compounds can burn
easily, can give off harmful
vapors, and are harmful to
skin and clothing. To avoid
injury or death, keep away
from open fire and use in
well-ventilated area. If
adhesive, solvent, or sealing
compound gets on skin or
clothing, wash immediately
with soap and water.
(7) Coat threads of pipe
plugs (4 and 5) with pipe
thread sealing compound and install pipe plug (4) in back side of flywheel housing (1).
(8) Install pipe plug (5) in bottom of flywheel housing (l).
(9) Coat lip of crankshaft oil seal (2) with lubricating oil.
(10) Install four alining studs in engine block (6).
5-11
TM9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
5-3. FLYWHEEL HOUSING AND REAR OIL SEAL REMOVAL/INSTALLATION (CONT). [
(11) Soldier A operates lifting device
while Soldier B installs flywheel
housing (1) over crankshaft (7)
against engine block (6).
(12) Install new screw (8).
(13) Install screw (9) and washer (10) to air box
drain retaining clip (11) on right side of
engine.
5-12
TM9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
(14) Install two screws (12) and lockwashers (13).
(15) Apply grease to gasket (14) and install gasket
and access plate (15) to flywheel housing (1).
(16) Install screw (16), new copper washer (17),
and nut (18),
(17) Install three screws (19) and lockwashers (20).
5-13
TM9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
5-3. FLYWHEEL HOUSING AND REAR OIL SEAL REMOVAL/INSTALLATION (CONT). 1
(18) Install two screws (21) and lockwashers (22).
(19) Apply grease to gasket (23).
(20) Install gasket (23), access plate (24),
screw (25), and washer (26) to flywheel
housing (1).
(21) Install two screws (27) and lockwashers (28).
5-14
TM9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cent)
(22) Install three screws (29), washers (30),
lockwashers (31), and nuts (32).
(23) Install four screws (33) and
washers (34) in flywheel
housing (1).
(24) Install three new screws (35)
and washers (36).
(25) Coat six screws (37) with
sealing compound and install
screws and washers (38).
(26) Remove lifting eyes and four
alining studs from engine block (6).
5-15
TM9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
5-3. FLYWHEEL HOUSING AND REAR OIL SEAL REMOVAL/INSTALLATION (CONT). [
(27) Install six screws (39) and washers (40).
(28) Install three screws (41), lockwashers (42), washers (43), and right bank bracket (44).
(29) Install three screws (45), lockwashers (46), washers (47), and left bank bracket (48).
5-16
TM 9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
NOTE
Screws are numbered to show tightening sequence. Screws must be tightened in
order.
(30 Tighten first six screws in flywheel housing (1) to 90 to 100 lb-ft (122 to 136 N•M).
(31) Tighten seventh through ninth screws to 40 to 45 lb-ft (54 to 61 N•m).
(32) While Soldier A turns crankshaft screw (49) clockwise, Soldier B tightens tenth through twelth
screws to 10 to 45 lb-ft (5.4 to 61 N•m) then tells Soldier A to stop turning Screw (49).
(33) Tighten thirteenth through twenty seventh screws to 25 to 30 lb-ft (34 to 41 N•m).
(34)
Tighten screw (9) on right side of engine to
40 to 45 lb-ft (54 to 61 N•m).
5-17
TM 9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
5-3.
FLYWHEEL HOUSING AND REAR OIL SEAL REMOVAL/INSTALLATION (CONT).
(35)
(36)
(37)
(38)
(39)
(40)
(41)
Tighten twenty-eighth screw on flywheel
housing (1) to 30 to 35 lb-ft (41 to 47 N•m).
Tighten twenty-ninth and thirtieth screws to
137 to 147 lb-ft (186 to 200 N•m).
Apply grease to gasket (50).
Install screw (51), copper washer (52), access cover (53), and gasket (50)
Install five screws (54) and lockwashers (55).
Tighten screws (51 and 54) to 25 to 30 lb-ft (34 to 41 N•m).
Tighten four screws (21 and 27) to 25 to 30 lb-ft (34 to 41 N•m).
5-18 Change 2
TM 9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
CAUTlON
Standard rear crankshaft oil seal with Teflon lip should only be installed on new
crankshaft. Oversize oil seal with Teflon lip and sleeve should be installed on worn
crankshaft. Failure to comply could result in seal damage and oil leakage.
During installation of sleeve, make sure outside diameter of sleeve remains clean and
dry. Failure to comply could result in oil leakage.
NOTE
To install oversize rear crankshaft oil seal, do steps (42) through (48) and continue
with step (55). To install standard oil seal, do steps (49) through (60).
(42)
Apply a thin even coating of sealing
compound (Item 30.1, Appendix C) to
inside diameter of sleeve (56).
(43)
Install sleeve (56) in housing with
chamfered end of sleeve out.
CAUTION
Do not lubricate Teflon seal lip or outside of sleeve before installing seal. Teflon lip
seals must be installed dry to allow transfer of Teflon to sleeve for proper sealing.
Seals are designed for use on either right-hand or left-hand rotating engines.
Direction is indicated by an arrow molded into seal face. Failure to install correct
rotation seal will result in seal damage and oil leaks.
(44)
With arrow showing crankshaft rotation toward housing, slide oversize oil seal (57) onto
protruding end of sleeve (56) and against housing.
Change 2
5-18.1
TM 9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
5-3. FLYWHEEL HOUSING AND REAR OIL SEAL REMOVAL/INSTALLATION (CONT).
(45)
Install base on end of crankshaft (7) with two
guide studs. Tighten guide studs until base
is firmly against end of crankshaft.
(46)
Install spacer over center screw of base.
(47)
Install installation tool housing, with sleeve
(56) and oversize oil seal (57), onto guide
studs with thrust washer and nut. Tighten
nut by hand until snug. Further tighten nut
until installation tool housing is seated
against base.
Remove installation tools from end of
crankshaft (7).
(48)
5-18.2 Change 2
TM 9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
(49)
(50)
Install two guide studs in rear of
crankshaft (7).
Install oil seal expander on guide studs and
against end of crankshaft (7).
CAUTION
(51)
(52)
(53)
(54)
(55)
(56)
(57)
Do not lubricate Teflon seal lip or outside of
crankshaft before seal installation. Teflon lip
seals must be installed dry to allow transfer
of Teflon to crankshaft for proper sealing.
Seals are designed for use on either
right-hand or left-hand rotating engines.
Direction is normally indicated by an arrow
on seal case. Failure to install correct
rotation seal will result in seal damage and
oil leaks.
With lip of seal (2) pointed toward engine,
slide seal over expander and onto crankshaft.
Remove seal expander and guide studs.
Install guide studs in rear of crankshaft (7).
Position seal installer on guide studs and
install handle.
Drive seal (2) in place until seal installer
seats squarely on end of crankshaft (7).
Remove installation tools.
Attach magnetic base dial indicator to end of
crankshaft (7).
Position point of dial indicator on face of seal (2).
Pry crankshaft (7) toward one end of block to ensure
end play is in one direction only.
CAUTION
When using front crankshaft screw to bar over engine, always
turn crankshaft in clockwise direction. Turning engine over in
a counterclockwise direction may loosen screw and vibration
damper. Failure to comply may result in serious engine
damage.
(58)
(59)
(60)
Soldier A rotates crankshaft (7) clockwise while
Soldier B records readings at 12,9,6, and 3 o’clock
positions. Total runout at each position should not
exceed 0.015 in. (0.38 mm).
If any dial indicator reading exceeds 0.015 in. (0.38
mm), place appropriate seal installer over seal (2)
and lightly tap at high points.
Repeat step (58). If seal (2) will not seat properly,
remove and replace seal.
Change 2
5-18.3
TM 9-2815-224-34&P
Flexplate and Flywheel Housing Maintenance Instructions (Cont)
5-3. FLYWHEEL HOUSING AND REAR OIL SEAL REMOVAL/INSTALLATION (CONT).
c.
Follow-on
(1)
(2)
(3)
(4)
(5)
(6)
Install
Install
Install
Install
Install
Install
END OF TASK
5-18.4 Change 2
Maintenance.
flexplate (para 5-2).
oil pan (para 8-3).
steering hydraulic pump (TM 9-2320-279-34).
starting motor (TM 9-2320-279-20).
air compressor (TM 9-2320-279-20).
engine (TM 9-2320-279-34).
TM9-2815-224-34&P
CHAPTER 6
PISTON AND CONNECTING ROD MAINTENANCE
Para
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Piston, Connecting Rod and Liner Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Section 1.
Page
6-1
6-1
6-7
INTRODUCTION
6-1. GENERAL. This chapter covers removal and installation of the piston and connecting rod
assemblies. The subassemblies and parts which must be removed before the piston and connecting rod can
be removed will be referenced to other paragraphs chapter of this manual, TM 9-2320-279-10,
TM 9-2320-279-20, or TM 9-2320-279-34.
Section Il.
PISTON AND CONNECTING ROD
Piston and Connecting Rod Maintenance Instructions
6-2. PISTON, CONNECTING ROD, AND LINER REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Remover assembly, cylinder liner J24563-A
Clamp, cylinder liner J24565-02
Supplies
Oil, lubricating, Item 48, Appendix C
Tags, identification, Item 61, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-34 Engine installed on engine
stand.
Oil pan removed.
Para 8-3
Oil pump removed.
Para 8-4
Cylinder head removed.
Para 3-7
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
None
6-1
TM9-2815-224-34&P
Piston and Connecting Rod Maintenance Instructions (Cont)
6-2. PISTON, CONNECTING ROD,
AND LINER REMOVAL/INSTALLATION (CONT). I
a. Removal.
NOTE
Repeat steps (1) through (4) for each
cylinder liner.
(1) Move piston (1) so top is just above
air inlet ports in cylinder liner (2).
(2) Place clean rag on top of piston (1)
to catch carbon deposits as they are
removed from cylinder liner (2).
(3) Scrape carbon ridge from top of
cylinder liner (2).
(4) Remove rag and carbon residue
from cylinder liner (2).
(5)
(6)
6-2
TM9-2815-224-34&P
Piston and Connecting Rod Maintenance Instructions (Cont)
NOTE
Cylinder liner may come out with piston.
(7) Soldier A pushes piston (l), connecting
rod (7), and bearing shell (8) out through
engine block (9) and Soldier B removes
piston from engine block.
(8) Place bearing cap (5), upper shell (6),
lower shell (8), and two nuts (3) back on
two bearing cap screws (4) to keep
matched parts together.
(9) Remove seven remaining pistons (1) and
connecting rods (7).
(10) Turn engine stand to place cylinder
head bank facing up.
(11) Matchmark cylinder liner (2) and
engine block (9).
NOTE
Crankshaft may have to be turned to
allow for clearance of special tool.
(12) Using cylinder liner removal tool,
remove liner (2).
6-3
TM9-2815-224-34&P
Piston and Connecting Rod Maintenance Instructions (Cont)
6-2. PISTON, CONNECTING ROD, AND LINER REMOVAL/INSTALLATION (CONT). [
NOTE
Tag cylinder liner insert noting cylinder number.
(13) Remove cylinder liner insert (10).
(14) Remove two cylinder liner seal rings (11 ).
b. Installation.
(1) Wipe cylinder bore, counterbore, and seal
ring grooves clean.
(2) Install two cylinder liner seal rings (1) in
engine block (2).
(3) Apply lubricating oil to inner surface of
cylinder liner seal rings (1).
(4) Install liner insert (3) in counterbore of
engine block (2).
(5) Apply lubricating oil to piston rings (4),
(6) Install piston (5) into ring compressor.
6-4
TM 9-281 5-224-34&P
Piston and Connecting Rod Maintenance Instructions (Cont)
(7) Coat inside of cylinder liner (6) with lubricating oil.
(8) Soldier A holds cylinder liner (6), flange end down, on wood block
and Soldier B places ring compressor with piston and connecting rod
assembly (7) on cylinder liner.
(9) Aline numbers on rod bearing cap (8) with marks on cylinder
liner (6).
(10) Push piston and connecting rod assembly (7) into cylinder liner (6)
until piston is free from ring compressor. Remove ring compressor.
(11) Remove two nuts (9), bearing cap (8), and bearing shells (10).
(12) Push piston into cylinder liner (6) until compression rings pass
cylinder liner ports (11 ).
(13) Coat connecting rod bearing shells (10) with lubricating oil.
(14) Position crankshaft connecting rod
journal (12) of cylinder being worked to
bottom of its travel.
(15) Coat journal (12) with lubricating oil.
(16) Aline mark on cylinder liner (6) with mark on engine
block (2).
(17) Soldier A slides cylinder liner (6) with piston and
connecting rod assembly (7) into engine block (2) while
Soldier B guides connecting rod assembly over
crankshaft journal.
6-5
TM 9-2815-224-34&P
Piston and Connecting Rod Maintenance Instructions (Cont)
6-2. PISTON, CONNECTING ROD, AND LINER REMOVAL/INSTALLATION (CONT).
(18) Seat connecting rod firmly on crankshaft
journal (12).
(19) Install cap (8) and bearing shell (10) over
studs (13).
(20) Install two nuts (9) and tighten to 70 lb-ft
(95 N•m).
TA357426
NOTE
Install holddown clamps, screws,
and washers to hold liners in
place.
(21) After all liners and pistons
have been installed, remove
screws, washers, and
holddown clamps.
HOLD DOWN
CLAMP
SCREWS AND
WASHERS
TA357427
(22) Using feeler gage, check that clearance
between each connecting rod attached to
same crankshaft journal is 0.008 to 0.016 in.
(0.2 to 0.4 mm).
c. Follow-on Maintenance.
(1) Install cylinder head (para 3-7).
(2) Install oil pump (para 8-4).
(3) Install oil pan (para 8-3).
(4) Remove engine from engine stand
(TM9-2320-279-34).
END OF TASK
6-6
FEELER
TA357428
TM 9-2815-224-34&P
Piston and Connecting Rod Maintenance Instructions (Cont)
6-3. PISTON REPAIR.
This task covers:
a. Disassemble y
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
Personnel Required
MOS 63W, Wheel vehicle repairer
Test Equipment
Spring scale
References
None
Special Tools
Tool, piston pin retainer J23762
Gage set, piston J3174-02
Gage, crown, piston J25397
Gage, piston groove J24599
Leak detector set J23987-01
Equipment Condition
Supplies
Solvent, dry cleaning, Item 60, Appendix C
Oil, lubricating, Item 48, Appendix C
Compound, international, No. 2, Item 26,
Appendix C
Tags, identification, Item 61, Appendix C
Brush, paint, oval 1-1/4 in. (32 mm) size 12,
Item 10, Appendix C
TM or Para
Para 6-2
Condition Description
Piston, connecting rod and
liner removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
a. Disassembly.
(1) Place connecting rod (1) in vise
with soft jaws.
(2) Remove three upper piston
rings (2) using piston ring
remover and installer. Remove
four lower piston rings (3) by
hand.
(3) Remove oil ring expander (4)
from each lower piston ring
groove.
(4) Punch hole in two piston pin
retainers (5). Remove both
retainers.
(5) Loosen two screws (6).
(6) Remove connecting rod (1) and
piston (7) from vise.
(7) Remove two screws (6) and two
spacers (8).
TA357429
NOTE
Matchmark connecting rod before removal.
(8) Remove connecting rod (1) from piston (7).
6-7
TM 9-2815-224-34&P
Piston and Connecting Rod Maintenance Instructions (Cont)
6-3. PISTON REPAIR (CONT).
NOTE
Matchmark piston pin, piston crown, piston skirt, and
piston pin bearing before removal.
(9) Remove piston pin (9).
(10) Separate piston crown (10) from piston skirt (11).
(11) Remove metal seal ring (12) from piston crown (10).
(12) Remove piston pin bearing (13).
b. Cleaning/lnspection.
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful to
skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and water.
(1) Clean all metal parts with dry cleaning solvent.
(2) Clean ring grooves and oil holes in pistons with paint brush and dry cleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(3) Dry parts with compressed air.
(4) Inspect all parts for damage. Replace damaged parts.
(5) Check fire ring groove (1) of piston crown (2) with
piston groove gage tool.
NOTE
Piston crown, bearing, and pin must be replaced as an
assembly.
(6) Slide groove gage completely around groove (1). If
wire is below flush at any one area, replace
crown (2).
6-8
TM 9-2815-224-34&P
Piston and Connecting Rod Maintenance Instructions (Cont)
(7) Measure diameter of piston skirt (3) and check for roundness.
Diameter must not be less than 4.829-in. (122,6 mm) at any one
point.
TA357432
(8) With cylinder liner (4) installed in
engine block (5), Soldier A holds
piston skirt (3) upside down in liner.
Soldier B attaches spring scale to
feeler gage set and checks clearance
in four places 90 degrees apart.
(9) Select feeler gage thickness that will
require a pull of 6 pounds (2.7 kg).
Clearance will be 0.001-in. (0.25 mm)
greater than feeler gage thickness
when it is withdrawn with a pull of
6 pounds (2.7 kg). Clearance must not
exceed 0.012-in. (0.3 mm).
(10) Insert piston rings (6), one at a time inside
cylinder liner (4) far enough to be in area of ring
travel 2 to 3 in. deep. Use piston skirt to
position ring parallel with top of cylinder liner.
(11) Measure ring gap (7) with feeler gage. Three
compression rings should have a gap of 0.025 to
0.045 in. (0.63 to 1.1 mm). Top compression ring
is marked with two punch marks, middle
compression ring is marked with one punch
mark and bottom compression ring is not punch
marked. Two oil rings (upper slotted) should
have a gap of 0.007 to 0.017 in. (0.2 to 0.4 mm).
Two oil rings (lower) should have a gap of
0.010 to 0.025 in. (0.25 to 0.63 mm).
TA357434
6-9
TM 9-2815-224-34&P
Piston and Connecting Rod Maintenance Instructions (Cont)
6-3. PISTON REPAIR (CONT).
(12) Install top compression ring (8)
with two punch marks up.
(13) Measure clearance between ring (8)
and groove; clearance should be
0.001 to 0.005 in. (0.025 to
0.13 mm).
PUNCH
MARKS
TA357435
(14) Put middle compression ring (9)
with one punch mark in groove on
piston dome (10); clearance should
be 0.010 to 0.013 in. (0.25 to
0.33 mm).
(15) Put lower compression ring in
groove on side of piston dome (10);
clearance should be 0.004 to
0.007 in. (0.10 to 0.18 mm).
(16) Put seal ring in groove on side of
piston dome (10); clearance should
be 0.0010 to 0.003 in. (0.025 to
0.08 mm).
(17) Using edge of piston crown gage marked "92T
Go, 92 NA No Go”, check piston dome (10) by
setting piston crown gage into bowl of piston
crown. Gage must rest fully down on rim of
piston crown.
6-10
TA357436
TM 9-2815-224-34&P
Piston and Connecting Rod Maintenance Instructions (Cont)
c. Assembly.
NOTE
Be sure to aline all match marks.
(1) Place piston crown (l), top end down, on work
bench.
(2) Install piston pin bearing (2).
(3) Coat metal seal ring (3) with lubricating oil.
(4) Install metal seal ring (3) on piston crown (1).
Beveled side must face toward bottom of piston
crown (l).
(5) Rotate metal seal ring (3) fully around piston
crown (1) and be sure it turns freely with no
sticking or binding.
(6) Compress metal seal ring (3) and push piston
skirt (4) down into position on piston crown (1).
(7) Hold piston crown (1) and spin piston skirt (4).
Piston skirt (4) must turn freely with no binding.
(8) Coat piston pin (5) with lubricating oil.
(9) Line up hole in piston skirt (4) with hole in piston crown (l).
(10) Install piston pin (5) with threaded holes toward bottom of piston skirt (4).
TA357438
NOTE
Retainers must be seated fully and evenly in piston skirt.
(11) Install piston pin retainers (6) in piston skirt (4) at each side of piston pin (5) using piston pin
retainer tool; install until they bottom out.
(12) Using leak detector, apply 10-in. (254 mm) of vacuum to each piston pin retainer (6). There
should be no loss of pressure.
(13) Install two spacers (7) on two screws (8).
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing. To
avoid injury or death, keep away from open
fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets
on skin or clothing, wash immediately with
soap and water.
(14) Apply small amount of international No. 2
compound to threads and head contact
surface of two screws (8).
(15) Insert connecting rod (9) into piston skirt (4).
(16) Install screws (8) and tighten finger tight.
(17) Clamp connecting rod (9) in vise with soft jaws.
(18) Tighten screws (8) to 55 to 60 lb-ft (75 to 81 N•m).
TA357439
6-11
TM 9-2815-224-34&P
Piston and Connecting Rod Maintenance Instructions (Cont)
6-3. PISTON REPAIR (CONT).
NOTE
Replace piston rings in sets only.
(19) Coat piston crown (1) and skirt (4) with lubricating oil.
NOTE
Position ring gaps 1200 apart, around piston crown.
(20) Install lower piston ring (10) (ring without marks).
(21) Install middle piston ring (11) (ring with one punch mark)
toward top of piston crown (1).
(22) Install top piston ring (12) (ring with two punch marks)
toward top of piston crown (1).
CAUTION
To prevent damage to oil rings when piston is
installed in ring compressor, make sure ends of
expander rings do not overlap.
(23) Install two oil ring expanders (13) on piston
skirt (4) with ends pointing upward.
NOTE
Install oil rings wit h beveled edge facing
upward.
(24) Install chrome nonsloted, oil ring (14) with
gap posit ion 180 degrees from gap in
expander ring (1 3).
(25) Install nonslot ted oil ring (15) with gap
positioned 90 degrees from gap in oil
TA357441
ring (14).
(26) Install oil ring (16) wit h black, slotted bottom down and gap positioned 180 degrees from gap in
expander ring ( 13).
(27) Install oil ring ( 17) with black slotted bot tom down and gap positioned 90 degrees from gap in oil
ring (16).
d. Follow-on Maintenance. Install piston, connecting rod and liner (para 6-2).
END OF TASK
6-12
TM 9-2815-224-34&P
CHAPTER 7
VALVE MECHANISM MAINTENANCE
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Bridge Guide Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Guide Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Valve Removal/Repair/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arm Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cam Follower/Push Rod Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cam Follower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Valve Bridge Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Removal/Repair/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft End Bearing Bushing Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Gear Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Balance Cover and Vibration Damper Removal/Installation . . . . . . . . . . . . . . . . . . . . .
Section I.
Para
7-1
7-2
7-3
7-4
745
7-6
7-7
7-8
7-9
7-10
7-11
7-12
Page
7-1
7-1
7-3
7-5
7-8
7-11
7-15
7-16
7-20
7-34
7-36
7-43
INTRODUCTION
7-1. GENERAL. This chapter covers removal, installation, and repair of the valve mechanism. The
subassemblies and parts which must be removed before these components can be removed will be
referenced to other paragraphs of this manual, TM 9-2320-279-10, TM 9-2320-279-20, or TM 9-2320-279-34.
Section II.
VALVE MECHANISMS
Valve Mechanism Maintenance Instructions
7-2. VALVE BRIDGE GUIDE REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
Equipment Condition
TM or Para
Condition Description
Para 11-2
Engine brake retarder
removed.
Rocker arms removed.
Exhaust valve bridges
removed.
Fuel injectors removed.
Exhaust valves removed.
None
Special Tools
Installer, valve bridge guide J7482
Supplies
None
Personnel Requi red
MOS 63W Wheel vehicle repairer
References
None
Para 7-5
Para 7-8
Para 12-2
Para 7-4
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
7-1
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-2. VALVE BRIDGE GUIDE REMOVAL/INSTALLATION (CONT).
a. Removal.
TA357657
(1) Break off bridge guide (1).
(2) Center punch bridge guide (l).
(3) Drill hole into bridge guide (1) using no. 3, 0.213 in. drillbit.
(4) Using screw extractor, remove bridge guide (1) from cylinder head (2).
b. Installation.
(1) Install undercut edge of bridge
guide (1) in tap hole.
(2) Install bridge guide (1) straight into
cylinder head (2) using valve bridge
guide installer.
c. Follow-on Maintenance.
(1) Install exhaust valves (para 7-4).
(2) Install fuel injectors (para 12-2).
(3) Install exhaust valve bridges (para 7-8).
(4) Install rocker arms (para 7-5).
(5) Install engine brake retarder (para 11-2).
END OF TASK
7-2
TA357658
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-30 VALVE GUIDE REMOVAL/lNSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Equipment Condition
Models
All
Test Equipment
None
Special Tools
Remover, valve guide J6569
Installer, valve guide J2 1520
Supplies
Oil, lubricating, Item 48, Appendix C
Brush, bore, Item 9, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
TM or Para
Para 11-2
Para 7-5
Para 7-8
Para 12-2
Para 7-4
Para 7-6
Condition Description
Engine brake retarder
removed.
Rocker arms removed.
Exhaust valve bridges
removed.
Fuel injectors removed.
Exhaust valves removed.
Cam followers and push rods
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
TA357659
NOTE
There are 16 valve guides on cylinder heads. Repeat steps (1) through (3) for
removal of each valve guide.
(1) Clean valve guide (1) using bore brush.
7-3
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-3. VALVE GUIDE REMOVAL/lNSTALLATION (CONT).
(2) Set cylinder head (2) upside
down on two wood blocks.
(3) Drive valve guide (1) out of
valve bore (3) using valve
guide remover.
b. Installation.
NOTE
There are 16 valve guides on cylinder heads. Repeat steps (1)
through (3) to install each valve guide.
(1) Turn cylinder head (1) on right side.
(2) Install threaded end of valve guide (2) into valve guide
installer.
(3) Install valve guide (2) into cylinder head (1) until valve guide
extends above face of cylinder head 0.67 to 0.7 l-in. (17.02 to
18.03 mm).
c. Follow-on Maintenance.
(1) Install cam followers and push rods (para 7-6).
(2) Install exhaust valves (para 7-4).
(3) Install fuel injectors (para 12-2).
(4) Install exhaust valve bridges (para 7-8).
(5) Install rocker arms (para 7-5).
(6) Install engine brake retarders (para 11-2).
END OF TASK
7-4
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-4. EXHAUST VALVE REMOVAL, REPAIR, AND INSTALLATION.
This
a.
b.
c.
task covers:
Removal
Cleaning/Inspection
Repair
d. Installation
e. Follow-on Maintenance
INITIAL SETUP
Models
All
Equipment Condition
Test Equipment
None
TM or Para
Para 7-5
Para 7-8
Special Tools
None
Para 12-2
Para 7-6
Condition Description
Rocker arms removed.
Exhaust valve bridges
removed.
Fuel injectors removed.
Cam followers and push rods
removed.
Supplies
Solvent, dry cleaning, Item 60, Appendix C
Oil, lubricating, Item 48, Appendix C
Special Environmental Conditions
None
Personnel Required
MOS 63W, Wheel vehicle repairer
General Safety Instructions
None
References
None
Level of Maintenance
General Support
a. Removal.
TA357662
(1) Remove valve spring retainers (1) by compressing spring (2) on valve (3).
(2) Release pressure on spring (2).
(3) Remove seat (4), spring (2), and washer (5).
(4) Remove valve (3) from cylinder head (6).
7-5
TM9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-4. EXHAUST VALVE REMOVAL, REPAIR, AND INSTALLATION (CONT).
b.
Cleaning/lnspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Clean all metal parts with dry cleaning solvent,
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.)
(2) Dry all parts with compressed air.
Inspect spring for pitting or fractures.
(4) Check tension of each spring using valve spring compressor. Replace spring when a load of less
than 25 lbs. (111 N•m) will compress it to 1.80 in. (45.72 mm) installed length.
(5) Inspect valve stem (1) and valve face (2) for cracks, pitting, and warpage.
Replace if damaged.
(6) Inspect outer diameter of valve face (2) for scoring or galling. Grind or
replace as necessary.
c. Repair.
NOTE
Valve seat must be ground before valve is installed.
(1) Grind exhaust valve (1) using 300 grinding
stone.
(2) Edge of valve (1) must not be less than
0,03 l-in. (0.79 mm) thick after grinding.
TA357664
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(3) Clean valve with dry cleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(4) Dry with compressed air.
7-6
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
d. Installation.
NOTE
Repeat steps (2) through (4) for each valve.
(1)
(2)
(3)
(4)
Set cylinder head (1) on side.
Lubricate valve (2) with lubricating oil.
Install valve (2) in cylinder head (1).
Secure valve (2) with tape to keep from falling out.
NOTE
Board must be thick enough to keep exhaust valves from touching work surface
while installing spring retainers.
(5) Set cylinder head (1) right side up on top of a board.
NOTE
Repeat steps (6) through (9) for each valve being installed.
(6)
(7)
(8)
(9)
Install washer (3), spring (4), and seat (5).
Compress spring (4) using valve spring compressor.
Install valve spring retainer (6) on valve (2).
Release pressure on spring (4).
e. Follow-on Maintenance.
(1) Install cam followers and push rods (para 7-6).
(2) Install fuel injectors (para 12-2).
(3) Install exhaust valve bridges (para 7-8).
(4) Install rocker arms (para 7-5).
END OF TASK
7-7
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-5. ROCKER ARM REMOVAL/REPAIR/INSTALLATION.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Wrench, fuel line nut J8932-01
Supplies
Solvent, drycleaning, Item 60, Appendix C
Oil, lubricating, Item 48, Appendix C
Caps, shipping and sealing, Item 11,
Appendix C
Tags, Identification, Item 61, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Batteries disconnected.
TM 9-2320-279-20 Rocker cover removed.
Equipment Condition
TM or Para
Condition Description
Para 11-2
Engine brake retarder
removed.
Para 11-4
Engine brake wire harness
removed.
Para 15-5
Throttle delay removed (right
front rocker arm only)
(engines equipped with
throttle delay only).
Para 15-5.1
Fuel modulator removed
(left rear rocker arms only)
(engines equipped with fuel
modulator only).
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
NOTE
This task shows removal of one set of rocker arms. Remove other rocker arms in
the same way.
(1)
(2)
7-8
Soldier A tells Soldier B to stop turning nut (1) when three rocker arms (2) line up.
Soldier B turns nut (1) on camshaft pulley (3) clockwise until told to stop by Soldier A.
Change 2
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
NOTE
Fuel pipes have changed from flare style to preformed packing style pipes and
connectors. Use new style pipes and connectors to replace old style pipes and
connectors. Refer to TM 9-2320-279-24P for parts identification.
Flare and preformed packing style pipes and connectors are not interchangeable.
When replacing one flare type pipe or connector, all pipes and connectors must be
replaced with new preformed packing style pipes and connectors.
(3)
Tag and loosen four fuel tube nuts (4)
and remove two fuel tubes (5 and 6).
(3.1) Remove and discard four preformed
packings (6.1).
(4) Cover four fuel line connectors (7) with
caps.
(5) Remove two brackets (8) from cylinder
head (9).
CAUTION
Do not force rocker arms all the way back with
shaft in place. This could result in damage to
push rods.
(6)
Move three rocker arms (2) up and
toward center of engine to permit
shaft (10) to be removed.
(7)
Hold three push rods (11) and loosen three
locknuts (12).
NOTE
Tag rocker arms before removal.
(8)
Remove three rocker arms (2) from three push
rods (11).
(9)
Measure inside diameter of bushing (13) in
rocker arms (2) and outside diameter of
shaft (10). Clearance between bushing (13) and
shaft (10) must not exceed 0.004-in. (0.102 mm).
Change
2
7-9
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-5. ROCKER ARM REMOVAL/REPAlR/INSTALLATlON (CONT).
b. Disassembly.
(1) Place rocker arm (1) in press.
(2) Remove bushing (2) from rocker arm (1).
c.
Cleaning/lnspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Clean metal parts in dry cleaning solvent.
(2) Inspect rocker arm assembly and brackets for cracks and other damage.
d. Assembly.
(1) Place rocker arm (1) in press.
(2) Install bushing (2) in rocker arm (1).
(3) Ream replacement bushing (2) to 7/8 in. (22 mm).
e. Installation.
(1) Thread each of three rocker
arms (1) onto push rod (2)
until end of push rod is above
inside of clevis yoke (3).
(2) Coat shaft (4) with oil and
slide it through three rocker
arms (1).
(3) Install two brackets (5) one
over each end of shaft (4)
with finished face next to
rocker arms (1).
(4) Position rocker arms (1) down
on valve bridge (6).
(5) Hold each push rod (2) while
tightening three locknuts (7).
7-10
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
(6)
Remove caps from four fuel line
connectors (8).
NOTE
Preformed packings must be installed dry. Do
not apply oil.
(7)
(8)
(9)
f.
Install two fuel tubes (9 and 10) and four
preformed packings (10.1).
Tighten four nuts (11) to 160 lb-in.
(18.1 N•m) using fuel line nut wrench.
Loosen four nuts (11) slightly and
retighten to 10 lb-ft (14 N•m).
Follow-on Maintenance.
Install throttle delay (right front rocker arm only) (engines equipped with throttle delay only)
(para 15-5).
(1.1) Install fuel modulator (left rear rocker arms only) (engines equipped with fuel modulator only)
(para 15-5.1).
(2) Install engine brake retarder (para 11-2).
(3) Install engine brake wire harness (para 11-4).
(4) Install rocker cover (TM 9-2320-279-20).
(5) Connect batteries (TM 9-2320-279-20).
(1)
END OF TASK
7-6. CAM FOLLOWER/PUSH ROD REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Gage, feeler FB310B
Supplies
Tags, identification, Item 61, Appendix C
Oil, lubricating, Item 48, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
Equipment Condition
Condition Description
TM or Para
Cylinder head removed from
Para 3-7
engine.
Rocker arms removed.
Para 7-5
Exhaust valve bridge
Para 7-8
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Change 2
7-11
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-6. CAM FOLLOWER/PUSH ROD REMOVAL/lNSTALLATlON (CONT).
a. Removal.
NOTE
Tag cam follower and associated parts so they may be installed in original
location.
This procedure shows removal of one cam follower. Remove other cam
followers in same way.
(1)
(2)
(3)
(4)
(5)
Set cylinder head (1) on side on 1 in. (25 mm) wooden blocks
Remove two screws (2) and lockwashers (3) from camfollower guide (4).
Remove cam follower guide (4) from cylinder head (1).
Remove cam follower (5) and push rod assembly (6), as a unit, from cylinder head (1).
Remove cam follower (5) from push rod assembly (6).
(6) Remove locknut (7), spring (8), and lower spring seat (9), and push rod (10).
7-12
TM 9-281 5-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
NOTE
Spring retainer must point in proper direction when
installed. Mark direction of spring retainer for
installation.
(7) Remove spring retainer (11) from top side of cylinder
head (l).
(8) Remove upper spring seat (12) from cylinder
head (l).
TA357676
b. Installation.
NOTE
Apply lubricating oil to all parts before installation.
(1) Install spring retainer (1) in top of cam follower bore
in cylinder head (2).
TA357677
(2) Install lower spring seat (3), spring (4),
upper spring seat (5), and nut (6) on
push rod (7).
(3) Install push rod (7) in cylinder head (2).
7-13
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-6. CAM FOLLOWER/PUSH ROD REMOVAL/INSTALLATION (CONT).
(4) Position cam follower (8) so oil hole points
away from exhaust valves (9).
(5) Install cam follower (8) over push rod (7)
and into cylinder head (2).
(6) Install other push rods (7) and cam
followers (8) in same manner.
(7) Install cam follower guide (10), two screws (11), and
lockwashers (12).
(8) Tighten screws (11) to 15 lb-ft (20 NŽm).
NOTE
There must be 0.005-in. (0. 13 mm) clearance
between cam follower guide and cam follower.
(9) Insert 0.005 in. 013 mm) feeler gage
between cam follower guide (10) and legs of
cam followers (8).
(10) If there is not enough clearance, loosen
screws (11), move guide (10), and repeat
steps (8) and (9).
c. Follow-on Maintenance.
(1) Install exhaust valve bridge (para 7-8).
(2) Install rocker arms (para 7-5).
(3) Install cylinder head (para 3-7).
END OF TASK
7-14
TA357681
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-7. CAM FOLLOWER REPAIR.
This task covers:
a. Cleaning/Inspection
b. Disassembly
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
Set, dial indicator J7872
Gage, feeler FB310B
Supplies
Solvent, dry cleaning, Item 60, Appendix C
Oil, lubricating, Item 48, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
TM or Para
Condition Description
Cam follower on clean work
surface.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Cleaning/lnspectlon.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off
harmful vapors, and are harmful to skin and clothing. To avoid injury or
death, keep away from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or clothing, wash
immediately with soap and water.
(1) Clean cam follower (1) with dry cleaning solvent.
(2) Inspect cam follower (1) for damage.
(3) Check side clearance between cam follower body (1) and roller (2) is
not more than 0.023 in. (0. 58 mm). If clearance is more than 0.023 in.
(0.58 mm) go to disassembly.
(4) Put cam follower in vise. Check for more than 0.010 in. (0.25 mm) pin-to-bushing clearance using
dial indicator. If clearance is more than 0.010 in. (0.25 mm), go to disassembly.
b . Disassembly.
NOTE
Pin and roller must be replaced together.
(1) Drive pin (1) out of cam follower body (2).
(2) Remove roller (3).
TA3S7683
7-15
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-7. CAM FOLLOWER REPAIR (CONT).
c. Assembly.
NOTE
Apply lubricating oil to all parts before assembly.
(1) Install roller (1) in cam follower body (2).
(2) Install pin (3) through cam follower body (2) and roller (l).
(3) Check side clearance between cam follower body (2) and
roller (1) using feeler gage. Clearance must be between 0.011
and 0.023 in. (0.28 and 0.58 mm).
(4) Check pin-to-bushing clearance using dial indicator. Clearance must be less than 0.010 in.
(0.25 mm).
f. Follow-on Maintenance. N o n e .
END OF TASK
7-8. EXHAUST VALVE BRIDGE REMOVAL/iNSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
Gage, feeler FB310B
Supplies
Oil, lubricating, Item 48, Appendix C
Tags identification, Item 61, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
7-16
TM or Para
Para 7-5
Condition Description
Rocker arms removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
a. Removal.
NOTE
Tag valve bridges when removed so bridges may be installed in original locations
at installation.
(1) Remove valve bridges (1 and 2) from valve bridge guides (3).
NOTE
Remove remaining valve bridges in same way.
(2) Remove screw (4) and nut (5) from valve bridge (1 and 2).
(3) Remove nut (5) from screw (4).
b . Installation.
(1) Place valve bridge (1) in vise with soft jaws.
(2) Install screw (2) into valve bridge (l).
(3) Install nut (3) on screw (2). Do not tighten.
7-17
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-8. EXHAUST VALVE BRIDGE REMOVAL/INSTALLATION (CONT).
(4) Install valve bridges (1 and 4) on bridge guides (5), making sure grooves in bridges fit over top of
valve stem (6).
(5) Push down on top of valve bridge (1 or 4) and turn adjusting screw (2) until it just touches valve
stem (7).
(6) Turn screw (2) an additional 1/4-turn and tighten nut (3) finger tight
(7) Remove valve bridge (1 or 4) and mount in vise with soft jaws.
(8) Hold screw (2) and tighten nut (3) to 20 to 25 lb-ft (27 to 34 N•m).
7-18
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
(9) Coat valve bridges (1 and 4) and valve bridge
guides (5) with lubricating oil.
(10) Install valve bridges (1 and 4) on valve bridge
guides (5) making sure grooves in bridges fit
over top of valve stem (6).
TA357689
(11) Insert 0.0015-in. feeler gage between end
of valve bridge (1) and exhaust valve
stem (7).
(12) Press down on top surface of valve
bridge (l). Feeler gage must be tight.
(13) Repeat steps (11) and (12) for other end of
valve bridge (1).
(14) Install all other valve bridges in the same
manner.
C.
Follow-on Maintenance. Install rocker arm (para 10-2).
END OF TASK
7-19
TM9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-9. CAMSHAFT REMOVAL/REPAIR/lNSTALLATION.
This
a.
b.
c.
task covers:
Removal
Disassembly
Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
Puller, camshaft gear J1902-01
Remover, camshaft gear and water pump
pulley J7932
Set, dial indicator J7872
Gage, feeler FB310B
Supplies
Solvent, dry cleaning, Item 60, Appendix C
Oil, lubricating, Item 48, Appendix C
Grease, automotive and artillery, Item 36,
Appendix C
Tags, identification, Item 61, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
a. Removal.
(1) Remove four screws (l), adapter (2), and
retainer (3) from left camshaft gear (4).
7-20
Condition Description
TM or Para
TM 9-2320-279-34 Engine installed on engine
stand.
Cylinder heads removed.
Para 3-7
Flywheel housing and rear
Para 5-3
oil seal removed.
Front balance cover
Para 7-12
removed.
Water pump drive gear
Para 10-5
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
(2) Remove four screws (5),
adapter (6), and retainer (7)
from right camshaft gear (8).
TM7692
NOTE
Shop cloth is used between camshaft gears to prevent turning.
(3) Place a clean shop cloth between gears (4 and 8).
(4) Remove two nuts (9) from rear end of camshafts (10 and 11).
7-21
9-2015-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-9. CAMSHAFT REMOVAL/REPAIR/INSTALLATION (CONT).
(5) Remove nut (12), lockwasher (13),
and accessory drive pulley (14)
from front of camshaft (10).
(6) Remove woodruff key (15) and spacer (16)
from front end of camshaft (10).
(7) Remove oil seal (17) from camshaft (10).
(8) Remove three intermediate bearing lock
screws (18) from camshafts (10 and 11).
7-22
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
NOTE
Remove cloth from between gears. Gears can
be turned to reach rear end camshaft bearing
screws using nut on end of camshaft.
(9) Install nut (9) on rear end of camshaft (10).
(10) Remove three camshaft rear end bearing
screws (19) and Iockwashers (20) from each
rear camshaft bearing (21).
(11) Remove nut (9).
CAUTION
Use care when removing camshafts.
Camshafts can be damaged by scraping or
hitting engine block or hard surface.
NOTE
Tag and mark all parts to aid in assembly,
(12) Remove camshaft assemblies (10 and 11)
from engine block (22).
(13) Remove three screws (23)
and lockwashers (24) from
each front camshaft
bearing (25).
NOTE
Gasket is on left-hand bearing
only.
(14) Remove two bearings (25)
and gasket (26).
7-23
TM 9-281 5-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-9. CAMSHAFT REMOVAL/REPAIR/INSTALLATION (CONT).
b. Disassembly.
NOTE
Repeat steps (1) through (5) for disassembly of other camshaft.
(1) Remove gear (1) from end of camshaft (2) using camshaft gear puller and remover.
(2) Remove woodruff key (3) from end of camshaft (2).
(3) Remove end bearing (4) with thrust washers (5) from end of camshaft (2).
NOTE
Tag and mark three camshaft bearings for later installation.
(4) Remove six lockrings (6) and three camshaft intermediate bearings (7) from camshaft (2).
7-24
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
c. Cleaning/lnspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately
with soap and water.
(1) Clean all camshaft parts with dry cleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(2) Dry parts with compressed air.
FEELER
GAGE
TA357702
(3) Inspect camshaft (1) for scratches or damage,
(4) Damaged keyways maybe filed smooth.
(5) Threaded holes may be retapped.
NOTE
Flat measurement must not exceed 0.003 in. (0.076 mm).
(6) Measure flat spots (2) on 12 cam lobes using a straight edge and 0.003 in. (0.076 mm) feeler gage.
7-25
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-9. CAMSHAFT REMOVAL/REPAIR/INSTALLATION (CONT).
FRONT END
BEARING
TA357703
NOTE
Both ends of lockring must cover split line of bearing.
(7) Measure and note diameters of three bearing journals (3). Replace camshaft (1) if any diameter is
less than 1.4980 in. (38.049 mm).
(8) Measure and note diameters of two end bearing journals (4). Replace camshaft (1) if any
diameter is less than 1.4960 in. (37.998 mm).
(9) Measure and note inside diameter of four end bearing bushings (5).
(10) Put lower half (6) of three intermediate bearings (7) together with top half (8).
(11) Install six lockrings (9) over three intermediate bearings (7).
(12) Measure and note inside diameter of three intermediate bearings (7).
(13) Take measurement recorded in step (7) and subtract from measurement recorded in step (12).
Total difference may not exceed 0.009 in. (0.23 mm).
(14) Replace three intermediate bearings (7) if clearance exceeds limit.
(15) Measure thickness of four rear end bearing thrust washers (10) and replace if less than 0.119 in.
(3.02 mm).
(16) Take measurement recorded in step (8) and subtract it from measurement recorded in step (9).
Total difference may not exceed 0.006 in. (0. 15 mm).
(17) Replace front or rear end bearing bushings if clearance exceeds limits (para 7-10).
(18) Inspect spacers and oil seal. Replace if damaged.
(19) Inspect two camshaft gears for worn or damaged teeth. Replace if damaged.
7-26
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
(20) Place camshaft (1) in V blocks
and use dial indicator to check
center bearing surface for
runout. Runout should not
exceed 0.002 in. (0.05 mm).
(21) If runout exceeds 0.002 in.
(0.05 mm) replace camshaft.
(22) Repeat steps (1) to (21) for other
camshaft.
d . Assembly.
NOTE
. Repeat steps (1) through (11) for assembly of both
camshafts.
. Steel faces of thrust washers are next to bearing.
(1) Apply grease to steel faces of two thrust washers (1).
(2) Put thrust washer (1) against each end of camshaft rear
end bearing (2).
—
TA357705
(3) Apply lubricating oil to camshaft rear
bearing journal (3).
(4) Install two thrust washers (1) and
camshaft rear end bearing (2) on
camshaft (4).
TA357706
(5) Install woodruff key (5) in keyway at rear of
camshaft (4).
(6) Aline camshaft gear (6) with key (5).
(7) Press gear (6) onto shoulder of camshaft (4).
(8) Install nut (7) on camshaft (4) and tighten finger
tight.
TA357707
7-27
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-9 CAMSHAFT REMOVAL/REPAIR/INSTALLATION (CONT).
(9) Apply lubricating oil to camshaft
intermediate bearing journals (8).
(10) Put six halves of intermediate bearing (9)
on camshaft journals (8).
TA357708
NOTE
Both ends of lockring must cover split line of
bearing and be installed over bottom half of
bearing. Bottom half of bearing is half
without hole.
BOTTOM
(11) Install six lockrings (10) over bottom half of
three intermediate bearings (11).
T O P ’
e. Installation.
(1) Install right-hand camshaft (1) into engine
block (2).
7-28
TA357709
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
(2) Install left-hand camshaft (3) into engine
block (2).
(3) Aline left camshaft gear (4), right camshaft gear (5), idler gear (6), and crankshaft timing gear (7)
so that timing marks on gears (4, 5, 6, and 7) line up as shown.
(4) Slide camshaft gears (4 and 5) into place until camshaft gears (4 and 5) and idler gear (6) are
fully meshed.
(5) Check timing marks again to make sure gears (4, 5, 6, and 7) are alined as shown.
7-29
TM 9-2015-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-9. CAMSHAFT REMOVAL/REPAIR/INSTALLATION (CONT).
(6) Turn gear (5) to reach all rear end bearing screw
holes.
(7) Install six screws (8) and lockwashers (9) to both
camshaft rear end bearings (10) and engine
block (2).
(8) Tighten screws (8) to 40 lb-ft (54 N•m).
(9) Aline holes in three intermediate
bearings (11) on right and left camshafts (1
and 3) with tapped holes in engine
block (2).
(10) Install three lock screws (12).
(11) Tighten lock screws (12) to 20 lb-ft
(27 N•m).
(12) Apply clean engine oil to
left camshaft front end
bearing journal (13).
(13) Install gasket (14) and
bearing (15) on
camshaft (3).
(14) Install three screws (16) and
lockwashers (17) to
bearing (15) and engine
block (2).
(15) Tighten screws (16) to
40 lb-ft (54 N•m).
NOTE
Spacers have polished outside
diameters.
(16) Install oil seal (18) and spacer (19).
7-30
TM 9-28 15-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
(17) Install woodruff key (20) in camshaft (3).
(18) Install pulley (21) on camshaft (3).
(19) Install nut (22) and lockwasher (23) on camshaft (3). Tighten nut finger tight.
TA357717
(20)
(21)
(22)
(23)
Apply lubricating oil to right camshaft front end bearing journal (24).
Install bearing (25) on camshaft (1).
Install three screws (26) and lockwashers (27) in bearing (25) and engine block (2).
Tighten screws (26) to 40 lb-ft (54 N•m).
7-31
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-9. CAMSHAFT REMOVAL/REPAIR/INSTALLATION (CONT).
(24) Place clean cloth between teeth of camshaft gears (4 and 5).
(25) Tighten nuts (28) on rear end of camshafts (1 and 3) to 300 lb-ft (407 N•m).
(26) Tighten nut (22) on front end of camshaft (3) to 300 lb-ft (407 N•m).
NOTE
Remaining nut on right camshaft is installed with water pump drive gear.
(27) Put two retainers (29) in mounting position on camshaft gears (4 and 5).
(28) Install eight screws (30) in two adapters (31) and retainers (29).
(29) Tighten screws (30) to 40 lb-ft (54 N•m).
7-32
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
(30) Check clearance between thrust
washer (32) and shoulder (33) of
camshaft (1). If clearance is less than
0.004 in. (0.1 mm) or greater than 0.018 in.
(0.45 mm), replace camshaft (l).
(31) Check backlash between gears (4 and 5). Minimum backlash is
0.002 in. (0.05 mm). Maximum backlash is 0.010 in. (0.25 mm).
f. Follow-on Maintenance.
(1) Install water pump drive gear (para 10-5).
(2) Install front balance cover (para 7-12).
(3) Install flywheel housing and rear oil seal (para 5-3).
(4) Install cylinder heads (para 3-7).
(5) Remove engine from engine stand (TM 9-2320-279-34).
END OF TASK
7-33
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-10. CAMSHAFT END BEARING BUSHING REMOVAL/lNSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Equipment Condition
TM or Para
Para 7-9
Condition Description
Camshaft end bearings
removed.
Special Tools
None
Special Environmental Conditions
None
Supplies
None
General Safety Instructions
None
Personnel Required
MOS 63W, Wheel vehicle repairer
Level of Maintenance
General Support
References
None
a. Removal.
NOTE
Do this procedure only if camshaft end
bearing bushings fail inspection specifications
in para 7-9. If one bushing in end bearing has
failed both bushings must be replaced.
(1) Remove two thrust spacers (1) from
camshaft rear end bearing (2).
(2) Remove two bushings (3) from camshaft
front and rear end bearing (4 and 2).
7-34
TM9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
b. Installation.
(1) Press two bushings (1) into camshaft front end
bearing (2) until flush with ends of bearing (2).
(2) Press two bushings (1) into camshaft rear end bearing (3) until
bushing sticks out approximately 0.045 to 0.055 in. (1.14 to
1.40 mm).
(3) Install two thrust spacers (4) on rear end bearing (3).
(4) Bore bushing (1) to 1.496 to 1.498 in. (37.998 to 38.049 mm).
C . Follow-on Maintenance. Install camshaft end bearings (para 7-9).
END OF TASK
7-35
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-11 IDLER GEAR REMOVAL/REPAIR/INSTALLATION
This
a.
b.
c.
task covers:
Removal
Disassembly
Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
Holding fixture, idler gear 2SK900
Set, dial indicator J7872
Supplies
Solvent, dry cleaning, Item 60, Appendix C
Oil, lubricating, Item 48, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
Condition Description
TM or Para
TM 9-2320-279-34 Engine mounted on engine
stand.
Flywheel housing removed.
Para 5-3
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
a . Removal.
(1) Remove screw (1) and special washer (2).
(2) Remove idler gear assembly (3) from engine
block (4).
TA357727
7-36
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
b . Disassembly.
(1) Remove six screws (l).
(2) Remove retainer (2) from idler gear
assembly (3).
TA357728
NOTE
Mark parts of idler gear bearings if they will be used again. Do not scratch or
damage bearings.
(3) Place idler gear assembly (3) in press with outer bearing cone (4) supported on steel blocks.
CAUTION
Idler gear assembly must be rotated during removal to prevent damage to bearing
cones.
(4) Rotate idler gear assembly (3) while pressing idler gear hub (5) out of bearing cones (4 and 6).
(5) Remove idler gear assembly (3) as a unit from the press.
7-37
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-11. IDLER GEAR REMOVAL/REPAIR/INSTALLATION (CONT).
Remove outer bearing cone (6), inner spacer ring (7), and inner bearing cone (4) from idler gear
assembly (3).
NOTE
Do not remove bearing cups unless they are damaged or loose.
(7) Remove outer bearing cup (8), outer spacer ring (9), and inner bearing cup (10) from idler gear
assembly (3).
c. Cleaning/Inspection.
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1)
(2)
(3)
(4)
(5)
(6)
Clean idler gear and bearing parts with dry cleaning solvent.
Inspect bearing for scoring, pitting, or flat spots on rollers or cones.
Inspect bearing cups for scoring, pitting, and dents in bearing surface.
Examine gear teeth for scoring, pitting, and chips.
Replace all damaged parts.
Coat all parts with lubricating oil.
d. Assembly.
(1) Support idler gear (1), shoulder down, on
bed of press.
(2) Apply lubricating oil to bearing cup (2) and
start inner bearing cup, numbered side up,
into bore of gear (l).
(3) Press inner bearing cup (2) to seat against
shoulder of gear (1).
(4) Install outer spacer ring (3) on inner
bearing cup (2).
(5) Apply lubricating oil to outer bearing
cup (4) and start outer bearing cup,
numbered side down, into bore of idler
gear (l).
(6) Press outer bearing cup (4) against outer spacer ring (3).
7-38
TA357731
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
(7) Apply lubricating oil to all parts, place outer bearing cone (5)
numbered side down on bed of press.
(8) Press idler gear hub (6) into outer bearing cone (5) until bottom of
hub (6) is flush with bottom of cone (5).
(9) Install inner spacer ring (7) on idler gear hub (6).
(10) Position gap in spacer ring (7) on side opposite of oil hole in idler
gear hub (6).
TA357734
(11) Support outer bearing cone (5) and idler gear hub (6).
(12) Install idler gear assembly (1) onto idler gear hub (6).
CAUTION
Turn gear while installing bearing cone on idler gear hub to prevent damage to
bearing cups.
(13) Turn idler gear assembly (1) while pressing inner bearing cone (8), numbered side up, over
hub (6).
(14) Hold hub (6) and turn gear assembly (1) to see if binding occurs.
7-39
TM9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-11. IDLER GEAR REMOVAL/REPAIR/INSTALLATION (CONT).
NOTE
To check idler gear pre-load, do steps (15) through (25).
(15) Mount idler gear (1) in soft jaw vise.
(16) Mount two test fixture plates (9 and 10) on idler gear (1) with screw (11) and nut (12). Tighten to
90 lb-ft (122 N•m).
(17) Mount test fixture plate (13) on idler gear (1) with three screws (14), lockwashers (15), and
washers (16). Tighten to 40 lb-ft (54 N•m).
(18) Place plate (10) in jaws of vise.
NOTE
Pull to start gear moving must not be less than 0.5 lb (0.23 kg) or more
than 4.0 lbs (1.8 kg).
(19) Wrap cord several times around idler gear assembly (1) and attach
spring scale.
(20) Pull idler gear assembly (1) several times and record pull required to
start gear moving. Maximum difference between pulls is 2 lbs,
11 ounces (1.22 kg).
(21) If difference between pulls does not fall in correct ranges, replace
bearings.
7-40
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
TA357737
(22)
(23)
(24)
(25)
Place idler gear assembly (1) in soft jaw vise.
Remove three screws (14), lockwashers (15), washers (16), and test fixture plate (13).
Remove nut (12), screw (11), and two test fixture plates (10 and 9).
Remove idler gear assembly (1) from vise.
TA357738
(26) Install retainer (17) and six new nylon patch screws (18) on idler gear assembly (l).
(27) Tighten screws (18) to 30 lb-ft (41 N•m).
7-41
TM 9-2015-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
17-11. IDLER GEAR REMOVAL/REPAIR/INSTALLATION (CONT).
e. Installation.
(1) Aline timing marks on camshaft
gear (1) and crankshaft gear (2)
with timing marks on idler gear (3).
(2) Slide idler gear (3) into place until
crankshaft gear (2) and camshaft
gear (1) are fully meshed.
(3) Rotate gear hub (4) so dowel in hub
alines with hole in end plate (5).
(4) Tap hub (4) until it seats against
end plate (5).
(5) Check timing marks again to make
sure gears (1, 2, and 3) are alined as
shown.
TA357739
(6) Install screw (6) and special washer (7).
(7) Tighten screw (6) to 90 lb-ft (122 N•m).
(8) Coat bearing (8) and idler gear (3) with lubricating oil.
7-42
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
(9) Mount dial indicator on end plate (5)
and check backlash between gears (2,
3, and 4). Minimum backlash is
0.002 in. (0.05 mm). Maximum
backlash is 0.008 in. (0.20 mm).
f. Follow-on Maintenance.
(1) Install flywheel housing (para 5-3).
(2) Remove engine from engine stand (TM 9-2320-279-34).
END OF TASK
7-12. FRONT BALANCE COVER AND VIBRATION DAMPER REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
None
Supplies
Grease, automotive and artillery, Item 36,
Appendix C
Tags, identification, Item 61, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
TM or Para
Condition Description
TM 9-2320-279-20 Fan clutch removed.
Para 17-2
Water pump removed.
Special Environmental Condition
None
General Safety Instructions
None
Level of Maintenance
Direct Support
7-43
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-12. FRONT BALANCE COVER AND VIBRATION DAMPER REMOVAL/INSTALLATION
(CONT).
a. Removal.
(1) Remove two screws (1) and lockwashers (2).
(2) Remove screw (3), Iockwasher (4), alternator adjusting strap (5), and fan clutch support (6).
(3) Remove screw (7), Iockwasher (8), and engine lifting bracket (9)
7-44
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
(4) Remove screw (10), Iockwasher (11), and washer (12).
NOTE
Engines between serial numbers 8VF-120299 and 8VF-122899 may not have a
Woodruff key.
(5) Remove vibration damper (13) and Woodruff key (14).
NOTE
Tag and mark screws, lockwashers, washers, and front balance cover before
removal.
(6) Remove screw (15), Iockwasher (16), and washer (17) from front balance cover (18).
Change 1
7-45
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
‘ 7-12. FRONT BALANCE COVER AND VIBRATION DAMPER REMOVAL/INSTALLATION
(CONT).
(7) Remove two screws (19),
lockwashers (20), and washers (21),
(8) Remove screw (22), Iockwasher (23),
and washer (24).
(9) Remove screw (25), washer (26),
Iockwasher (27), and nut (28).
(10) Remove screw (29), Iockwasher (30),
washer (31), and nut (32).
(11) Remove three screws (33), washer (34),
Iockwasher (35), and nut (36) from front
balance cover (18).
7-46
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
(12) Remove front balance cover (18) and gasket (37) from end plate (38).
(13) Remove oil seal (39) from front balance cover (18).
(14) Inspect oil seal mounting area for scratches or nicks.
b. Installation.
(1) Install oil seal (1) in front balance cover (2). Seal lip (3) will point inward.
7-47
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-12. FRONT BALANCE COVER AND VIBRATION DAMPER REMOVAL/INSTALLATION
(CONT).
(2) Coat gasket (4) with grease and
install on front cover (2).
(3) Aline studs (5) on front balance
cover (2) with holes in end
plate (6).
(4) Install front balance cover (2) on
end plate (6).
(5) Install three screws (7), washers (8), lockwashers (9),
and nuts (10). Tighten nuts to 30 to 35 lb-ft (40 to
47 N•m).
(6) Install screw (11), washer (12), Iockwasher (13),
and nut (14) in front balance cover (2).
Tighten screw to 35 to 40 lb-ft (47 to 54 N•m).
(7) Install screw (15), Iockwasher (16),
washer (17), and nut (18). Tighten screw to
35 to 40 lb-ft (47 to 54 N•m).
7-48
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
(8) Install two screws (19), lockwashers (20),
and washers (21). Tighten screws to
30 to 35 lb-ft (41 to 47 N•m).
(9) Install screw (22), Iockwasher (23),
and washer (24). Tighten screw to
35 to 40 lb-ft (47 to 54 N•m).
(10) Install screw (25), Iockwasher (26), and
washer (27). Tighten screw to 30 to 35 lb-ft (41 to
47 N•m).
NOTE
Some pulley shafts do not
have grooves for the Woodruff
key. The key is not used on
this type of shaft.
(11) Install Woodruff key (28)
and vibration damper (29)
on pulley shaft (30).
Change 1
7-49
TM 9-2815-224-34&P
Valve Mechanism Maintenance Instructions (Cont)
7-12. FRONT BALANCE COVER AND VIBRATION DAMPER REMOVAL/INSTALLATION
(CONT).
(12) Install screw (31), Iockwasher (32), and
washer (33). Tighten screw to 25 lb-ft (34 N•m).
(13) Install screw (34), washer (35), and engine lifting
bracket (36). Do not tighten screw.
(14) Install screw (37),
Iockwasher (38), and fan
clutch support (39) in front
balance cover (2). Do not
tighten screw.
(15) Install two screws (40),
lockwashers (41), and
alternator adjusting strap (42).
Tighten screws (34 and 40) to
140 to 150 lb-ft (189 to
203 N•m).
(16) Tighten screw (37) to 90 to
100 lb-ft (122 to 135 N•m).
c. Follow-on Maintenance.
(1) Install water pump
(para 17-2).
(2) Install fan clutch
(TM 9-2320-279-20).
END OF TASK
7-50
TM 9-2815-224-34&P
CHAPTER 8
OIL SYSTEM MAINTENANCE
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Block Breather Pipe Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Removal/Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Relief Valve Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Regulator Valve Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section I.
Para
8-1
8-2
8-3
8-4
8-5
8-6
8-7
Page
8-1
8-1
8-2
8-8
8-14
8-17
8-20
INTRODUCTION
[8-1. GENERAL. This chapter covers removal, installation, and repair of the oil system. Subassemblies
and parts which must be removed before the oil system can be removed will be referenced in other
chapters of this manual or TM 9-2320-279-10, TM 9-2320-279-20, or TM 9-2320-279-34.
Section II
OIL SYSTEM
Oil System Maintenance Instructions
8-2. ENGINE BLOCK BREATHER PIPE REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
ModeIs
All
Test Equipment
None
Special Tools
None
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer
References
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-34 Engine mounted on engine
stand.
Rear end plate removed.
Para 3-4
Special Environmental Conditions
None
General Safety Instruction
None
Level of Maintenance
Direct Support
None
8-1
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
8-2. ENGINE BLOCK BREATHER PIPE REMOVAL/INSTALLATION (CONT).
a. Removal.
(1) Remove two clamps (1) and hose (2).
(2) Remove two clamps (3), hose (4), and elbow (5).
(3) Remove pipe (6) from engine block (7).
b. Installation.
(1) Install pipe (6) in engine block (7).
(2) Install hose (4), elbow (5), and two clamps (3).
(3) Install hose (2) and two clamps (l).
c. Follow-on Maintenance. Install rear end plate (para 3-4).
END OF TASK
8-3 OIL PAN REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Adhesive-sealant, silicone, Item 6, Appendix C
Compound, sealing, lubricating, Item 31,
Appendix C
Compound, sealing, pipe thread, Item 32,
Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
8-2
Equipment Condition
TM or Para
TM
TM
TM
TM
LO
TM
TM
Condition Description
9-2320-279-10 Engine off.
9-2320-279-10 Parking brake on.
9-2320-279-10 Engine side panel removed.
9-2320-279-20 Batteries disconnected.
9-2320-279-12 Engine oil drained.
9-2320-279-20 Splash guards removed.
9-2320-279-20 Rear propeller shaft removed
from No. 2 axle.
Special Environmental Conditions
None
General Safety Instructiom
None
Level of Maintenance
Direct Support
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
a. Removal.
(1) Disconnect oil return line (1) from elbow (2) on oil pan (3).
(2) Remove two screws (4) and lockwashers (5) from oil pan (3) and flywheel housing (6).
(3) Remove two screws (7), lockwashers (8), and washers (9) from rear end of oil pan (3).
8-3
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
8-3. OIL PAN REMOVAL/INSTALLATION (CONT).
(4) Remove 26 screws (10) and
lockwashers (11) from oil pan (3).
(5) Lower oil pan (3) and gasket (12) until
oil pump front pickup screen
elbow (13) is visible.
(6) Remove two screws (14),
lockwashers (15), gasket (16) and oil
pump front pickup screen elbow (13).
(7) Remove oil pan (3) and gasket (12).
(8) Remove gasket (12) from oil pan (3)
and engine.
(9) Remove gasket (16) from oil pump
front pickup screen elbow (13) and oil
pump (17).
(10) Remove plug (18) from oil pan (3).
(11) Remove elbow (19) and reducer bushing (20)
from oil pan (3).
8-4
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
(12) Remove plugs (21 and 22) from oil pan (3).
b. Installation.
WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. To avoid injury or
death, keep away from open fire and use in
well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash
immediately with soap and water.
(1) Coat threads of plugs (1 and 2) with pipe
thread sealing compound.
(2) Install plugs (1 and 2) in oil pan (3).
(3) Coat threads of reducer bushing (4),
elbow (5), and drain plug (6) with pipe thread
sealing compound.
(4) Install reducer bushing (4), elbow (5) and
drain plug (6) in oil pan (3).
8-5
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
8-3. OIL PAN REMOVAL/INSTALLATION (CONT).
(5) Apply silicone adhesive-sealant to
mating surface of oil pan (3).
(6) Aline holes in gasket (7) with holes in oil
pan (3) and install gasket.
(7) Position oil pan (3) under oil
pump (8).
(8) Mount gasket (9) and oil pump front
pickup screen elbow (10) on oil
pump (8).
(9) Install two screws (11) and
lockwashers (12).
(10) Position oil pan (3) on block (13).
(11) Coat threads of 28 screws (14) with
sealing and lubricating compound.
(12) Install two screws (14) and
lockwashers (15) in right and left
center hole of oil pan (3).
(13) Install 24 screws (14) and
lockwashers (15) finger tight.
8-6
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
(14) Install two screws (14),
lockwashers (15), and
washers (16).
(15) Install two screws (17) and
lockwashers (18) to oil pan (3)
and flywheel housing (19).
(16) Tighten 28 screws (14),
starting at center of oil
pan (3), to 15 lb-ft
(21.69 N•m).
(17) Tighten two screws (17) 30 to
35 lb-ft (41 to 47 N•m).
(18) Connect oil return line (20) to
elbow (21) on oil pan (3).
c. Follow-on Maintenance.
(1) Install oil pan drain plug and refill engine oil system (LO 9-2320-279-12).
(2) Install propeller shaft (TM 9-2320-279-20).
(3) Install splash guard (TM 9-2320-279-20).
(4) Connect batteries (TM 9-2320-279-20).
(5) Install engine side panel (TM 9-2320-279-10).
(6) Start and run engine for a short time. Inspect for oil leaks.
(7) Stop engine. After 20 minutes, check oil level. Add oil if necessary.
END OF TASK
8-7
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
8-4. OIL PUMP REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Equipment Condition
TM or Para
Condition Description
Para 8-3
Para 8-6
Oil pan removed.
Pressure relief valve
removed.
Special Tools
Set, dial indicator J7872
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
None
a. Removal.
(2) Remove two screws (1) and lockwashers (2).
8-8
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
(2) Remove four nuts (3) and lockwashers (4).
(3) Soldier A and Soldier B remove oil pump (5) from engine (6),
(4) Remove two shims (7) from under pump (5).
(5) Remove two screws (8),
lockwashers (9), washers (10),
and oil pump rear screen (11)
from tube assembly (12).
(6) Remove two screws (13),
lockwashers (14), and bracket
assemblies (15).
(7) Remove screw (16), four
washers (17), and nut (18)
from each bracket
assembly (15).
8-9
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
[ 8-4. OIL PUMP REMOVAL/INSTALLATION (CONT).
(8) Remove two screws (19), lockwashers (20), tube assembly (12), gasket (21), oil pump baffle (22),
and gasket (23) from oil pump (5).
(9) Remove two screws (24),
lockwashers (25),
cover (26), and gasket (27)
from oil pump (5).
(10) Remove screw (28) and washer (29)
from shaft (30).
(11) Remove gear (31) from shaft (30).
b. Installation.
NOTE
Be sure curved surface of washer is
toward head of screw.
(1) Install oil pump drive gear (1) onto
end of shaft (2). Install washer (3)
and screw (4).
(2) Tighten screw (4) to 57 to 61 lb-ft
(77 to 83 N•m).
8-10
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
(3) Install gasket (5), cover (6),
two lockwashers (7), and
screws (8).
(4) Install gasket (9), oil pump
baffle (10), gasket (11), and
tube assembly (12) on oil
pump (13) with two
screws (14) and
lockwashers (15).
(5) Tighten screws (14) to 30 to
35 lb-ft (41 to 47 N•m).
(6) Install screw (16), four
washers (17), and nut (18) to
each bracket assembly (19).
(7) Install two bracket
assemblies (19) on tube
assembly (12).
(8) Install two screws (20) and
lockwashers (21). Tighten
screws (20) to 30 to 35 lb-ft
(41 to 47 N•m).
(9) Install oil pump rear
screen (22) on tube
assembly (12).
(10) Install two screws (23),
lockwashers (24), and
washers (25). Tighten
screws (23) to 13 to 17 lb-ft
(18 to 23 N•m).
8-11
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
[8-4. OIL PUMP REMOVAL/INSTALLATION (CONT).
(11) Install two shims (26).
(12) Position oil pump (13) on engine (27).
(13) Install four lockwashers (28) and nuts (29).
NOTE
• Each 0.005-in (0.13 mm) shim changes gear backlash 0.0035-in. (0.088 mm).
• Backlash should be 0.006 to 0.012-in (0. 15 to 0.030 mm),
(14) Measure backlash between crankshaft gear (30) and oil pump drive gear (1) with dial indicator.
Install same number and thickness of shims (26) under pump (13) to obtain correct backlash.
(15) Loosen two nuts (18).
(16) Install two screws (31) and
lockwashers (32). Tighten
screws finger tight.
8-12
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
(17) Tighten four nuts (29) to 40 lb-ft (54.2 N•m).
(18) Adjust oil tube brackets (19)
to seat firmly against engine
mounting surface.
(19) Tighten two screws (31 ) to
15 lb-ft (20.3 N•m).
(20) Tighten two nuts (18).
c. Follow-on Maintenance.
(1) Install oil pan (para 8-3).
(2) Install pressure relief valve (para 8-6).
END OF TASK
8-13
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
8-5. OIL PUMP REPAIR.
This task covers:
c. Assembly
d. Follow-on Maintenance
a. Disassembly
b. Cleaning/Inspection
INITIAL SETUP
Models
All
References
None
Test Equiprnent
None
Equipment Condition
TM or Para
Special Tools
None
Supplies
Tags, identification, Item 61, Appendix C
Solvent, dry cleaning, Item 60, Appendix c
Oil, lubricating, Item 48, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
Special Environrnental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
a. Disassembly.
(1) Remove four screws (1) and cover (2) from oil pump (3).
NOTE
Tag and matchmark gears before removal.
(2) Remove gears (4 and 5), and two keys (6) from drive gear
shafts (7 and 8).
(3) Remove spacer (9).
8-14
Condition Description
Oil pump on clean work
surface.
TM 9-2815-224-34&P
Oil System Maintenance instructions (Cont)
(4) Remove gear (10) and shaft (7) from oil pump (3).
(5) Remove gear (11) and shaft (8) as
an assembly from pump (3).
(6) Press gears (10 and 11) from shafts (7 and 8).
(7) Remove two keys (12) from shafts (7 and 8).
b. Cleanig/lnspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Clean all metal parts with dry cleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(2) Dry parts with compressed air.
(3) Examine all parts for damage. Replace if damaged.
(4) Check for bushing diameters. Replace housing if bushing diameter is larger than 1.0056 inches
(25.542 mm).
8-15
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
8-5. OIL PUMP REPAIR (CONT).
c. Assembly.
(1) Install two keys (1) in shafts (2 and 3).
(2) Lubricate shafts (2 and 3) with lubricating oil.
(3) Press gear (4) on shaft (2).
(4) Press gear (5) on shaft (3).
(5) Install shaft (2) and gear (4) into
pump body (6).
(6) Install shaft (3) and gear (5) into pump (6).
(7) Install spacer (7) onto shafts (2 and 3).
(8) Install two keys (8) in shafts (2 and 3).
(9) Aline matchmarks and install gears (9 and 10) on shafts (2
and 3).
8-16
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
(10) Install pump cover (11) and
four screws (12).
(11) Tighten screws (12) to 30 to
35 lb-ft (41 to 47 N•m).
d. Follow-on Maintenance. None.
END OF TASK
8.6.PRESSURE RELEIF VALVE REMOVAL/REPAIR/INSTALLATION.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
RefERences
None
Test Equipment
None
Equipment Condition
Special Tools
None
Supplies
Solvent, dry cleaning, Item 60, Appendix C
Oil, lubricating, Item 48, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
TM or Para
Para 8-3
Condition Description
Oil pan removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
8-17
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
8-6. PRESSURE RELIEF VALVE REMOVAL/REPAIR/INSTALLATION (CONT).
a. Removal.
(1) Remove two screws (1) and lockwashers (2) from pressure relief valve (3).
(2) Remove two screws (4) and Iockwasher (5) from pressure relief valve (3).
(3) Remove pressure relief valve (3) and gaskets (6 and 7).
b. Disassembly.
(1) Mount pressure relief valve (1) in vise with soft jaws.
WARNING
Spring is under compression load and can cause injury if released suddenly. Keep
spring compressed when removing pin, then release spring slowly.
(2) Soldier A drives spring seat retaining pin (2) out of pressure relief valve body (1) while Soldier B
keeps spring (3) under pressure.
(3) Remove spring seat (4), spring (3), end cap (5), inner spring (6), end cap (5), and valve (7).
8-18
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
c. Cleaning/lnspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Clean metal parts of valve with dry cleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves etc.).
(2)
(3)
(4)
(5)
Dry valve with compressed air.
Clean gasket material from mounting surface of valve, oil pump, and cylinder block.
Inspect all parts for damage. Replace damaged parts.
Make sure relief valve moves freely in valve body.
d . Assembly.
(1) Mount-valve body (1) in vise with
soft jaws.
(2) Apply lubricating oil to valve (2).
Install valve, closed end first, into
valve body (1).
(3) Install two end caps (3) on inner
spring (4). Insert inner spring (4)
into valve body (1).
(4) Insert spring (5) over inner
spring (4) into valve body (1).
(5) Install spring seat (6) closed end
first, into valve body (1).
(6) Soldier A compresses spring (5)
while Soldier B installs pin (7).
e . Installation.
(1) Install gasket (1) and pressure relief
valve (2) on engine (3).
(2) Install two screws (4) and
lockwashers (5). Turn screws three or
four turns only.
(3) Install gasket (6) under pressure relief
valve (2).
(4) Install two screws (7) and
lockwashers (8).
(5) Tighten screws (4 and 7) to 30 to
35 lb-ft (41 to 47 NŽm).
f . Follow-on Maintenance. Install oil pan (para 8-3).
END OF TASK
8-19
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
8-7. PRESSURE REGULATOR VALVE REMOVAL/REPAIR/INSTALLATION.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equiprnent
None
Equipment Condition
Special Tools
None
Supplies
Solvent, dry cleaning, Item 60, Appendix C
Oil, lubricating, Item 48, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
TM or Para
Para 8-3
Condition Description
Oil pan removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
(1) Remove two screws (1) and washers (2) from oil pressure regulator (3).
(2) Remove oil pressure regulator (3) and gasket (4).
b. Disassembly.
(1) Mount oil pressure regulator (1) in vise with soft
jaws.
WARNING
Spring is under compression load and can cause
injury if released suddenly. Keep spring
compressed when removing pin, then slowly
release compression.
(2) Drive spring seat retaining pin (2) out of
pressure regulator body (1).
(3) Remove spring seat (3), spring (4), and valve (5) from regulator body (1).
8-20
TM 9-2815-224-34&P
Oil System Maintenance Instructions (Cont)
c. Cleaning/lnspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area, If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Clean regulator with dry cleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(2) Dry regulator with compressed air.
(3) Inspect all parts for damage. Replace damaged parts.
(4) Make sure regulator valve moves freely in valve body.
d . Assembly.
(1) Install regulator body (1) in vise with soft jaws.
(2) Apply lubricating oil to valve (2) and insert into
regulator body (1), closed end first.
(3) Insert spring (3) into regulator body (1).
(4) Install spring seat (4), open end first, and
compress spring (3).
(5) Install pin (5).
e. Installation.
(1) Install gasket (1) and oil pressure regulator (2) on
engine (3).
(2) Install two screws (4) and washers (5).
(3) Tighten screws (4) to 30 to 35 lb-ft (41 to 47 N•m).
f. Follow-on Maintenance.
(1) Install oil pan (para 8-3).
(2) Start engine (TM 9-2320-279- 10).
(3) Check oil pressure (TM 9-2320-279-10).
END OF TASK
8-21/(8-22 blank)
TM 9-2815-224-34&P
CHAPTER 9
EXHAUST MANIFOLD MAINTENANCE
Para Page
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Exhaust Manifold Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Section I.
9-1
9-1
INTRODUCTION
9-1. GENERAl. This chapter includes removal and/or replacement of the exhaust manifold.
Equipment conditions will be referenced from TM 9-2320-279-10, TM 9-2320-279-20, TM 9-2320-279-34,
and other chapters in this technical manual.
Section II.
EXHAUST MANIFOLD ASSEMBLY
Exhaust Manifold Maintenance Instructions
9-2. EXHAUST MANIFOLD REMOVAL/INSTALLATION.
I
This task covers:
a. Removal
b. Inspection
c. Installation
d. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-10 Engine side panels removed.
TM 9-2320-279-10 Engine cover open.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
References
None
9-1
TM 9-2815-224-34&P
Exhaust Manifold Maintenance Instructions (Cont)
9-2. EXHAUST MANIFOLD REMOVAL/INSTALLATION (CONT).
a. Removal.
NOTE
Instructions cover right hand exhaust manifold, Removal of left hand manifold is
the same.
(1)
(2)
(3)
(4)
Loosen clamps (1).
Loosen three nuts (2).
Remove two nuts (3) and two crabs (4).
Remove exhaust tube (5) from exhaust manifold (6).
(5) Remove manifold (6), three
nuts (7), and washers (8).
(6) Remove two gaskets (9) from
cylinder head (10).
b . Inspection.
(1) Inspect manifold (6) for cracks and
breaks.
(2) Inspect for broken, worn, or
stripped threads on studs (11) and
nuts (7).
9-2
TM 9-2815-224-34&P
Exhaust Manifold Maintenance Instructions (Cont)
c.
Installation.
NOTE
Instructions cover right hand exhaust manifold.
Installation of left hand manifold is the same.
(1) Install studs (1) if necessary.
(2) Tighten studs (1) to 25 to 40 lb-ft (34 to
54 N•m).
(3) Install
. . . gaskets (2) with crimped side facing
cylinder head (3).
NOTE
Manifold retaining washers are special
curved washers. Convex side must be
mounted toward manifold.
(4) Install manifold (4) on studs (1).
(5) Install three washers (5) and nuts (6)
loosely.
(6) Install exhaust tube (7) with clamps (8).
(7) Install but do not tighten two crabs (9)
and nuts (10).
CAUTION
Be sure to tighten nuts from center nut
outward. Tightening outside nuts first can
crack exhaust manifold.
(8) Tighten nuts (6 and 10) in the following
order:
(a) Tighten nut (6) to 30 to 35 lb-ft (41 to
47 N•m).
(b) Tighten nut (10) to 30 to 35 lb-ft (41 to
47 N•m).
d. Follow-on Maintenance.
(1) Install engine side panels
(TM 9-2320-279-10).
(2) Close engine cover (TM 9-2320-279-10).
END OF TASK
9-3/(9-4 blank)
TM 9-2815-224-34&P
CHAPTER 10
BLOWER AND WATER PUMP DRIVES MAINTENANCE
Para
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Blower Drive Support Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Blower Accessory Drive Hub Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Blower Drive Seal Ring Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Water Pump Drive Gear Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Section I.
Page
10-1
10-1
10-7
10-11
10-12
INTRODUCTION
10-1. GENERAL. This chapter includes removal, installation, and repair of the blower and water pump
drives. The subassemblies and parts which must be removed before the blower and water pump drives can
be removed will be referenced-to other paragraphs or chapters of this manual, TM 9-2320-279-10,
TM 9-2320-279-20, or TM 9-2320-279-34.
Section Il.
BLOWER DRIVE ASSEMBLY
Blower and Water Pump Drives Maintenance Instructions
10-2. BLOWER DRIVE SUPPORT REMOVAL/REPAIR/INSTALLATION.
This
a.
b.
c.
task covers:
Removal
Disassembly
Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
References
All
None
Test Equipment
None
Special Tools
None
Supplies
Solvent, dry cleaning, Item 60, Appendix C
Grease, automotive and artillery, Item 36,
Appendix C
Oil, lubricating, Item 48, Appendix C
Personnel Required
Equipment Condition
TM or Para
Condition Description
Para 14-3
Blower removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
MOS 63W, Wheel vehicle repairer
10-1
TM 9-2815-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
10-2. BLOWER DRIVE SUPPORT REMOVAL/REPAIR/lNSTALIATION (CONT).
a. Removal.
(1) Loosen clamp (1) and remove two screws (2),
lockwashers (3), and crossover pipe (4).
(2) Remove two screws (5) and copper
washers (6) from blower drive assembly (7).
(3) Remove blower drive assembly (7) and
gasket (8) from flywheel housing (9).
b.
10-2
Diassembly.
(1) Remove three screws (1), and accessory
drive hub assembly (2) from blower drive
assembly (3).
TM 9-2815-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
(2) Remove three screws (4), and two spring
plates (5) from auxiliary drive hub (6).
(3) Position blower drive support (7) in vise with soft jaws.
(4) Bend tangs of Iockwasher (8) away from nut (9).
(5) Remove nut (9), Iockwasher (8),
thrust washer (10), thrust
bearing (11), drive gear (12), and
second thrust bearing (13) from
blower drive support (7).
(6) Remove blower drive support (7)
from vise,
(7) Check inside diameter of two bushings (14). If diameter is more than
0.005 in. (0. 127 mm) larger than shaft diameter, replace bushings.
(8) Press two bushings (14) from drive gear (12).
10-3
TM 9-2815-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
10-2. BLOWER DRIVE SUPPORT REMOVAL/REPAIR/INSTALLATION (CONT).
c.
Cleaning/lnspection.
WARNING
. Adhesives, solvents, and sealing compounds can burn easily, can give off
harmful vapors, and are harmful to skin and clothing. To avoid injury or death,
keep away from open fire and use in well-ventilated area. If adhesive, solvent,
or sealing compound gets on skin or clothing, wash immediately with soap and
water.
• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa).
Use only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Clean all metal parts with dry cleaning solvent.
Dry parts, except bearings, with compressed air. Let bearings air dry.
Make sure oil passages are clear.
Inspect threads for damage. Replace parts if damaged.
Check that thrust washer thickness is between 0.2350 and 0.2450-in. (5.969 and 6.223 mm).
Inspect thrust washer for scoring.
Check that two thrust bearings thickness is between 0.0590 and 0.0610-in. (1.498 and
1.549 mm). Inspect thrust bearings for scoring.
Check that inside diameter of support bushing is between 1.6260 and 1.6265-in. (41.300 and
41.313 mm). Record diameter.
Check diameter of drive hub at base. It must be between 1.6240 and 1.6250-in. (41.249 and
41.275 mm). Record diameter.
Subtract diameter recorded in step (7) from diameter recorded in step (8). Make sure that
clearance between drive hub and support bushing is between 0.0010 and 0.0025-in. (0.025 and
0.063 mm) when parts are new. Limit is 0.0050-in. (0. 127 mm) for used parts.
If support bushing is worn beyond limits in step (7), replace bushings.
Inspect drive gear teeth for scoring, pitting, and burning (blue or dark spots). Replace if teeth are
defective.
Inspect auxiliary drive hub for cracks, breaks, stripped threads or worn-out splines in bore.
Replace if damaged.
Inspect both flex spring plates for cracks, distortion, or other damage. Replace if defective.
d. Assembly.
NOTE
If bushing were removed, do step (1). If not, go to step (2).
(1) Press two bushings (1) into drive gear (2) flush with drive gear.
10-4
TM 9-2815-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
(2) Place blower drive support (3) in
vise with soft jaws.
(3) Apply light coat of lubricating oil to
blower drive support (3), support
bushing (1), thrust bearings (4
and 5), and thrust washer (6),
(4) Install thrust bearing (4) onto
blower drive support (3).
(5) Install drive gear (2) with flat side
towards blower drive support (3).
(6) Install second thrust bearing (5) and thrust washer (6) with notches fitting in bearing.
(7) Install Iockwasher (7).
(8) Install nut (8) flat side down.
(9) Tighten nut (8) to 50 to 60 lb-ft (67.8 to 81.4 N•m).
(10) Measure clearance between thrust washer (6) and thrust
bearing (5). Clearance must not be less than 0.005-in. or
more than 0.010-in. (0.13 mm and 0.25 mm).
(11) Bend tangs of Iockwasher (7) against nut (8).
(12) Install two spring plates (9) and three
screws (10) on auxiliary drive hub (11).
(13) Tighten screws (10) to 35 to 40 lb-ft (47.5 to
54.0 N•m).
(14) Install accessory drive hub assembly (12)
and three screws (13) on blower drive
support (3). Tighten screws to 35 to 40 lb-ft
(47.5 to 54.0 N•m).
10-5
TM 9-2815-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
10-2. BLOWER DRIVE SUPPORT REMOVAL/REPAIR/INSTALLATION (CONT).
e. Installation.
NOTE
Apply light coat of grease to both sides of
gasket.
(1) Install gasket (1) and blower drive
assembly (2) in flywheel housing (3).
(2) Install two screws (4) and copper washers (5).
(3) Tighten two screws (4) to 25 to 30 lb-ft (34 to
41-N”m).
(4) Install crossover pipe (6), two
lockwashers (7), and screws (8).
(5) Tighten clamp (9).
NOTE
Used gear backlash cannot be over 0.010-in. (0.25 mm).
New gear backlash will measure 0.002-in. (0.05 mm) to
0.008-in. (0.20 mm). If backlash cannot be checked at face
of blower drive gear, check at accessory drive hub.
(6) Check backlash between blower drive gear (10) and
right bank camshaft gear (11).
f. Follow-on Maintenance. Install blower (para 14-3).
END OF TASK
10-6
TM 9-2815-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
10-3. BLOWER ACCESSORY DRIVE HUB REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Cleaning/Inspection
c. Installation
d. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
Tool, blower drive shaft alinement J24619 or
J33001
Supplies
Solvent, dry cleaning, Item 60, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
TM or Para
Condition Description
TM 9-2320-279-20 Engine cover removed.
TM 9-2320-279-20 Air compressor removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
(1) Remove nut (1), copper washer (2), and screw (3).
(2) Remove three screws (4) and lockwashers (5).
(3) Remove two screws (6), lockwashers (5), cover (7), and gasket (8).
10-7
TM 9-2815-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
[ 10-3. BLOWER ACCESSORY DRIVE HUB REMOVAL/INSTALLATION (CONT).
(4) Remove retaining ring (9) from blower drive shaft (10).
CAUTION
Be careful when removing shaft; spring may fall
out.
(5) Remove blower drive shaft (10) with spring (11).
(6) Remove three screws (12).
(7) Remove accessory drive hub
assembly (13).
(8) Remove three screws (14) and two
spring plates (15) from accessory drive
hub assembly (13).
b . Cleaning/lnspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Clean metal parts with dry cleaning solvent.
10-8
TM 9-2815-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
WARNING
Compressed air used for cleaning purposes shall not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves etc.).
(2)
(3)
(4)
(5)
Dry parts with compressed air.
Inspect splines in bore of hub. If defective, replace hub.
Inspect spring plates and washers for breaks, cracks, dents, or distortion. Replace if defective,
Inspect hub bosses for stripped threads.
c. Installation.
(1) Install two spring plates (1) and three screws (2) on
hub ,assembly (3). Tighten screws to 35 to 40 lb-ft
(47.5 to 54.2 N•m).
(2) Install accessory drive hub assembly (2).
(3) Install three screws (4).
(4) Tighten three screws (4) to 35 to 40 lb-ft (47.5 to
54.2 N•m).
(5) Using blower drive shaft alining tool, install
blower drive shaft (5) and spring (6).
(6) Push in on shaft (5) and install retaining ring (7).
10-9
TM 9-2015-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
10-3. BLOWER ACCESSORY DRIVE HUB REMOVAL/INSTALLATION (CONT).
(7)
(8)
(9)
(10)
Install gasket (8) and cover (9) with screw (10), copper washer (11), and nut (12).
Install three screws (13) and lockwashers (14).
Install two screws (15) and lockwashers (14).
Tighten screws (13 and 15) to 35 to 40 lb-ft (47.5 to 54.2 N•m).
d. Follow-on Maintenance.
(1) Install air compressor (TM 9-2320-279-20).
(2) Install engine cover (TM 9-2320-279-20).
(3) Start engine and check operation (TM 9-2320-279-10).
END OF TASK
10-10
TM 9-2815-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
10-4. BLOWER DRIVE SEAL RING REMOVAL/INSTALLATION.
This task covers:
c. Follow-on Maintenance
a. Removal
b. Installation
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Engine cover removed.
Special Tools
None
Supplies
Cement, general purpose, synthetic base,
Item 12, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
(1) Loosen seal ring clamp (1) and slide clamp off blower drive seal ring (2)
(2) Cut and remove blower drive seal ring (2).
b. Installation.
NOTE
Make sure cut ends of blower drive seal ring are straight and
clean.
(1) Cut blower drive seal ring (1) straight across.
WARNING
Use general purpose cement lightly and avoid contact with skin.
Cement will burn on contact.
(2) Apply general purpose cement to one end (2) of cut blower drive seal ring (1).
10-11
TM 9-2815-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
10-40 BLOWER DRIVE SEAL RING REMOVAL/INSTALLATION (CONT).
(3) Install blower drive seal ring (1) on blower drive (3)
with cement coated cut end (2) on top.
(4) Slide other cut end of blower drive seal ring (1) up to
mate with cement coated end.
(5) Hold joined ends of blower drive seal ring (1)
together for 30 seconds.
(6) Position seal ring clamp (4) between raised edges of
blower drive seal ring (1).
(7) Tighten seal ring clamp (4).
c. Follow-on Maintenance.
(1) Start engine (TM 9-2320-279-10).
(2) Let engine idle for three or four minutes. Then check around blower drive seal ring for oil leaks.
(3) Install engine cover (TM 9-2320-279-20).
END OF TASK
Section Ill.
WATER PUMP DRIVE GEAR ASSEMBLY
10-5. WATER PUMP DRIVE GEAR REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
I
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Equipment Condition
TM or Para
Para 7-12
Condition Description
Front balance cover
removed.
Special Tools
None
Special Environmental Conditions
None
Supplies
None
General Safety Instructions
None
Personnel Required
MOS 63W, Wheel vehicle repairer
Level of Maintenance
Direct Support
References
None
10-12
TM 9-2815-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
a. Removal.
(1) Remove three screws (1), lockwashers (2), and hub (3) from drive gear (4).
(2) Remove retaining nut (5) and Iockwasher (6) from drive gear (4).
(3) Remove drive gear (4).
(4) Remove two screws (7) from balance weight (8).
(5) Remove balance weight (8) from drive gear (4).
(6) Remove spacer (9) and key (10).
10-13
TM 9-2815-224-34&P
Blower and Water Pump Drives Maintenance Instructions (Cont)
10-5. WATER PUMP DRIVE GEAR REMOVAL/INSTALLATION (CONT).
b. Installation.
(1) Install spacer (1) and key (2).
(2) Install balance weight (3) on gear (4) with two screws (5).
Tighten screws to 35 to 40 lb-ft (47 to 54 N•m).
(3) Install gear (4), Iockwasher (6), and retaining
nut (7). Hold gear and tighten nut to 300 to
325 lb-ft (407 to 441 N•m).
(4) Install hub (8) with three lockwashers (9) and
screws (10).
c. Follow-on Maintenance. Install front balance cover (para 7-12).
END OF TASK
10-14
TM 9-2815-224-34&P
CHAPTER 11
ENGINE BRAKE RETARDER MAINTENANCE
Para Page
Contents
11-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1
11-2
11-1
Engine Brake Retarder Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-6
11-4
Engine Brake Retarder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-11
11-4
Engine Brake Wire Harness Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section I. INTRODUCTION
11-1. GENERAL. This chapter covers the removal, disassembly, cleaning and inspection, assembly and
installation of the engine brake retarder which consists of supply housing, drone housing, solenoid, control
valve, slave piston and master piston. The subassemblies and parts which must be removed before these
components can be removed will be referenced to other paragraphs of this manual, TM 9-2320-279-10,
TM 9-2320-279-20, or TM 9-2320-279-34.
Section II.
ENGINE BRAKE RETARDER ASSEMBLY
Engine Brake Retarder Maintenance Instructions
11-2. ENGINE BRAKE RETARDER REMOVAL/lNSTALLATlON.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
None
Supplies
Connector, electrical, butt, Item 34,
Appendix C
Tags, identification, Item 61, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
Condition Description
TM or Para
TM 9-2320-279-20 Batteries disconnected.
TM 9-2320-279-20 Rocker covers removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
11-1
TM 9-2815-224-34&P
Engine Brake Retarder Maintenance instructions (Cont)
11-2.
a.
ENGINE BRAKE RETARDER REMOVAL/INSTALLATION (CONT).
Removal.
(1)
(2)
(3)
(4)
NOTE
Tag and mark wires before removal.
There are two kinds of engine brake wiring harnesses. Model A has a wire extending
through the cylinder head and uses a “butt type” connector while Model B has a
“spade type” connector. Model A is shown.
Cut wire (1) for Model A and disconnect wire (1) for Model B.
Remove screw (2), lockwasher (3), and solenoid valve wire (4) from solenoid (5) for Model A.
Disconnect wire (4) from engine brake solenoid valve (5) for Model B.
Loosen connector nut (6) between supply brake (7) and drone (8).
Screw connector (9) into drone (8) to clear supply brake (7).
11-2 Change 2
TM 9-2815-224-34&P
Engine Brake Retarder Maintenance Instructions (Cont)
(5) Remove two mounting screws (10) from supply brake (7) and two mounting screws (11) from
drone (8).
(6) Remove supply brake (7) and drone (8) from cylinder head (12).
(7) Remove connector (9) and nut (6)
from drone (8).
(8) Remove seal ring (13) from supply
brake (7).
(9) Repeat steps (2) through (8,) for
remaining supply brake and drone.
b. Installation.
(1) Install seal ring (1) in supply brake (2).
11-3
TM 9-2815-224-34&P
Engine Brake Retarder Maintenance Instructions (Cont)
11-2.
(2)
(3)
ENGINE BRAKE RETARDER REMOVAL/INSTALLATION (CONT).
Install connector (3) with nut (4) in drone (5).
Screw connector (3) in about 1/2-in. (13 mm).
NOTE
Clean engine mounting surface before
positioning supply brakes and drones on
engine.
(4)
(5)
(6)
(7)
(8)
(9)
Position master piston fork assembly (6)
over injector rocker clevis (7).
Install supply brake (2) and drone (5)
with four mounting screws (8) through
rocker arm shaft (9) to cylinder
head (10).
Tighten screws (8) to 45 lb-ft (61 N•m).
Tighten screws (8) to 88 to 92 lb-ft (119
to 124 N•m).
Move master piston fork assembly (6) up
and down several times to make sure it
rides freely on injector rocker clevis (7).
Unscrew connector (3) from drone (5)
until connector covers seal ring (1) and
makes contact with supply brake (2).
CAUTION
Be sure screw is backed out 1/3 turn from
contact point to provide working clearance. If
the screw is allowed to contact adjacent
housing during brake operation, the screw will
break resulting in leakage and loss of engine
braking.
(10)
11-4
After connector (3) makes contact, back
off connector 1/3 turn. Hold connector
and tighten nut (4) against drone (5).
Change 2
TM 9-2815-224-34&P
(11)
(12)
Engine Brake Retarder Maintenance Instructions (Cont)
Install solenoid valve wire (11),
screw (12), and lockwasher (13) on
solenoid valve (14) for Model A.
Connect wire (11) on engine brake
solenoid valve (14) for Model B.
Repeat steps (1) through (11) for
remaining supply brake and drone.
NOTE
Tag and mark wires before removal.
There are two kinds of engine brake wiring
harnesses. Model A has a wire extending
through the cylinder head and uses a “butt
type” connector while Model B has a “spade
type” connector. Model A is shown.
(13)
Connect engine brake wire (15) with butt
connector (16) for Model A, and connect
wire (15) for Model B.
c. Follow-on Maintenance.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Adjust exhaust valve clearance (para 19-2).
Adjust fuel injector timing (para 19-4).
Adjust engine brake retarder (para 19-3).
Install rocker covers (TM 9-2320-279-20).
Connect batteries (TM 9-2320-279-20).
Start and run engine for 10 minutes (TM 9-2320-279-10).
Turn on engine brake switch (TM 9-2320-279-10).
Open throttle to full engine speed and release.
Check engine brake operation when returning to idle.
Repeat full-throttle and release procedure six to eight times to bleed air from engine brake
system.
Shut off engine (TM 9-2320-279-10).
END OF TASK
Change 2
11-5
TM 9-2815-224-34&P
Engine Brake Retarder Maintenance Instructions (Cont)
11-3.
ENGINE BRAKE RETARDER REPAIR,
This task covers:
a.
b.
Disassembly
Cleaning/Inspection
c.
d.
Assembly
Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
TM or Para
Condition Description
Engine brake retarder on
clean work surface.
Special Tools
Gage, feeler 007958
Supplies
Oil, fuel, diesel, Item 44, Appendix C
Oil, lubricating, Item 48, Appendix C
Compound, sealing, lubricating, Item 31,
Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Disassembly,
(1)
(2)
Remove screw (1) and cover (2) from supply housing (3).
Remove two springs (4 and 5) and control valve (6) from
supply housing (3).
11-6 Change 2
TM 9-2815-224-34&P
Engine Brake Retarder Maintenance Instructions (Cont)
NOTE
Solenoid valve is used on supply
housing only.
There are three models of
solenoid valves. Models A and B
use a screw and lockwasher to
attach the solenoid wire, while
Model C has a spade (push-on)
type connector. If a Model A or B
solenoid must be replaced with a
Model C solenoid, the housing
must be changed also. Refer to
TM 9-2320-279-24P for proper
identification of parts.
(3)
(4)
(5)
(6)
Remove solenoid valve (7) from supply
housing (3).
Remove two seals (8 and 9) from solenoid
valve (7).
Remove seal (10) from supply housing (3).
Remove nut (11) and setscrew (12) from
supply housing (3).
WARNING
Slave piston is retained by spring under
compression. Spring can be discharged and
cause personal injury.
(7)
(8)
(9)
(10)
Turn supply housing (3) over and use
press to hold slave piston spring (13)
and spring retainer (14) in place.
Remove retaining ring (15).
Slowly release force from spring
retainer (14) and release slave piston
spring (13).
Remove spring retainer (14),
spring (13), and slave piston (16) from
supply housing (3).
Change 2
11-7
TM 9-2815-224-34&P
Engine Brake Retarder Maintenance Instructions (Cont)
11-3 ENGINE BRAKE RETARDER REPAIR (CONT).
(11) Remove screw (17), lockplate assembly (18), and fork assembly (19) from supply housing (3).
(12) Remove master piston (20).
b. Cleaning/Inspection.
WARNING
When working with fuel, post signs that read “NO SMOKING WITHIN 50 FEET”.
To avoid serious injury or death, keep fuel away from open fire and keep fire
extinguisher within easy reach when working with fuel.
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa).
Use only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(1) Clean housings and parts with diesel fuel, and dry with compressed air.
(2) Inspect all parts for damage. Replace damaged parts.
11-8
TM 9-2815-224-34&P
Engine Brake Retarder Maintenance Instructions (Cont)
c. Assembly.
(1) Apply lubricating oil to master piston (1).
(2) Install master piston (1) and fork assembly (2) in bottom
of supply housing (3).
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful to
skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and water.
(3) Apply sealing and lubricating compound to screw (4)
and install lockplate assembly (5) and screw. Tighten
screw to 50 lb-in (5.5 N•m).
(4) Apply lubricating oil to slave piston (6) and slave
piston spring (7).
(5) Install slave piston (6) and slave piston spring (7) in
supply housing (3).
(6) Aline tab on spring retainer (8) with slot in supply
housing (3).
(7) Press spring (7) and spring retainer (8) into supply
housing (3), to just below retaining ring groove (10)
and install retaining ring (11).
11-9
TM 9-2815-224-34&P
Engine Brake Retarder Maintenance Instructions (Cont)
11-3.
(8)
(9)
ENGINE BRAKE RETARDER REPAIR (CONT).
Apply oil to seal (12) and install
in supply housing (3).
Apply lubricating oil to two
seals (13 and 14), and install on
solenoid valve (15).
NOTE
There are three models of solenoid valves.
Models A and B use a screw and
lockwasher to attach the solenoid wire,
while Model C has a spade (push-on) type
connector. If a Model A or B solenoid must
be replaced with a Model C solenoid, the
housing must be changed also. Refer to
TM 9-2320-279-24P for proper
identification of parts.
(10)
(11)
(12)
Install solenoid valve (15) in
supply housing (3).
Install setscrew (16) with nut (17)
in supply housing (3).
Apply lubricating oil to control valve (18) and
install control valve and two springs (19 and
20) in supply housing (3).
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful to
skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and water.
(13)
(14)
Apply sealing and lubricating compound to
screw (21) and install cover (22) and screw in
supply housing (3).
Tighten screw (21) to 110 lb-in. (12 N•m).
d. Follow-on Maintenance. None,
END OF TASK
11-10 Change 2
TM 9-2815-224-34&P
Engine Brake Retarder Maintenance Instructions (Cont)
11-4.
ENGINE BRAKE WIRE HARNESS REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-20 Batteries disconnected.
TM 9-2320-279-20 Rocker covers removed.
Special Tools
None
Supplies
Connector, electrical butt, Item 34,
Appendix C
Tags, identification, Item 61, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
a.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Removal.
(1)
NOTE
There are two models of engine brake wire harnesses. Model A has a wire extending
through the cylinder head and uses a butt connector to connect to the engine
harness. Model B has a spade (push-on) type connector. The following procedure
covers both models.
Engine brake wire harness is removed from left and right cylinder heads the same
way.
Tag and mark wires before removal.
Cut wire (1) for Model A. Disconnect wire (1) for Model B.
Change 2
11-11
TM 9-2815-224-34&P
Engine Brake Retarder Maintenance Instructions (Cont)
11-4.
(2)
(3)
(4)
ENGINE BRAKE WIRE HARNESS REMOVAL/INSTALLATION (CONT).
Remove screw (2), lockwasher (3), and
wire (4) from both engine brake
solenoids (5) for Model A. Disconnect
wire (4) from both engine brake
solenoids (5) for Model B.
Remove spacer (6) and harness (7) from two fuel tubes (8).
Remove bushing (9).
11-12 Change 2
TM 9-2815-224-34&P
Engine Brake Retarder Maintenance Instructions (Cont)
b. Installation.
NOTE
There are two models of engine brake wire harnesses. Model A has a wire extending
through the cylinder head and uses a butt connector to connect to the engine harness.
Model B has a spade (push-on) type connector. The following procedure covers both
models.
Engine brake wire harness is installed in left and right cylinder heads the same way.
(1)
(2)
(3)
Install bushing (1).
Install spacer (2) and harness (3) on two fuel tubes (4).
Install wire (5) on both engine brake
solenoids (6) with screw (7) and
lockwasher (8) for Model A. Connect
wire (5) on both engine brake solenoids
for Model B.
Change 2
11-13
TM 9-2815-224-34&P
Engine Brake Retarder Maintenance Instructions (Cont)
11-4.
(4)
c.
ENGINE BRAKE WIRE HARNESS REMOVAL/INSTALLATION (CONT).
Connect wire (9) using butt connector for
Model A. Connect wire (9) for Model B.
Follow-on Maintenance.
(1)
(2)
Install rocker covers (TM 9-2320-279-20).
Connect batteries (TM 9-2320-279-20).
END OF TASK
11-14 Change 2
TM 9-2815-224-34&P
CHAPTER 12
FUEL INJECTOR MAINTENANCE
Para Page
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Fuel Injector Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Fuel Injector Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Fuel Injector Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Injuetor Control Tube Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Section 1.
12-1
12-1
12-5
12-21
12-29
INTRODUCTION
12-1. GENERAL. [This chapter covers removal, installation, and repair of the fuel injectors. The
subassemblies and parts which must be removed before the fuel injector components can be removed will
be referenced to other paragraphs or chapters of this manual, TM 9-2320-279-10, TM 9-2320-279-20, or
TM 9-2320-279-20.
Section Il.
FUEL INJECTOR ASSEMBLY
Fuel Injector Maintenance Instructions
12-2. FUELINJECTORREMOVAL/iNSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Oil, diesel fuel, Item 44, Appendix C
Caps, shipping, Item 11, Appendix C
Personnel Required
MOS 63W, Vehicle wheel repairer
Equipment Condition
TM or Para
Condition Description
Para 11-2
Engine brake retarder
removed.
Rocker arms removed.
Para 7-5
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
References
None
12-1
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-2. FUEL INJECTOR REMOVAL/INSTALLATION (CONT).
a. Removal.
NOTE
This procedure tells how to remove
and install one injector. Remove and
install other seven injectors in same
way.
(1) Loosen retaining nut (1) and
injector control rack lever adjusting
screw (2).
(2) Slide injector control rack lever (3)
away from injector control rack (4).
(3) Mark and remove screw (5), convex
washer (6), and clamp (7).
NOTE
Injector tube hole in cylinder head
must be covered to keep dirt out.
(4) Remove injector (8).
WARNING
● Compressed air used for cleaning
purposes will not exceed 30 psi
(207 kPa). Use only with effective
chip guarding and personal
protective equipment
(goggles/shield, gloves, etc.).
●
When working with fuel, post signs
that read “NO SMOKING WITHIN
50 FEET”. To avoid serious injury
or death, keep fuel away from open
fire and keep fire extinguisher
within easy reach when working
with fuel.
(5) Clean exterior of each injector (8)
with diesel fuel and dry with
compressed air.
12-2
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
b. Installation.
(1) Add diesel fuel to fuel inlet filter cap(l) to fill injector 2).
(2) Remove cover from injector tube hole\ (3).
(3) Insert injector (2) into injector tube hole (3) in cylinder head (4). Aline dowel pin (5) in body of
injector with locating hole in cylinder head.
(4) Slide injector rack control lever (6) into
injector control rack (7).
12-3
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-2. FUEL INJECTOR REMOVAL/INSTALLATION (CONT).
Make sure clamp does not interfere with injector spring or valve springs.
Interference of clamp with spring travel can cause damage to components.
(5) Install clamp (8), screw (9), and convex washer (10). Tighten screw to 20 to 25 lb-ft (27 to
34 N•m).
(6) Check injector control rack (7) for free movement. Loosen screw (9) if injector control rack is too
tight to allow easy checking. Retighten to 20 to 25 lb-ft (27 to 34 N-m).
c. Follow-on Maintenance.
(1) Install rocker arms (para 7-5).
(2) Install engine brake retarder (para 11-2).
(3) Adjust exhaust valve clearance (para 19-4).
(4) Adjust fuel injector timing (para 19-4).
(5) Adjust injector rack control lever (para 19-6).
(6) Install rocker covers (TM 9-2320-279-20).
END OF TASK
12-4
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-3. FUEL INJECTOR REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Needle Valve Lift Test
d. Needle Valve Tip Test
e. Assembly
f. Follow-on Maintenance
INITIAL SETUP
Models
All
Equipment Condition
TM or Para
Condition Description
Test Equipment
Fuel injector on clean work
surface.
Tension tester
Special Tools
Injector tip gage J5119
Rack tester kit J22396
Injector service kit J23435-02
Brass wire brush J7944
Reamer, injector J2 1089
Block set, lapping J22090-A
Polishing stick set J22964
Injector test kit J23010
Spray tip gage J9462-02
Special Environmental Conditions
Work in a clean, well ventilated work area.
General Safety Instructions
WARNING
●
Fuel and test oil are very flammable and
can explode easily. To avoid serious injury
or death, keep fuel away from open fire
and keep fire extinguisher within easy
reach when working with fuel.
●
When working with fuel, post signs that
read “NO SMOKING WITHIN 50 FEET.”
●
When testing or adjusting fuel injectors, do
not place hands or arms in front of injector
spray tip.
●
Fuel spray from an injector has sufficient
penetrating power to puncture the flesh
and destroy tissue. Should fuel enter blood
stream, it can cause blood poisoning.
Supplies
Oil, fuel, diesel, Item 44, Appendix C
Methyl ethyl ketone, Item 42, Appendix C
Solvent, dry cleaning, Item 60, Appendix C
Lapping and grinding compound, Item 27,
Appendix C
Oil, test, fuel injector, Item 52, Appendix C
Compound, polishing Item 28, Appendix C
Caps, shipping and sealing, Item 11,
Appendix C
Ties, cable, plastic, Item 66, Appendix C
Personnel Required
MOS 63W, Vehicle wheel repairer
Level of Maintenance
General Support
References
None
12-5
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12.3. FUEL INJECTOR REPAIR (CONT).
a. Disassembly.
(1) Put injector assembly (1) upright in rack tester kit.
NOTE
One filter is used in inlet side injector. No filter is
used in outlet side injector.
(2) Remove two injector fittings (2), two gaskets (3),
and one filter (4) from injector body (5).
(3) Press follower guide (6) down by hand, raise follower spring (7) above stop pin (8), and remove
stop pin. Allow follower spring to rise slowly.
(4) Remove follower guide (6), plunger pin (9), and follower spring (7).
12-6
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
(5) Turn injector (1) upside down in rack tester kit.
(6) Loosen injector valve nut (10) using injector nut socket from injector service kit.
(7) Lift injector valve nut (10) straight out without touching spray tip assembly (11).
CAUTION
If spray tip assembly does not remove easily from injector valve
nut, follow step (8). Use of other removal procedures can damage
spray tip assembly.
(8) Drive spray tip assembly (11) through injector valve nut (10)
using injector spray tip driver from injector service kit.
12-7
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-3. FUEL INJECTOR REPAIR (CONT).
(9) Remove spray tip assembly (11), spring cage (12), spring seat (13), valve helical spring (14), check
valve cage (15), and check valve (16) from bushing (17).
(l0) Lift bushing (17) and spill deflector (18) straight out of injector body (5).
12-8
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
NOTE
Sleeve spacer and spur gear may fall out of
injector body when body is turned over.
(11)
(12)
Turn injector body (5) upside down to
remove sleeve spacer (19) and spur
gear (20).
Remove injector body (5) from rack
tester kit.
NOTE
There are two colors of preformed packing.
Model A is black and Model B is red. Either
packing may be used.
(13)
(14)
Remove injector rack (21) and preformed
packing (22) from injector body (5).
Remove needle valve (23) from spray tip (11).
b. Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
CAUTION
Injector parts must be cleaned and placed on an extremely clean surface. Dirt
particles cause most injector problems, and dirt in injectors can result in serious
engine damage.
Do not clean injector parts with rags. Lint particles can become trapped in injectors
and cause damage. Use lint-free cloths.
(1)
Wash all injector parts in clean diesel fuel oil.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(2)
Dry injector parts with compressed air. Clean out all passages, drilled holes, and slots in injector
parts.
Change 2
12-9
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-3. FUEL INJECTOR REPAIR (CONT).
(3) Clean carbon from inside spray tip (1) by
soaking in methyl ethyl ketone for 15
minutes.
CAUTION
Use care when inserting carbon remover in
spray tip. Contact with valve seat can
damage valve.
(4) Clean spray tip (1) using carbon remover
from injector service kit.
(5) Clean spray tip (1) in diesel fuel oil, and dry with compressed air.
CAUTION
Do not buff excessively. Do not use steel wire buffing wheel or damage to spray
tip holes can result.
(6) Clean needle valve (2) and outside surface of injector body (3), injector valve nut (4), and spray
tip (1) with brass wire brush. Use spray tip carbon remover to hold spray tip against brass wire
brush.
(7) Hone a 0.006 in. (0.152 mm) spray hole wire from injector service kit until free of burrs. Taper
one end of-spray hole wire on wire sharpening stone from injector service kit.
(8) Clean orifices in spray tip (1) using pin vise and spray hole wire from injector service kit.
(9) Clean and brush passages in injector body (3), using fuel hole cleaning brush and rack hole
cleaning brush from injector service kit.
(10) Dry and blow out passages with compressed air.
(11) Insert injector body reamer in injector body (3) turning clockwise until bore face is reamed.
NOTE
Use straight fluted reamer with 0.375-in. diameter.
(12) Insert reamer into ring bore inside injector body (3) and turn clockwise to remove bum.
(13) Wash injector body (3) in container of diesel fuel oil.
(14) Dry injector body (3) with compressed air.
CAUTION
When removing carbon deposits, use care not to remove excess metal or cause
burrs on spray tip seat. Remove only enough metal to make a clean uniform seat
to prevent leakage between seat and nut. Excessive reaming can damage injector
parts.
(15) Remove carbon deposits from lower inside diameter of injector valve nut (4) using taper reamer
from injector service kit.
(16) Inspect seating surface of injector valve nut (4) for nicks, burrs, erosion, or scratches.
12-10
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
Do not touch finished plunger surfaces with fingers. Dirt and oils from fingers
can result in defective operation of injector.
NOTE
Plunger and bushing are matched and must always be replaced as a set.
(1 ?’) Inspect plunger pin (5) and bushing (6) for scoring, erosion, chipping, or wear, Remove any sharp
(18)
(19)
(20)
(21)
edges with a fine stone. Inspect bushing port holes and high pressure bleed hole with injector
bushing inspectalite. Replace plunger pin and bushing, as a set, if any damage is found.
Place parts of each injector assembly in clean containers of clean diesel fuel oil. Dry parts with
compressed air for inspection.
Inspect teeth on injector rack (7) and spur gear (8) for wear or damage. Inspect gear bore and
sleeve spacer (9) for excessive wear, sharp edges, and burrs that might cause flakes of metal in
injector.
Inspect follower spring (10) for defects. Check spring with tension tester.
Replace follower spring (10) if a load of less than 70 pounds (3 1.78 kg) will compress it to
1.028-in. (26. 11 mm).
(22) Inspect injector body (3) surface where it contacts injector
bushing (6) for scratches or damage.
(23) Lap bushing (6) if slight damage is found. Use lapping block and
lapping and grinding compound. See steps (31) to (41) for
lapping instructions.
(24) Inspect injector body (3) plugs and dowel pins. Replace injector
body if plugs or dowel pins are found loose.
12-11
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-3. FUEL INJECTOR REPAIR (CONT).
(25) Inspect valve spring (11 ) for
wear or damage. Replace if worn
or damaged.
(26) Inspect sealing surfaces of
injector valve parts. Use
magnifying glass and inspect
bushing (6), check valve (12),
check valve cage (13), and spring
cage (14) for burrs, nicks,
erosion, and scratches. Replace
damaged parts.
(27) Inspect seating area of needle valve (15) for wear or damage. Inspect needle quill (16) and
contact point with spring seat (17).
CAUTION
Make sure no polishing compound gets on lapped surfaces located higher than
end of spray tip. Any lapping on these surfaces can alter near-perfect fit between
needle valve and tip.
(28) Inspect needle valve seat in spray tip (l). Polish seat area with polishing stick from injector
service kit coated with polishing compound.
(29) Insert polished tapered end of polishing stick directly into center of spray tip (1) until it bottoms.
Rotate polishing stick 6 to 12 times with light pressure.
(30) Lap sealing surfaces (see arrows) of injector
valve parts. Follow given lapping procedures for
bushing (6), check valve (12), check valve
cage (13), spring cage (14), and spray tip (1).
(31) Clean lapping blocks with compressed air only.
(32) Spread lapping and grinding compound on first
lapping block.
CAUTION
●
●
Do not press on parts when lapping, but use enough pressure to keep part flat
on lapping block or injector malfunction will result.
Do not lap parts excessively. Inspect injector parts for minimum thickness.
Excessive lapping can result in improper seating surfaces and injector
malfunction.
NOTE
Minimum thicknesses of used injector parts are:
Spray tip (shoulder) O. 199-in. (5.05 mm)
Check valve cage 0.165 to 0.163-in. (4.19 to 4.14 mm)
Check valve 0.022-in. (0.55 mm)
Valve spring cage 0.602-in. (15.29 mm)
(33) Place injector part flat on lapping block and using a figure-eight motion, move part back and
forth.
(34) Wash injector parts in dry cleaning solvent after lapping.
12-12
TM 9-2815-224-34&P
Fuel Injectior Maintenance Instructions (Cont)
(35) Dry injector parts with compressed air.
(36) Apply lapping and grinding compound to second lapping block.
(37) Move dry injector part flat on lapping block lightly in a figure-eight motion. Lap part until finish
(38)
(39)
(40)
(41)
is smooth.
Clean injectr parts in dry cleaning solvent and dry with compressed air.
Place dry injector part on third lapping block, using no lapping and grinding compound.
Keep injector part flat and move it across third block several times in a figure-eight motion.
Clean all lapped injector parts in diesel fuel oil and dry with compressed air.
c. Needle Valve Lift Test.
(1) Adjust spray tip gage to zero.
(2) Install spray tip (1) and needle
valve (2) assembly on gage with
needle valve quill (3) in plunger of
gage.
NOTE
Needle valve lift limits are 0.008 to
0.018-in. (0.203 to 0.457 mm).
(3) If valve lift is above limits, replace
spray tip and needle valve
assembly (4). If valve lift is below
limits, inspect for contamination and clean needle valve assembly (4).
d. Needle Valve Tip Test.
(1) Install tip test adapter (1) in vise
and install check valve cage (2),
spring (3), spring seat (4), spring
cage (5), needle valve (6), and
spray tip (7).
(2) Install injector valve nut (8) over
spray tip assembly (7) onto tip
test adapter (l).
(3) Tighten injector valve nut (8) to
75 to 85 lb-ft (102 to 115 N-m).
(4) Remove tip test adapter (1) and
assembled parts from vise.
12-13
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-3. FUEL INJECTOR REPAIR (CONT).
(5) Set up injector test kit (refer to
para 12-4).
(6) Loosen thumb screw (9) and lift
clamping head (10).
(7) Install oil flow adapter (1 1), open end
up, on injector test fixture (12).
(8) Install clamping head (10) on post (13) so
that thumb screw (9) fits in upper
hole (14) on post.
(9) Tighten thumb screw (9).
(10) Position fuel connector adapter (15) over
oil flow adapter (11).
(11) Pull pump lever (16) forward to seat fuel
connector adapter (15) on oil flow
adapter (11).
(12’) Install coupling nut (17), small hole first, on
tube (18) as far as it will go.
(13) Install tube (18) and coupling nut (17) on tip
test adapter (l).
(14) Install tube (18) and tip test adapter (1) on oil
flow adapter (11).
12-14
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
(15) Position valve lever (19) so it points down.
(16) Pull pump lever (16) forward 40 to 80 times a
minute with steady strokes and watch oil spray
pattern from tip of injector (20).
(17) If injector (20) does not spray oil evenly in a fine
mist, disassemble injector and inspect for
contamination.
(18) Check left gage (21) to find pressure that causes
injector (20) to spray. If injector spray pressure is
less than 2200 psi (15 169 kPa) or more than
3300 psi (22 753 kPa), disassemble injector and
inspect for contamination or damage.
(19) Move pump lever (16) forward several times slowly
to let pressure build up to 1500 psi (10 335 kPa) on
left gage (2 1). Keep moving lever (16) as needed to
keep pressure at 1500 psi (10 335 kPa) for
15 seconds.
(20) Check injector tip (7) for signs of leakage or oil
droplets. Slight wetting of tip is all right, but if tip
leaks or if there are drops of oil present,
disassemble injector, clean and reassemble.
(21) Loosen coupling nut (17) slowly to allow release of pressure and remove tip test adapter (1).
(22) Move clamp release lever (22) down.
(23) Remove oil flow adapter (11) and
tube (18). Disconnect adapter from tube.
12-15
TM 9-2815-224-34&P
Fuel Injector Maintenance lnstructions (Cont)
2-3. FUEL INJECTOR REPAIR (CONT).
(24)
(25)
Place adapter (1) in vise.
Remove injector valve nut (8),
spray tip (7), needle valve (6),
cage (5), spring seat (4), spring (3),
and check valve cage (2).
e. Assembly
NOTE
Outlet side injector does not have filter.
(1)
(2)
(3)
Insert filter (1), slotted end up, in inlet side fuel
cavity in top of injector body (2).
Install two gaskets (3) in each of two injector
caps (4).
Apply injector test oil to thread of injector caps (4)
and install in injector body (2).
CAUTION
Some injector caps (4) and injector bodies (2) could have a blued
or non-blued finish. These parts are fully interchangeable,
however, to avoid parts damage due to overtightening, the
correct torque values listed below must be used.
(a)
Torque a non-blued injector cap (4) on a non-blued injector
body (2) to 62 lb-ft (84 N•m).
(b)
Torque a blued injector cap (4) on a blued injector body (2)
to 70 lb-ft (95 N•m).
(c)
Torque a non-blued injector cap (4) on a blued injector body (2) or a blued injectorcap (4) on a
non-blued injector body (2) to 62 lb-ft (84 N•m).
(4)
(5)
(6)
(7)
(8)
Place injector body (2) in rack tester kit and tighten injector caps (4).
Purge filter (1) with diesel fuel oil directed through injector caps (4).
Install clean shipping caps on injector caps (4) to prevent dirt from entering injector body (2).
Support injector body (2), bottom end up,
in rack tester kit.
Slide injector rack (5) through injector
body (2) with teeth of rack pointing
towards center of injector body.
2-16 Change 2
TM 9-2815-224-34&P
Fuel lnjector Maintenance Instructions (Cont)
(9)
(10)
(11)
(12)
Look through bore of injector body (2) and move injector rack (5) until punch marks (6) on teeth
are visible.
Aline timing mark (7) on gear (8) between two punch marks (6) on rack (5).
Install gear (8), recheck alinement from step (9), and repeat step (9) if necessary to get proper
alinement.
Install sleeve spacer (9).
NOTE
There are two colors of preformed packings. Model A is black and Model B is red.
Either packing may be used.
(13)
(14)
(15)
Install preformed packing (10) on shoulder of injector body (2).
Aline pin (11) in bushing (12) with slot in injector body (2) and slide end of bushing into injector
body.
Install spill deflector (13) over barrel of bushing (12).
Change 2
12-17
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-3. FUEL INJECTOR REPAIR (CONT).
(16) Install check valve (14) into check valve cage (15).
(17) Install cage (1.5) and valve (14) over bushing (12).
(18) Install spring seat (16) in valve spring (17).
(19) Install spring cage (18) over spring seat (16) and valve spring (17).
(20) Put spring cage (18), spring end down, on check valve cage (14).
(21) Install needle valve (19), point first. in spray tip (20).
12-18
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
(22)
(23)
(24)
Put spray tip (20) and needle valve (19) on spring cage (18) with end of needle valve in hole in
spring cage.
Apply fuel injector test oil on injector nut (21) threads. Install injector nut carefully on injector
body (2).
Tighten injector valve nut (21) as tightly as possible by hand.
CAUTION
Do not exceed specified torque or injector nut may stretch and result in improper
sealing of lapped surfaces.
Some injector nuts (21) and injector bodies (2) could have a blued or non-blued finish.
These parts are fully interchangeable, however. To avoid parts damage due to
overtightening, the correct torque values listed below must be used.
(a) Torque a non-blued injector nut (21) on a non-blued injector body (2) to 50 lb-ft
(68 N•m).
(b)
Torque a blued injector nut (21) on a blued injector body (2) to 80 lb-ft (108 N•m).
(c)
Torque a non-blued injector nut (21) on a blued injector body (2) or a blued injector
nut (21) on a non-blued injector body (2) to 65 lb-ft (88 N•m).
(25)
Tighten injector valve nut (21) using injector nut socket.
(26)
(27)
Turn injector assembly (22) over in rack tester kit and push injector rack (5) all the way in.
Place follower spring (23) on injector body (2).
Change 2
12-19
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-3. FUEL
(28) Install plunger pin (25) into follower guide (26).
(29) Aline slot on follower guide (26) with flat side of plunger pin (25) and stop pin (24) on injector
body (2).
(30) Install plunger pin (25) and follower guide (26).
NOTE
Make sure follower spring holds stop pin in body.
(31) Hold spring (23) up from body (2), push follower guide (26) down and install stop pin (24) into
slots in body (2) and on follower guide.
(32) Remove injector assembly (22) from rack tester kit.
12-20
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
(33)
(34)
(35)
Put injector assembly (22) in injector tip gage and adjust dial to zero.
Rotate injector assembly (22) 360°. If total runout exceeds 0.008-in. (0.203 mm), do steps(35)
through (38). If runout is less than 0.008-in., go to follow-on maintenance.
Remove injector assembly (22) from injector tip gage. Loosen injector nut (21), using injector nut
socket, and center spray tip (20).
CAUTION
Some injector nuts (21) and injector bodies (2) could have a blued or non-blued
finish. These parts are fully interchangeable, however. To avoid parts damage due
to overtightening, the correct torque values listed below must be used.
(a) Torque a non-blued injector nut (21) on a non-blued injector body (2) to 50
lb-ft (68 N•m).
(b) Torque a blued injector nut (21) on a blued injector body (2) to 80 lb-ft (108
N•m).
(c) Torque a non-blued injector nut (21) on a blued injector body (2) or a blued
injector nut (21) on a non-blued injector body (2) to 65 lb-ft (88 N•m).
(36) Tighten injector nut (21).
(37) Check spray tip again, following procedures in steps(33) and (34).
(38) Replace injector nut (21) if spray tip (20) cannot be positioned correctly.
f . Follow-on Maintenance. Test fuel injector (para 12-4).
END OF TASK
12-4.
FUEL INJECTOR TESTING.
This task covers:
a. Set-Up Injector Test Kit
b. Testing
INITIAL SETUP
Models
All
Test Equipment
None
c. Follow-on Maintenance
Special Environmental Conditions
Work in clean, well-ventilated work area.
General Safety Instructions
Special Tools
Rack tester kit J22396
Spray tip gage J9462-02
Injector test kit J23010 or J23010-A
Fuel and test oil are very flammable and
can explode easily. To avoid serious injury
or death, keep fuel away from open fire and
keep fire extinguisher within easy reach
when working with fuel.
Supplies
Oil, test, fuel injector, Item 49, Appendix C
When working with fuel, post signs that
read “NO SMOKING WITHIN 50 FEET.”
Personnel Required
MOS 63W, Vehicle wheel repairer
When testing or adjusting fuel injectors, do
not place hands or arms in front of injector
spray tip.
References
None
Equipment Condition
Condition Description
TM or Para
Fuel injector on clean
work surface.
The fuel spray from an injector has
sufficient penetrating power to puncture
the flesh and destroy tissue. Should the fuel
enter the blood stream, it can cause blood
poisoning.
Level of Maintenance
General Support
Change 2
12-21
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-4. FUEL
a. Set Up Injector Test Kit.
(1) Loosen set screw (1).
(2) Install pump lever (2) on injector test kit (3) and tighten set screw (1).
There are two clamping heads with injector test kit.
(3) Select offset clamping head (4).
(4) Install preformed packing (5) and valve tip (6) on control valve (7).
(5) Install control valve (7) in clamping head (4).
(6) Install thumb screw (8).
12-22
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
(7) Install clamping head (4) on post (9) so that thumb screw (8) fits in lower hole (10) on post.
Tighten thumb screw.
(8) Install fuel discharge line (11) on clamping head (4) using plastic ties.
(9) Install fuel delivery line (12) on clamping head (4).
12-23
TM 9-2015-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-4. FUEL INJECTOR TESTING (CONT).
(10) Install four preformed packings (13 and 14) in two fuel connector
adapters (15).
(11) Install two fuel connector adapters (15) on
clamping head (4).
(12) Install adapter plate (16) on injector test kit (3).
(13) Install injector (17) in adapter plate (16) with injector locating pin (18) in hole (19).
12-24
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
(14) Remove two screws (20) and drain plate (21).
NOTE
Reservoir holds one quart test oil.
(15) Fill reservoir (22) to top of filter (23).
(16) Install plate (21) with two screws (20).
(1 ?“ Install spray shield (24).
(18) Position two fuel connector
adapters (15) over fuel
injector caps (25).
(19) Point plunger position
lever (26) towards the rear.
(20) Push rocker arm engagement
lever (27) to its rear position.
(21) Push valve lever (28) so it
points forward.
(22) Open control valve (7).
(23) Move pump lever (2) down to
seat clamping head (4) on
injector caps (25).
12-25
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-4. FUEL INJECTOR TESTING (CONT).
(24) Push valve lever (28) down.
(25) Pull pump lever (2) and watch flow of test oil
(26)
(27)
(28)
(29)
(30)
(31)
(32)
12-26
passing through discharge line (11). When no
air bubbles pass through line (11 ), do next
step.
Push injector control rack (29) in to full fuel
position.
Position pump lever (2) so it points straight
up.
Move rocker arm engagement lever (27) to
forward position.
Pull pump lever (2) forward 40 to 80 times a
minute with steady strokes and read
maximum reference value from right hand
gage (30).
Injector (17) must be repaired (refer to
para 12-3) if maximum reference value is less
than 138 or more than 162.
Pull pump lever (2) forward several times
with steady strokes and observe spray pattern
produced by injector (17).
Injector must be repaired (refer to para 12-3)
if spray pattern is uneven or if test oil does
not break up into a fine mist.
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
(33) Position pump lever (2) so it points straight up.
(34) Move rocker arm engagement lever (27) to rear.
CAUTION
Do not over tighten control valve or nylon bushing may be damaged.
(35) Close control valve (7).
(36) Pull pump lever (2) forward several times to slowly build up to 1600 to 2000 psi (11032 to
13790 kPa) on left gage (31).
(37) Check for leaks at injector caps (25), body plugs (32), rack (29), and injector nut (33).
(38) Open control valve (7).
CAUTION
Do not over tighten control valve or nylon
bushing may be damaged.
(39) Close control valve (7).
(40) Pull pump lever (2) forward several times
until pressure builds up to 500 psi
(3447.5 kPa) on left gage (31).
(41) Move valve lever (28) so it points forward,
(42) If it takes less than 15 seconds for pressure to
drop from 450 to. 250 psi (3102 to 1723 kPa)
on left gage (31), disassemble injector clean
and reassemble.
(43) Open control valve (7).
(4-4) Move clamp release lever (34) down.
(45) Remove injector (17) and adapter plate (16)
from injector test kit (3).
b.
Testing.
(1) Injectors which pass all tests can be installed (refer to para 12-2).
(2) Injectors which fail one or more tests will be repaired (refer to para 12-3). Perform all injector
tests before repairing injectors.
NOTE
To test injector control rack do
steps (3) through (10).
(3) Install fuel injector (1) in
rack freeness tester.
12-27
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-4. FUEL INJECTOR TESTING (CONT).
(4) Make sure dowel (2) on injector (1)
fits in hole (3) in rack freeness tester.
(5) Put handle on top of injector
follower (4).
(6) Pull injector control rack (5)
out to no-fuel position and
push injector follower (4) in
with handle.
(7) Loosen locknut (6) and adjust screw (7) so it is in center
of injector follower (4) when injector” spring (8) is fully
compressed. Tighten locknut.
(8) Release handle slowly while moving injector control
rack (5) up and down to test for freedom of movement.
12-28
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
(9) Loosen injector valve nut (9) and turn spray tip (10). Tighten
injector valve nut 75 to 85 lb-ft (102 to 115 N•m) and repeat
steps (4) to (10) until control rack moves freely.
(10) If control rack (5) does not move freely, repair fuel injector (1)
(refer to para 11-3).
c. Follow-on Maintenance. None.
END OF TASK
12-5. INJECTOR CONTROL TUBE REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
1/4” drive 12 pt socket 819158 (34104)
Supplies
Tags, identification, Item 61, Appendix C
Solvent, dry cleaning, Item 60, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
Condition Description
TM or Para
TM 9-2320-279-20 Valve rocker covers
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
12-29
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-5. INJECTOR CONTROL TUBE REMOVAL/INSTALLATION (CONT).
a. Removal.
NOTE
Step (1) applies to right side only.
Some engines are equipped with throttle delay, others are equipped with a fuel
modulator. Perform step (1) for engines with throttle delay. Perform step (1.1) for
engines with fuel modulator.
(1)
Remove two nuts (1), lockwashers (2), and U-bolt (3) from throttle delay cylinder lever (4).
(1.1) Remove screw (4.1), lockwasher (4.2), clamp (4.3), and lever (4.4).
12-30
Change 2
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
(2)
(3)
(4)
(5)
Remove
Remove
Remove
Remove
cotter pin (5) and pin (6) from left injector control tube clevis (7).
cotter pin (5) and pin (6) from right injector control tube clevis (8).
four screws (9) and left injector control tube (10).
four screws (9) and right injector control tube (11).
Change 2
12.30.1/(12-30.2 blank)
TM 9-2815-224-34&P:
Fuel Injector Maintenance Instructions (Cont)
b. Disassembly.
(1) Remove bracket (1) from
left injector control
tube (2).
NOTE
Four control levers are removed
the same on both left and right
control tubes.
(2) Loosen locknut (3) and
screw (4) and remove
control lever (5). Remove
locknut and screw.
NOTE
Tag and mark springs before
removal.
(3) Remove spring (6) from
control lever (5).
(4) Remove pin (7) and injector control tube clevis (8).
(5) Remove spacer (9) and bracket (10).
(6) Remove return spring (11) from injector control tube (2).
12-31
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-5. INJECTOR CONTROL TUBE REMOVAL/INSTALLATION (CONT).
(7’) Remove bracket (12) and return spring (13) from right injector control tube (14).
(8) Loosen locknut (15) and screw (16), and remove control lever (17). Remove locknut and screw.
(9) Remove spring (18) from control lever (17).
NOTE
All three remaining control levers are removed the same.
(lo) Remove spring (19) from second control lever (20).
(11) Loosen locknut (21) and screw (22) and remove second control lever (20). Remove locknut and
screw.
(12) Remove pin (23) and right injecot control tube clevis (24).
(13) Remove spacer (25) and bracket (26) from right injector control tube (14).
12-32
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cent)
c. Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Clean all metal parts with dry cleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(2) Use compressed air to dry all metal parts.
(3) Inspect all parts for damage.
(4) Replace damaged parts.
d. Assembly.
(1) Install bracket (1) and spacer (2) on injector control tube (3).
(2) Install right injector control tube clevis (4) with pin (5).
12-33
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-5. INJECTOR CONTROL TUBE REMOVAL/INSTALLATION (CONT).
(3) Position control lever (6)
and spring (7) over slot in
right injector control
tube (8).
(4) Install control lever (6) with
screw (9) and locknut (10).
NOTE
Repeat steps (3) and (4) for
next two control levers.
(5) Position spring (11 ) and
control levers (12) over slot
in injector control tube (8).
(6) Install control lever (12)
with screw (9) and
locknut (10).
(7) Install return spring (13)
and bracket (14).
(8) Install return spring (15), bracket (16), and spacer (17) on left injector control tube (18).
(9) Install injector control tube clevis (19) with pin (20).
12-34
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
(10) Position control lever (21) and spring (22) over slot in left injector control tube (18).
(11) Install control lever (21) with screw (23) and locknut (24).
(12) Position next spring (25) and control lever (26) over slot in left injector control tube (18).
(13) Install control lever (26) with screw (23) and locknut (24).
NOTE
Repeat steps (12) and (13) for next two control levers.
(14) Install bracket (27).
12-35
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-5. INJECTOR CONTROL TUBE REMOVAL/iNSTALLATION (CONT).
e. Installation.
(1) Install right injector control tube (1) with four screws (2). Tighten to 10 lb-ft (13.5 N•m),
(2) Install left injector control tube (3) with four screws (2). Tighten to 10 lb-ft (13.5 N-m).
NOTE
Make sure injector control tubes move freely in brackets.
(3) Tap injector control tubes (1 and 3) lightly to aline bearings in brackets (4 and 5).
(4) Install right injector control tube clevis (6) to fuel rod (7) with pin (8) and cotter pin (9).
(5) Install left injector control tube clevis ( 10) to fuel rod (11) with pin (8) and cotter pin (9),
12-36
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
(6)
(7)
(8)
Pull eight injector control levers (12 through 19).
Tighten eight screws (20 and 21).
Tighten eight locknuts (22 and 23) to 35 lb-in (4 N•m).
NOTE
Step (9) applies to right side only.
Some engines are equipped with
throttle delay, others are equipped
with a fuel modulator. Perform
step (9) for engines with throttle
delay. Perform step (10) for engines
with fuel modulator.
(9)
Install U-bolt (24), two lockwashers (25),
and nuts (26) to throttle delay cylinder
lever (27).
Change 2
12-37
TM 9-2815-224-34&P
Fuel Injector Maintenance Instructions (Cont)
12-5.
f.
INJECTOR CONTROL TUBE REMOVAL/INSTALLATION (CONT).
(10) Install lever (28) and clamp (29) with screw (30) and lockwasher (31).
Follow-on Maintenance,
(1)
(2)
(2.1)
(3)
Adjust
Adjust
Adjust
Install
injector rack control lever (para 19-6).
throttle delay (engines equipped with throttle delay only) (para 19-8)
fuel modulator (engines equipped with fuel modulator only) (para 19-8.1).
valve rocker cover (TM 9-2320-279-20).
END OF TASK
12-38
Change 2
TM 9-2815-224-34&P
CHAPTER 13
FUEL SYSTEM MAINTENANCE
Para
Contents
_ General . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Fuel Pump Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Section I.
Page
13-1
13-1
INTRODUCTION
GENERAL. This chapter covers removal, installation, and repair of the fuel pump. The
subassemblies and parts which must be removed before the fuel pump can be removed will be referenced
to other paragraphs or chapters of this manual, TM 9-2320-279-20, TM 9-2320-279-10, or TM 9-2320-279-34.
To repair the fuel pump, use the fuel pump repair kit, part No. 5195078. Replace all the parts included in
this kit.
The fuel pump can be removed with the engine installed in the vehicle or with the engine removed.
[13-1.
Section Il.
FUEL SYSTEM
Fuel System Maintenance Instructions
13-2.
FUEL PUMP REMOVAL/REPAIR/iNSTALLATION.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Tool set, fuel pump J1508-3
Supplies
Solvent, dry cleaning, Item 60, Appendix C
Grease, automotive and artillery, Item 36,
Appendix C
Adhesive-sealant, silicone, Item 6, Appendix C
Oil, lubricating, Item 48, Appendix C
Crocus cloth, Item 17, Appendix C
Compound, pipe thread sealing, Item 32,
Appendix C
Tags, identification, Item 61, Appendix C
Personnel Required
References
None
Equipment Condition
TM
TM
TM
TM
or Para
9-2320-279-10
9-2320-279-10
9-2320-279-20
Para 15-10
Condition Description
Engine off.
Parking brake on.
Thermostat crossover tube
removed.
Engine stop solenoid
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
MOS 63W, Wheel vehicle repairer
MOS 63G, Fuel and electrical systems repairer
13-1
TM9-2815-224-34&P
Fuel System Maintenance Instructions (Cont)
I
13-2. FUEL PUMP REMOVAL/REPAIR/INSTALLATION (CONT). I
a. Removal.
(1) Remove screw (1) and lockwasher (2).
(2) Loosen screw (3) and move bracket (4) aside.
(3) Remove two fuel hoses (5).
(4) Remove three screws (6).
13-2
TM9-2815-224-34&P
Fuel System Maintenance Instructions (Cont)
(5) Remove fuel pump (7) and gasket (8) from
governor housing (9).
WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. To avoid injury or
death, keep away from open fire and use in
well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash
immediately with soap and water.
(6) Clean fuel pump (7) with dry cleaning solvent.
b. Disassembly.
(1) Remove fork (1) from fuel pump (2).
(2) Mount fuel pump holder in vise and install
fuel pump (2) on holder.
(3) Mark anti remove elbow (3), elbow (4),
coupling (5), and nipple (6).
13-3
TM9-2815-224-34&P
Fuel System Maintenance Instructions (Cont)
I
13-2. FUEL PUMP REMOVAL/REPAIR/INSTALLATION (CONT). I
(4) Remove eight screws (7), lockwashers (8),
and cover (9) from housing (10).
(5) Remove drive shaft and gear assembly (11).
Do not remove gear from- shaft.
(6) Remove drive shaft and gear assembly (12).
Do not remove gear from shaft.
(7) Remove plug (13), gasket (14), spring (15),
pin (16), and valve (17) from housing (10).
(8) Remove fuel pump holder from vise. Install
housing (10) in vise.
NOTE
Tag and mark how oil seals are installed, Install
new seals with lips pointing in same direction.
(9) Remove two oil seals (18 and 19) from
housing (10).
(10) Mark location and remove two pipe plugs (20)
from housing (10).
c.Cleaning/Inspection
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Inspect all parts for damage. Replace damaged parts.
(2) Inspect mating surfaces of housing and cover. Mating surfaces must be flat and smooth and fit
together tightly.
(3) Inspect valve. If valve is lightly scored, use crocus cloth to remove marks. If marks cannot be
removed with crocus cloth, replace valve,
13-4
TM9-2815-224-34&P
Fuel System Maintenance Instructions (Cont)
d. Assembly.
WARNING
Adhesives, solvents, and sealing compounds can
bum easily, can give off harmful vapors, and are
harmful to skin and clothing. To avoid injury or
death, keep away from open fire and use in
well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash
immediately with soap and water.
(1) Coat threads of two pipe plugs (1) with pipe
thread sealing compound and install in fuel
pump housing (2).
(2) Mount fuel pump holder in vise and install fuel pump housing (2) on holder.
(3) Lubricate valve (3) and install valve, pin (4), spring (5), gasket (6), and plug (7) in housing (2).
Tighten plug to 20 Ib-ft (27 N•m).
(4) Lubricate two oil seals (8 and 9) with lubricating oil.
(5) Set fuel pump housing (2) on top of two wooden blocks.
NOTE
Install new seals with lips pointing in same direction.
(6) Install inner oil seal (8) on pilot (pin) of oil seal installer. Install inner oil seal (8) in housing (2).
Tap seal until seated.
(7) Install adapter on tool.
(8) Install outer oil seal (9) on pilot of oil seal installer. Install outer oil seal in housing (2). Tap seal
until seated.
(9) Lubricate two shaft and gear
assemblies (10 and 11) with lubricating oil.
Install assemblies in housing (2).
CAUTION
When applying adhesive-sealant to pump
cover, insure no sealant gets into gear
compartment. Sealant in gear compartment
can damage equipment.
(10) Apply coating of adhesive-sealant to
mating surface of cover (12). Install cover
on housing (2).
(11) Install eight lockwashers (13) and
screws (14). Tighten screws evenly.
\
13-5
TM9-2815-224-34&P
Fuel System Maintenance Instructions (Cont)
I 13-2. FUEL PUMP REMOVAL/REPAIR/INSTALLATION (CONT). I
(12) Coat threads of nipple (15), coupling (16),
elbow (17), and elbow (18) with pipe thread sealing
compound and install on pump (19).
(13) Remove pump (19) from fuel pump holder.
(14) Install fork (20) in pump (19).
e. Installation.
(1) Apply grease to gasket (1).
(2) Install gasket (1) to governor housing (2).
(3) Aline fork (3) with blower shaft (4) and install
fuel pump (5).
13-6
TM9-2815-224-34&P
Fuel System Maintenance Instructions (Cont)
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors,and are harmful
to skin and clothing. To avoid injury or death, keep
away from open fire and use in well-ventilated area.
If adhesive, solvent, or sealing compound gets on
skin or clothing, wash immediately with soap and
water.
(4) Apply adhesive-sealant to three screws (6).
(5) Install three screws (6).
(6) Install two fuel hoses (7).
(7) Straighten up bracket (8), install screw (9) and lockwasher (10).
(8) Tighten screw (11).
f. FoIIow-on Maintenance.
(1) Install engine stop solenoid (para 15-10).
(2) Install thermostat crossover tube (TM 9-2320-279-20).
END OF TASK
13-7/(13-8 blank)
TM 9-2815-224-34&P
CHAPTER 14
BLOWER AND TURBOCHARGER MAINTENANCE
Para
Contents
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 - 1
Tachometer Drive Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 - 2
Blower Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 4 - 3
Blower Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
..
Air Inlet Adapter Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
Turbocharger Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
Turbocharger Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 4. - 7
Page
14-1
14-1
14-4
14-14.1
14-36
14-38
14-44
Section I. INTRODUCTION
14-1. GENERAL
This chapter includes removal, installation, and repair of the blower, tachometer drive,
and turbocharger assemblies. All assemblies can be removed with the engine in the vehicle. Preliminary
procedures may differ if assembly components are removed after engine is removed from vehicle. Subassemblies
and parts which must be removedbefore blower, tachometer drive, and turbocharger components can be removed
or repaired will be referenced to other paragraphs of this manual,TM 9-2320-279-10, TM 9-2320-279-20, or
TM 9-2320-279-34.
Section II. BLOWER ASSEMBLY
Blower Maintenance Instructions
14-2.
TACHOMETER DRIVE REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-10 Engine off.
TM 9-2320-279-10 Parking brake on.
TM 9-2320-279-10 Engine cover open.
TM 9-2320-279-10 Engine side panel removed.
TM 9-2320-279-20 Tachometer sending unit
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Change 2
14-1
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
14-2. TACHOMETER DRIVE REMOVAL/INSTALLATION (CONT)
a. Removal.
(1) Loosen jamnut (1).
(2) Loosen screw (2) and remove clamp (3).
(3) Remove tachometer drive housing (4) and gasket (5).
(4) Remove tachometer drive (6).
14-2
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
b. Installation.
(1) Install tachometer drive (1)in tachometer drive housing (2).
(2) Install gasket (3)on housing (2).
(3) Install housing (2).
(4) Install clamp (4)and tighten screw (5).
(5) Tighten jamnut (6).
c. Follow-on Maintenance.
(1) Install tachometer sending unit (TM 9-2320-279-20).
(2) Install engine side panel (TM 9-2320-279-10),
(3) Close engine cover (TM 9-2320-279-10).
(4) Start engine (TM 9-2320-279-10).
(5) Check operation of tachometer.
END OF TASK
14-3
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
14-3. BLOWER REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Tool, blower shaft alinement J-24619 or
J33001
Supplies
Grease, automotive and artillery, Item 36,
Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
None
Equipment Condition
TM or Para
TM 9-2320-279-20
TM 9-2320-279-20
TM 9-2320-279-20
Para 14-5
Para 15-10
Para 15-4
Para 13-2
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
(1) Disconnect blower lube line (1).
(2) Disconnect tachometer sender wire (2).
(3) Loosen clamp (3) on blower drive support seal (4).
14-4
Condition Description
Rocker covers removed.
Air compressor removed.
Coolant level lowered.
Air inlet adapter removed.
Engine stop solenoid
removed.
Governor cover removed.
Fuel pump removed,
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
(4) Loosen four hose clamps (5).
(5) Remove thermostat cross-over tube (6), hoses (7), and clamps (5).
(6) Remove nut (8), copper washer (9), and screw (10).
(7) Remove three screws (11) and lockwashers (12).
(8) Remove two screws (13), lockwashers (12), cover (14), and gasket (15).
14-5
\-l
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
I 14-3. BLOWER REMOVAL/INSTALLATION (CONT). [
(9) Remove retaining ring (16) from blower drive shaft (17).
CAUTION
Be careful when removing shaft; spring may fall out.
(10) Remove blower drive shaft (17) and spring (18) from
drive adapter (19).
14-6
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
NOTE
Tag and mark wires before disconnecting.
(11) Disconnect two wires (20) from buffer swtich (2 1).
(12) Remove two cotter pins (22) and clevis pins (23) from injector control tube levers (24) on both
sides of engine.
(13) Remove connecting pin (25) and fuel rod connecting pin (26).
NOTE
Tag and mark fuel control rods.
(14) Remove two fuel control rods (27) through cylinder head (28).
(15) Loosen four clamps (29) and slide hose (30) clear of cover tube onto governor.
(16) Disconnect variable low speed limiting governor (31 ) at hose fitting (32).
(17) Remove four screws (33) and
washers (34) from blower (35).
(18) Remove six screws (36) and
retainers (37).
14-7
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
I 14-3. BLOWER REMOVAL/INSTALLATION (CONT). [
(19) Soldier A and Soldier B
remove blower (35) and
gasket (38) from engine
block (39).
(20) Remove governor housing
assembly (para 15-2).
(21) Remove tachometer drive
(para 14-2).
(22) Remove clamp (40) and seal (41) from
drive end of cover (42).
14-8
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
b. Installation.
(1) Apply grease to bottom side of gasket (1).
(2) Position gasket (1)on engine block mounting flange (2).
(3) Position seal (3) and clamp (4) over drive end of cover (5).
14-9
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
I 14-3. BLOWER REMOVAL/INSTALLATION (CONT). [
(4) Install governor housing
assembly (para 15-2).
(5) Install tachometer drive
(para 14-2).
(6) Soldier A and Soldier B
position blower assembly (6)
on gasket (1).
14-10
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
(7)
(8)
(9)
(10)
(11)
Install four screws (7) and washers (8) finger tight.
Install six screws (9) and retainers (10) finger tight.
Using blower alinement tool, install blower drive shaft (11) and spring (12).
Tighten four screws (7) to 40 to 45 lb-ft (54.2 to 61.0 N-m),
Tighten six screws (9) in 5 lb-ft increments uniformly until tightened to 30 to 35 lb-ft (41.7 to
47.5 N-m).
(12) Retighten four screws (7) to 40 to 45 Ib-ft (54.2 to 61.0 N-m).
NOTE
Blower shaft should move freely, if not, loosen screws and repeat steps (10), (11),
and (12).
(13) Remove blower alinement tool.
(14) Push in on blower drive shaft (11) and install retaining ring (13).
(15) Install two hoses (14) and tighten four clamps (15) on two crossover tubes (16).
(16) Install fuel control rods (17), on both sides of engine, with connecting pin (18) and connecting
pin (19).
(17) Connect fuel control rods (17) to injector control tube levers (20) with two clevis pins (21) and
cotter pins (22).
(18) Install wires (23) on buffer switch (24).
14-11
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
I 14-3. BLOWER REMOVAL/INSTALLATION (CONT). ]
(19) Position blower drive seal (3) on blower drive
support (25).
(20) Position clamp (4) in groove of seal (3). Tighten
clamp.
(21) Position cover (26) with
gasket (27) on blower drive
support (25).
(22) Install three screws (28) and
lockwashers (29).
(23) Install two screws (30) and
lockwashers (31).
(24) Install screw (32), copper
washer (33), and nut (34).
(25) Connect and tighten blower lube line fittings (35).
14-12
TM9-2815-224-34&P
Blower Maintenance Instructions (Cent)
(26) Connect variable low speed limiting governor (36) to hose fitting (37).
(27) Connect engine tachometer sending unit (38) at plug (39).
14-13
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
I
14-3. BLOWER REMOVAL/INSTALLATION (CONT). I
(28) Install two hoses (40) and thermostat crossover tube (41) with four clamps (42).
c. Follow-on Maintenance.
(1) Install governor cover (para 15-4).
(2) Install air inlet adapter (para 14-5).
(3) Install engine stop solenoid (para 15-10).
(4) Install valve rocker covers (TM 9-2320-279-20).
(5) Install fuel pump (para 13-2).
(6) Install air compressor (TM 9-2320-279-20).
(7) Add coolant to engine (TM 9-2320-279-20).
END OF TASK
14-14
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
14-4.
BLOWER REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
Personnel Required
MOS 63W, Wheel vehicle repairer
Test Equipment
None
References
None
Special Tools
Tool set, blower service J6270-F
Gage set, piston J3174-02
Seal installer J35787-2
Spacer installer J35787-1
Equipment Condition
Condition Description
TM or Para
Governor housing
Para 15-2
assembly removed.
Blower on clean work
surface.
Supplies
Adhesive-sealant, silicone, Item 6, Appendix C
Cloth, crocus, Item 17, Appendix C
Oil, lubricating, Item 48, Appendix C
Sealant, Teflon, Item 57.1, Appendix C
Solvent, drycleaning, Item 60, Appendix C
Tags, identification, Item 61, Appendix C
a.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
Disassembly.
NOTE
Some engines are equipped with a bypass valve on
the blower. If equipped with bypass valve, do
steps (1) through (1.7). If not, go to step (1.8).
(1)
Remove two screws (0.1) from pressure
clamp (0.2).
(1.1) Remove pressure clamp (0.2) from bypass
valve (0.3).
(1.2) Compress clamp (0.4) and pull hose (0.5)
off of hose fitting (0.6).
(1.3) Remove bypass valve (0.3) with hose (0.5)
from blower (0.7).
(1.4) Remove two clamps (0.4 and 0.8) from
hose (0.5).
(1.5) Remove hose (0.5) from bypass valve (0.3).
(1.6) Remove and discard preformed
packing (0.9) from bypass valve (0.3).
(1.7) Note position of hose fitting (0.6) and
remove hose fitting (0.6).
Change 2
14-14.1/(14.2 blank)
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
NOTE
To keep gears from turning,
place clean folded shop towel
between blower rotors.
Some blowers have ten screws
and lockwashers. Others have
nine screws and lockwashers.
(1.8) Remove nine or ten screws (1),
lockwashers (2), rear end plate
cover (3), and gasket (4).
Change 2
14-15
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
14-4. BLOWER REPAIR (CONT).
NOTE
Some engines may have spacers and long screws. Turn in spacers
and use new short screws to install coupling.
(2) Remove three screws (5), coupling assembly (6), and
spacers (7).
(3) Remove three screws (8) and two spring plates (9) from
coupling (6).
(4) Remove two screws (10
and 11) and washers (12).
14-16
Blower Maintenance Instructions (Cont)
Use five screws with puller tools on rear end plate. Use 5/16 in. -24 x 1-1/2 in.
(38 mm) screws and aline with tapped holes in gears.
(5) Install puller tool on left timing gear (13) with two screws.
(6) Install puller tool on right timing gear (14).
CAUTION
If puller screws are not tightened evenly during removal of timing gears damage
may result to gears.
(7) Tighten screws (15) evenly to remove gears ( 13 and 14).
(8) Remove pullers from gears (13 and 14)
(9) Mark rear end plate to indicate top.
NOTE
Rig and mark shims and spacers.
(10) Remove shims (16) and two spacers (17) from
each rotor shaft (18).
14-17
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
I
14-4. BLOWER REPAIR (CONT). I
(11) Bend tangs of lockwasher (19) flat.
(12) Remove screw (20), lockwasher (19), fuel pump
disk (21), and spacer (22) from front end
plate (23).
NOTE
Remove shop cloth.
(13) Remove six screws (24) and two flanged
bearing retainers (25) from front end
plate (23).
(14) Loosen two screws (26) three turns.
(15) Remove six screws (27) and two flat bearing
retainers (28) from rear end plate (29).
(16) Remove two screws (30) from rear end
plate (29).
14-18
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
NOTE
Six puller screws must be 1/4 in.-20 x
1-1/4 in. (32 mm) or longer.
(17) Install three screws and aline two
puller tools to rear end plate (29).
(18) Turn both puller screws (15) evenly
and remove rear end plate (29).
(19) Remove puller tool from rear end
plate (29).
(20) Remove two screws (26) from front end
plate (23).
(21) Tag front end plate (23) and indicate top. Tag
front end of blower housing (31) and indicate
top.
(22) Remove front end plate (23) by tapping with
mallet.
CAUTION
Handle rotors with care to avoid
scratching surfaces.
NOTE
Tag rotors before removal.
(23) Remove right rotor (32) and
left rotor (33).
14-19
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
14-4. BLOWER
NOTE
There are two models of seals. Model A has three parts: collar, oil seal ring, and
carrier. Model B is a double-lip oil seal. Model B repair kit has a double-lip oil seal
and spacer.
Do steps (24) and (25) through (27) for Model A. Do step (24.1) for Model B only.
(24)
Remove oil seal ring (34) from ring carrier (35) on each end of rotors (32 and 33).
WARNING
To prevent personal injury, wear a face shield when removing spacer. Pieces of
spacer could cause severe eye injury if protection is not used.
(24.1) Using a sharp chisel, crack and remove spacer (35.1), if present, from each end of rotors (32
and 33).
NOTE
All carriers are removed the same. Tighten
vise just enough to hold rotor in place.
(25)
(26)
14-20
Clamp lobe of right rotor (32) in vise
with soft jaws.
Install adapter on right rotor (32).
Change 2
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
(27)
Install puller tool to adapter with two screws. Turn puller screw (15) to remove ring carrier (35)
and inner bearing race (36) from rotors (32 and 33).
NOTE
Repeat steps (29) through (31) for
front and rear end plates.
Seal ring collar on Model A only. Do
steps (28), (29), (30), and (31) for
Model A. Do steps (28), (29), (30.1),
and (31) for Model B.
(28) Position rear end plate (29) on wood
blocks.
(29) Place long end of remover and installer
tool through seal ring collar (37) into
ball bearing (38).
(30) Press out ball bearing (38) and seal ring
collar (37).
(30.1) Press out ball bearing (38) and double
lip seal (38.1).
(31) Inspect dowel pins (39) for breakage or
damage. Replace if broken or damaged.
b. Cleaning/Inspection.
WARNING
Adhesives and solvents burn easily and give off harmful vapors. To avoid injury, use
in a well ventilated area and keep away from flame.
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only
with effective chip guarding and personal protective equipment (goggles/shield,
gloves, etc.).
CAUTION
Do not use compressed air on bearings. Allow bearings to air dry. Compressed air
may cause damage to bearings.
( 1 ) C l e a n metal parts in drycleaning solvent. Dry parts other than bearings with compressed air.
(2) Inspect roller and ball bearings for corrosion, scoring, pitting, or other damage.
(3) Inspect both timing gears at teeth and at bore splines for chips or nicks.
(4) Inspect oil holes. If clogged, clean with drycleaning solvent.
(5) Inspect all finished surfaces for burrs and scoring. Use crocus cloth to clean.
Change 2
14-21
TM 9-2815-224-34&P
Blower Maintenance lnstructions (Cont)
14-4.
BLOWER REPAIR (CONT).
c. Assembly.
NOTE
Model A seal, with three parts: collar, oil seal ring, and carrier, is not available.
Model B seal repair kit has a double-lip oil seal and spacer.
(1) Support rotor (1) on blocks.
(2) Deleted.
(3) Deleted.
(4) Deleted.
CAUTION
Do not lubricate seal, spacer, or rotor shaft before assembly Seal is of
a Teflon type and must be installed dry for proper sealing.
(4.1) Install four spacers (4.1) on two rotors (1) with installer (4.2),
pressing until shoulder of tool or spacer contacts rotor.
NOTE
Numbered side of seal must be toward installation tool. Seal
is properly installed when installation tool contacts end
plate.
(4.2) Install four double-lipped oil seals (4.3) into two end
plates (6) and (10) (10 not shown) using installation
tool (4.4).
(4.3) Remove four plastic seal protectors (4.5) from four
double-lipped oil seals (4.3).
14-22
Change 2
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
(5) Deleted.
CAUTION
Blower housing and front end plate mating
surfaces must be perfectly flat and smooth or
parts will not seal.
Allow Teflon sealant to dry to the touch before
installing front end plate. Teflon sealant must
not protrude into blower housing or damage to
blower may result.
Teflon sealant must not prevent front end
plate from laying flat against the blower
housing or damage to blower may result.
(5.1) Apply a thin, even coating of Teflon sealant over entire end surface of front end plate side of
blower housing (7). Wipe off any excess sealant from housing bores.
(5.2) Aline dowel pins (8) and install front end plate (6) on blower housing (7).
(5.3) Install and tighten two screws (9) to 10 lb-ft (14 N•m).
CAUTION
To prevent double-lipped oil seal damage, do not apply oil to either the seals or rotor
shafts.
Installation of rotors without using plastic seal protectors could damage double-lipped
oil seals.
(5.4) Install plastic seal protectors (4.5) into double-lipped oil seals (4.3) with tapered edge facing out.
(5.5) Install two pilot tools (4.6) on
two rotor shafts (4).
NOTE
Gap between splines on rotor
shafts must face left and aline to
one another.
Plastic seal protectors will be
pushed out of seals when rotors
are installed.
(5.6,) Install the rotors (1) in
housing (7) and front end
plate (6).
(5.7) Remove two pilot tools (4.6)
from rotor shafts (4).
(6) Deleted.
(7) Deleted.
(8) Deleted.
(9) Deleted.
(10) Deleted.
(11) Deleted.
(12) Deleted.
(13) Deleted.
Change 2
14-23/(14-24 blank)
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
(14)
Deleted.
CAUTION
Blower housing and rear end plate mating
surfaces must be perfectly flat and smooth or
parts will not seal.
Allow Teflon sealant to dry to the touch before
installing rear end plate. Teflon sealant must
not protrude into blower housing or damage to
blower may result.
Teflon sealant must not prevent rear end plate
from laying flat against the blower housing or
damage to blower may result.
Apply a thin, even coating of Teflon sealant over entire end surface of rear end plate side of
blower housing (7). Wipe off any excess sealant from housing bores.
(16) Deleted.
(17) Deleted.
(17.1) Install two plastic seal protectors (4.3).
(17.2) Install two pilot tools (4.6) on rotor shafts (4).
(15)
NOTE
Plastic seal protectors will be pushed out of seals when rear end plate is installed.
(18)
(19)
(20)
Position rear end plate (10) and aline dowel pins (11) to holes in blower housing (7).
Tap rear end plate (10) into blower housing (7).
Install and tighten two screws (12) to 10 lb-ft (14 N•m).
(21)
Apply lubricating oil to two ball
bearings (13).
Install two ball bearings (13) numbered
end up, in rear end plate (10) with
bearing installer.
(22)
Change 2
14-25
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
14-4. BLOWER REPAIR (CONT).
(23) Position two flat bearing retainers (14) on rear end plate (10)
and install six screws (15) in retainers. Tighten six screws to
10 lb-ft (13.5 N•m).
(24) Install two roller bearing collars (16) to both
shafts (4) at front end plate (6) with bearing
installer tool.
(25) Apply lubricating oil to two roller bearings (17)
(26) Install roller bearing (17), over rotor shafts (4) with
bearing installer tool.
NOTE
Flanges on bearing retainers face front end plate.
(27) Install two flanged bearing retainers (18) with six
screws (19) in front end plate (6). Tighten screws to
10 lb-ft (13.5 N•m).
4-26
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
WARNIN6
Do not place fingers between rotors. If rotors
turn, they can cause serious injury.
(28) Set rotor shafts (4) at rear end plate (10) so
that each gap in splines aline with one
another.
(29) Install spacer (20) and shim (21) on each rotor
shaft (4).
(30) Apply lubricating oil to splines on rotor
shaft (4).
NOTE
Place folded shop towel between rotor lobes.
(31) Install both timing gears (22 and 23) at same time so gap in splines on gears mate with gap in
splines on rotor shafts (4).
(32) Install two timing gear screws (24 and 25) with washers (26).
(33) Tighten both timing gear screws (24 and 25) evenly to draw both timing gears (22 and 23) tight.
(34) Apply lubricating oil to both timing gear screws (24 and 25).
(35) Tighten timing gear screws (24 and 25) to 110 lb-ft (149.2 N-m).
14-27
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
I 14-4. BLOWER REPAIR (CONT). {
NOTE
Remove shop cloth before timing rotors and setting clearances.
(36) Install four screws (27) and washers (28) in front end plate (6) and rear end plate (10).
(37) Tighten screws (27) to 15 lb-ft (20.34 N-m).
NOTE
Correct rotor operating range is 0.004 to 0.006 in. (0.102 to 0.152 mm). If rotor
does not meet specification, do steps (41) through (46).
● Clearances between rotor lobes must be measured 1 in. (25.4 mm) from end plate.
(38) Place 0.004-in. (0.102 mm) feeler gage between rotor lobes (29 and 30). Rotate rotors while gage
is installed.
(39) Remove feeler gage.
●
14-28
TM9-2815-224-34&P
Blower Maintenance Instructions (Cont)
(40) Turn blower (7) upside down and
place 0.004-in. (0.102 mm) feeler gage
between rotor lobes (29 and 30).
Rotate rotors while gage is installed.
(41) Remove feeler gage.
NOTE
To increase or decrease gap between trailing edge of right rotor lobes and leading
edge of left rotor lobes, do steps (42) through (45).
(42) Install puller tool on left timing gear (23) with two screws.
(43) Install puller tool on right timing gear (22) with three screws.
NOTE
Place clean, folded shop towel between blower rotors to keep gears from turning.
(44) Tighten puller screws evenly to remove gears (22 and 23).
14-29
TM9-2815-224-34&P
Blower Maintenance Instructions (Cent)
I 14-4.
BLOWER REPAIR (CONT). I
NOTE
To change gap between rotor lobes by
0.001-in. (0.025 mm), add or remove a
0.003-in. (0.076 mm) shim.
(45) Add or remove shims (21) to left rotor
shaft (4) as necessary.
(46) Install blower timing gears according
to steps (31) through (35).
(47) Check rotor lobe clearance according
to steps (38) through (40).
NOTE
Correct rotor operating range is 0.009 to 0.011 in.
(0.23 to 0.28 mm). If rotors do not meet this
specification, do steps (52) through (54).
14-30
TM9-2815-224-34&P
Blower Maintenance Instructions (Cent)
(50) Turn blower (7) right side up and
place 0.010-in. (0.254 mm) feeler gage
between rotor lobes (29 and 30).
Rotate rotors while gage is installed.
(51) Remove feeler gage.
NOTE
To increase or decrease gap between leading edge of right rotor lobe and trailing
edge of left rotor lobe (30), do steps (52) through (55).
(52) Install puller tool on left timing gear (23) with two screws.
(53) Install puller tool on right timing gear (22) with three screws.
(54) Tighten puller screws evenly to remove timing gears (22 and 23).
14-31
TM9-2815-224-34&P
Blower Maintenance Instructions (Cent)
I 14-4.
BLOWER REPAIR (CONT). [
NOTE
To change gap between rotor lobes by
0.001-in. (0.025 mm), add or remove a
0.003-in. (0.076 mm) shim.
(55) Add or remove shims (21) to right
rotor shaft (4) as necessary.
(56) If rotor lobe clearances cannot be
corrected with shims, replace rotors.
(57) Install blower timing gears, followin
steps (31) through (35).
(58) Check clearance of rotor lobes,
following steps (48) through (51).
NOTE
There are six measurements
between rear end plate and rotor
lobes, one for each lobe of each
rotor.
(59) Using 0.007-in. (0. 178 mm)
feeler gage, check clearance
between rear end plate (10)
and both rotor lobes (29
and 30). If clearance is not
correct, replace rear end
plate.
(60) Using 0.012-in. (0.305 mm)
feeler gage, check clearance
between front end plate (6)
and both rotor lobes (29
and 30). If clearance is not
correct, replace front end
plate.
14-32
TM9-2815-224-34&P
Blower Maintenance Instructions (Cent)
NOTE
There are six measurements between rotors and
housing made through top of blower.
is not correct, replace housing.
NOTE
There are six measurements between rotors and
clearance is not correct, replace ‘housing.
14-33
TM9-2815-224-34&P
Blower Maintenance Instructions (Cent)
I
14-4. BLOWER REPAIR (CONT). [
(63) Remove four screws (27) and washers (28) from front end plate (6) and rear end plate (10).
(64) Install spacer (31) on rotor shaft (4) at front end
plate (6).
(65) Install fuel pump disk (32), lockwasher (33), and
screw (34).
(66) Tighten screw (34) to 65 lb-ft (88 N-m).
(67) Bend two more lockwasher tangs around head of
screw (34).
(68) Install three screws (35) and two spring plates (36) into
coupling (37).
(69) Tighten three screws (35) to 30 lb-ft (40 N-m).
14-34
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
NOTE
Install clean shop cloth between gears.
(70)
(71)
Install coupling assembly (37) with three screws (38).
Tighten three screws (38) to 30 lb-ft (40 N•m).
Change 2
14-34.1/(14-34.2 blank)
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
(72)
Install rear end plate
cover (39) with gasket (40).
NOTE
Some blowers have ten screws and
lockwashers. Others have nine screws and
lockwashers.
(73)
(74)
Install nine or ten screws (41)
and lockwashers (42).
Tighten screws (41) evenly to
15 lb-ft (20 N•m).
NOTE
Some engines are equipped with a bypass valve on
the blower. If equipped with bypass valve, do
steps (75) through (83). If not, go to Follow-on
Maintenance.
(75)
(76)
(77)
(78)
(79)
Install preformed packing (43) on
bypass valve (44).
Install bypass valve (44) until fully
seated.
Install pressure clamp (45) on bypass
valve (44).
Install two screws (46) in pressure
clamp (45). Tighten screws 23 to 26
lb-ft (31 to 35 N•m).
Install two clamps (47 and 48) on
hose (49).
WARNING
Adhesives solvents, and
vapors, and are harmful
from open fire and use
compound gets on skin
(80)
(81)
(82)
(83)
sealing compounds can burn easily, can give off harmful
to skin and clothing. To avoid injury or death, keep away
in well-ventilated area. If adhesive, solvent, or sealing
or clothing, wash immediately with soap and water.
Apply sealing compound on threads of hose fitting (50).
Install hose fitting (50) securely in position as noted during disassembly.
Install hose (49) on bypass valve (44) and hose fitting (50).
Position clamps (47 and 48) over hose (49) on bypass valve (44) and hose fitting (50).
d. Follow-on Maintenance. None.
END OF TASK
Change 2
14-35
TM 9-2815-224-34&P
Section III. TURBOCHARGER ASSEMBLY
Turbocharger Maintenance Instructions
14-5. AIR INLET ADAPTER REMOVAL/lNSTALLATlON.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
None
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer
TM or Para
Para 14-6
Condition Description
Turbocharger removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
(1) Remove ether starting aid line (1) and fitting (2) from air inlet adapter (3).
14-36
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
NOTE
There are two models of air inlet adapter. Model B has a removable air inlet. If
removing Model B, perform steps (1.1 through 3). If removing Model A, perform
steps (2 and 3).
(1.1)
(1.2)
(1.3)
(1.4)
(2)
Remove screw (3.1), lockwasher (3.2), and washer (3.3) from hose clamp (3.4).
Remove hose (3.5) from elbow (3.6).
Remove three screws (3.7), air inlet (3.81, and gasket (3.9) from air inlet adapter (3).
Remove plug (3.10) and elbow (3.6) from air inlet adapter (3).
Remove 10 screws (4) and lockwashers (5) from air inlet adapter (3).
CAUTION
Keep dirt and debris out of blower. Foreign material will damage blower.
(3)
Remove air inlet adapter (3), gasket (6), and two preformed packings (7) from top of blower (6).
Change 2
14-36.1/(14-36.2 blank)
TM 9-2815-224-34&P
Blower Maintenance Instructions (Cont)
b. Installation.
(1)
Position gasket (1) and two preformed packings (2) on blower (3).
NOTE
There are two models of air inlet adapter. Model B has a removable air inlet. If
installing Model A, perform step (2). If installing Model B, perform steps (3
through 3.4).
(2)
(3)
(3.1)
(3.2)
(3.3)
Install air inlet adapter (4) with 10 screws (5) and lockwashers (6). Tighten to 45 lb-ft (61 N•m).
Install elbow (6.1) and plug (6.2) in air inlet adapter (4).
Install air inlet adapter (4) with 10 screws (5) and lockwashers (6). Tighten to 45 lb-ft (61 N•m),
Install hose (6.3) in elbow (6.1).
Install gasket (6.4) and air inlet (6.5) on air inlet adapter (4) with three screws (6.6). Tighten
screws to 16 to 20 lb-ft (22 to 27 N•m).
(3.4) Install hose clamp (6.7) with screw (6.8), lockwasher (6.9, and washer (6.10).
Change 2
14-37
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
14-5. AIR INLET ADAPTER REMOVAL/INSTALLATION (CONT).
(4) Install fitting (7) and ether starting aid line (8)
to air inlet adapter (2).
c. Follow-on Maintenance. Install turbocharger (para 14-6).
END OF TASK
14-6. TURBOCHARGER REMOVAL/lNSTALLATlON.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Oil, lubricating, Item 48, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
14-38
Equipment Condition
TM or Para
TM 9-2320-279-20
TM 9-2320-279-10
TM 9-2320-279-20
Condition Description
Batteries disconnected.
Parking brake on.
Exhaust pipe removed from
turbocharger.
TM 9-2320-279-20 Air intake duct disconnected
from turbocharger.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
a. Removal.
(1) Loosen four nuts (1) and clamps (2).
(2) Remove two exhaust tubes (3) from two exhaust manifolds (4) and tee (5).
(3) Loosen nut (6) and disconnect oil tube (7)
from turbocharger (8).
(4) Remove four nuts (9), lockwashers (10),
gasket (11), and tee (5) from turbocharger (8).
14-39
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
14-6. TURBOCHARGER REMOVAL/INSTALLATION (CONT).
NOTE
Some vehicles have a screw, nut, lockwasher,
and washer. Others have a flanged screw, nut,
lockwasher, and washer.
(5)
Remove screw (12), nut (13),
lockwasher (14), and washer (15) from
clip (16).
NOTE
Some engines do not have screw, lockwasher,
and clip.
(6)
Remove screw (17), lockwasher (18), and
clip (19).
NOTE
Some engines have a connector. Others have
an elbow.
(7)
Disconnect oil hose (20) from connector
or elbow (21).
(8)
(9)
Loosen clamps (22) on hose (23).
Remove two screws (24) and
lockwashers (25) from
turbocharger (8).
NOTE
Hose should be pried loose if it sticks to
turbocharger.
(10) Remove turbocharger (8).
(11) Remove hose (23) and clamps (22).
14-40
Change 2
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
(12) Inspect air inlet adapter (26) for
breaks and cracks. Replace if damaged
(para 14-6).
(13) Remove preformed packing (27) from
air inlet adapter (26).
(14) Cover air inlet adapter (26) with clean
cloth over opening.
b. Installation.
(1) Install hose (1) on air inlet adapter (2).
(2) Slide clamps (3) over hose (1).
(3) Remove clean cloth from air inlet
adapter (2).
(4) Install preformed packing (4) in air inlet
adapter (2).
(5) Slide air outlet end of turbocharger (5) into
hose (1).
(6) Install turbocharger (5) on air inlet
adapter (2).
14-41
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
14-6. TURBOCHARGER REMOVAL/INSTALLATION (CONT)
(7) Install two screws (6) and
lockwashers (7) in
turbocharger (5).
(8) Tighten screws (6) to 45 to 50 lb-ft
(61 to 67 N•m).
(9) Position two clamps (3), one over
air inlet adapter (2) and one over
turbocharger (5).
(10) Tighten clamps (3).
(11)
(12)
(13)
Fill center housing (8) with lubricating oil
through fitting (9).
Connect oil tube (10) to fitting (9) and tighten
nut (11).
Install tee (12), gasket (13), four nuts (14), and
lockwashers (15) on turbocharger (5).
NOTE
Some engines have a connector. Others have an elbow. Refer
to TM 9-2320-279-24P
(14)
Connect oil hose (16) to elbow (17).
NOTE
Some engines do not have screw, lockwasher, and clip. Refer to
TM 9-2320-279-24P
(15)
14-42
Install clip (18) with screw (19) and lockwasher (20).
Change 2
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
NOTE
Some vehicles have a washer, lockwasher,
screw, and nut. Others have a washer,
lockwasher, flanged screw, and nut.
(16)
Connect clip (21) to bracket (22) with
washer (23), lockwasher (24),
screw (25), and nut (26).
(17)
Slide four clamps (27) over two exhaust
tubes (28).
Install two exhaust tubes (28) on
tee (12) and two exhaust manifolds (29).
Tighten four clamp nuts (30).
(18)
(19)
c.
Follow-on Maintenance.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Connect air intake duct to turbocharger (TM 9-2320-279-20).
Connect exhaust pipe to turbocharger (TM 9-2320-279-20).
Connect batteries (TM 9-2320-279-20).
Start engine and run at idle for ten minutes (TM 9-2320-279-10).
Check turbocharger gaskets and ducts for leaks.
Increase engine speed and listen for smooth operation of turbocharger.
Shut off engine (TM 9-2320-279-10).
Install engine top cover (TM 9-2320-279-20).
END OF TASK
Change 2
14-43
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
14-7.
TURBOCHARGER REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Set, dial indicator J7872
Fabricated Tools
Pliers, retaining ring 2BH945, Fig. D-3,
Appendix D
Holding fixture, turbocharger 2SK742,
Fig. D-4, Appendix D
Supplies
Solvent, drycleaning, Item 60, Appendix C
Grease, automotive and artillery, Item 36,
Appendix C
Compound, antiseize, Item 21, Appendix C
Oil, lubricating, Item 48, Appendix C
Compound, sealing, pipe thread, Item 32,
Appendix C
Brush, paint, oval, Item 10, Appendix C
a.
14-44
Disassembly.
Change 2
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
None
Equipment Condition
TM or Para
Condition Description
Turbocharger on clean work
surface.
Special Environmental Conditions
Work in extremely clean area.
General Safety Instructions
None
Level of Maintenance
General Support
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
CAUTION
Be careful when removing turbine housing and compressor housing in order to
prevent damaging housing.
(1)
(2)
(3)
(4)
(4.1)
(5)
Matchmark compressor housing (1), coupling (2), and compressor backplate (3).
Matchmark turbine housing (4), coupling (5), and center housing (6).
Loosen coupling (2) and remove housing (1) and coupling.
Loosen coupling (5) and remove center housing (6) and coupling from housing (4).
Remove turbocharger guard (6.1) and seal (6.2) from intake side of compressor housing (1).
Install turbine wheel (7) in holding fixture. Remove locknut (8).
NOTE
Distance between assembly and work surface should be no more than one inch.
(6)
With Soldier B holding the center housing (6), Soldier A supports the turbine wheel (7) in one
hand and with the other hand gently taps shaft (9) with rubber mallet to loosen impeller (10).
CAUTION
Do not pry off impeller. Damage will occur.
(7)
Remove impeller (10) from shaft (9).
Change 2
14-45
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
14-7. TURBOCHARGER REPAIR (CONT).
(8)
Remove center housing (6) from shaft (9).
(9) Remove retaining ring (11) from shaft (9).
(10) Remove turbine wheel shroud (12) from shaft (9).
(10.1) Remove seal ring (12.1) from shaft (9).
CAUTION
Lockplates must not be reused. Screws can come loose
and destroy turbocharger.
NOTE
Model B turbocharger does not have lockplates.
(11)
(12)
(13)
14-46
Straighten tabs (13) on lockplates (14).
Remove four screws (15) and lockplates (14).
Remove backplate (3) from center housing (6).
Change 2
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
(14)
(15)
Remove seal ring (16) from center housing (6).
Remove brass fitting (17).
(16)
(17)
Remove sleeve spacer (18) from backplate (3).
Remove two piston rings (19).
NOTE
There are two turbocharger models. DO
step (18) for Model A and steps (18.1)
and (18.2) for Model B.
(18)
Remove thrust collar (20) and
thrust washer (21) from center
housing (6).
(18.1) Remove three screws (21.1) from
thrust washer bearing (21.2).
(18.2) Remove shaft collar (21.3) and
thrust washer bearing (21.2) from
center housing (6).
Change 2
14-47
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
14-7. TURBOCHARGER REPAIR (CONT).
(19) Remove bearing (22) and washer (23) from center
housing (6).
(20) Remove retaining ring (24) from center housing (6).
(21) Remove retaining ring (25) and
bearing (26).
(22) Remove thrust washer (27) from
center housing (6).
(23) Using retaining ring pliers,
remove-retaining ring (28).
b. Cleaning/Inspection.
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. lb avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Soak metal parts in dry cleaning solvent for 25 minutes.
CAUTION
Do not clean with steel bristle brush. Turbocharger parts can be damaged by steel
bristles.
(2) Clean parts with stiff bristle brush after soaking in dry cleaning solvent.
14-48
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
(3) Clean oil passages (1, 2, and 3) in center housing (4) and oil passages (5 and 6) in backplate (7).
(4) Clean oil inlet line inside and out. If oil line is dented or crimped, replace.
Compressed air used for cleaning purposes shall not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(5) Dry turbocharger parts with compressed air.
CAUTION
Do not use compressed air on hearings. Allow bearings to air dry. Compressed air
may cause damage to bearing.
(6) Allow bearings to air dry.
(7) Inspect turbocharger parts for nicks, cuts, scratches, scoring or other damage.
(8) Inspect screw threads for stripping or cross-threading.
NOTE
Measurements given in this section are for used parts.
(9) Check diameters of turbine wheel shaft journals (8 and 9) on shaft (10).
Journal diameters must be between 0.6250 and 0.6254-in. (15.875 and
15.885 mm).
(10) Inside diameter of impeller bore (11) must not be greater than
0.3749-in. (9.522 mm).
14-49
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
14-7.
TURBOCHARGER REPAIR (CONT).
(11) Inside diameter of center housing (12) must not be greater
than 0.9842-in. (24.998 mm).
(12) Seal bore (13) must not be greater than 0.6895-in
(17.513 mm).
(13) Bearing (14) inside diameter must be 0.9783 to 0.9787-in. (24.849
to 24.859 mm) (Model A only).
(14) Thrust collar (15) thickness must not be less than 0.2970-in.
(7.543 mm) (Model A only). Thrust collar bore inside diameter
must not be greater than 0.3778-in. (9.596 mm) (Model A only).
(15) Ring groove width will not be greater than 0.0715-in (1.816 mm).
Sleeve spacer (16) outside diameter must not be less than 0.6705-in.
(17.030 mm).
(16) Replace damaged parts.
14-50
Change 2
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
c. Assembly
(1)
(2)
(3)
Using retaining ring pliers,
install retaining ring (1).
Install thrust washer (2),
bearing (3), and retaining
ring (4) in turbine side of center
housing (5).
Install retaining ring (6), thrust
washer (7), and bearing (8) in
center housing (5).
NOTE
There are two turbocharger models. DO
steps (4) and (5) for Model A and (5.11
through (5.3) for Model B. Refer to
TM 9-2320-279-24P.
(4)
Aline holes and notch (9) in
thrust. washer (10) and install
over pins (11) in center
housing (5).
(5) Install thrust collar (12) and
seal ring (13).
(5.1) Install shaft collar (13.1) in
thrust washer bearing (13.2).
(5.2) Install center housing (5) in
soft-jaw vise and install thrust
washer bearing (13.2) in center
housing with three
screws (13.3).
(5.3) Install seal ring (13.4).
Change 2
14-51
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
14-7. TURBOCHARGER REPAIR (CONT).
NOTE
Flat surface of sleeve spacer faces up.
(6)
(7)
(8)
Coat sleeve spacer (15) with grease and install two new
piston rings (14).
Install sleeve spacer (15) in compressor backplate (16).
Aline oil lubrication holes (17), and install backplate (16)
on center housing (5).
CAUTION
Used lockplates must not be reused. Screws can come loose and
destroy turbocharger.
NOTE
Model B turbochargers do not have lockplates. Refer to
TM 9-2320-279-24P.
(9)
(10)
(11)
14-52
Install four new lockplates (18) and four screws (19) in
backplate (16).
Tighten screws (19) to 80 to 100 lb-in. (9 to 11 N•m).
Bend tabs of lockplates (18) up against screws (19).
Change 2
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
(11.1) Install seal ring (19.1) on turbine
wheel shaft (21).
(12) Install turbine wheel shroud (20)
on turbine wheel shaft (21).
Fill
retaining ring groove in
(13)
turbine wheel shroud (20) with
grease and install retaining
ring (22) in groove.
(14) Install turbine wheel shaft (21)
in center housing (5).
(15)
(16)
Install impeller (23) on shaft (21).
Install locknut (24) on shaft (21).
(17)
Place center housing (5) in
holding fixture.
Tighten locknut (24) to 135
lb-in. (14.9 N•m).
Remove locknut (24).
Inspect face of locknut (24) and
impeller (23) for scratches.
Make sure both surfaces are
clean and smooth.
Apply grease to threads of
shaft (21) and base of
locknut (24).
Tighten locknut (24) to 35 to 55
lb-in. (4 to 6 N•m).
Tighten locknut (24) 1/4 turn
more.
(18)
(19)
(20)
(21)
(22)
(23)
Change 2
14-53
TM 9-2815-224-34&P
Turbocharger Maintenance Instructions (Cont)
14-7. TURBOCHARGER REPAIR (CONT).
(24) Place backplate (16) in vise with soft jaws.
(25) Check thrust float with dial indicator. Move
shaft (21) back and forth in center
housing (5). Indicator reading (thrust float)
must be 0.003 to 0.010-in. (0.08 to 0.25 mm).
(26) Aline matchmarks on center housing (5) with those on turbine housing (25).
(27) Install turbine wheel assembly (26) in turbine housing (25) and coupling (27).
(28) Apply antiseize compound to threads of screw (28).
CAUTION
Do not tighten turbine housing clamp until alined with turbine housing. If parts
are not alined, turbocharger will be damaged.
(29) Tighten locknut (29) to 160 lb-in. (18 N•m).
(30) Loosen locknut (29).
(31) Tighten locknut (29) to 165 lb-in. (18.9 N•m).
14-54
TM 9-2815-224-34&P
Turbrocharger Maintenance Instructions (Cont)
Aline matchmarks on compressor
housing (30) and center housing (5).
(33) Install compressor housing (30) and
coupling (31) on backplate (16).
(34) Apply lubricating oil to threads of screw (32).
(35) Tighten locknut (33) to 110 to 130 lb-in. (12
to 15 N•m).
(36) Coat threads of brass fitting (34) with pipe
thread sealing compound and install. Tighten
to 240 lb-in. (27.1 N•m).
(36.1) Install seal (34.1) and turbocharger
guard (34.2) on intake side of compressor
housing (30).
(37) Position magnetic base, equipped with swivel
adapter, dial indicator, and extension rod, on
flat surface of housing inlet flange (35).
(32)
NOTE
Do not allow extension rod to touch sides of
center housing. Inaccurate readings can result
in poor fit and damage.
(38)
(39)
(40)
Insert extension rod into oil drain hole so
that rod is against turbine wheel shaft (21).
Move turbine wheel shaft (21) up and down.
Turbine wheel shaft must not move more
than 0.0070 in. (0.177 mm) or less than
0.003 in. (0.076 mm).
Disassemble and inspect turbocharger (36) if
fit of turbine wheel shaft (21) is not within
limits.
d. Follow-on Maintenance. None.
END OF TASK
Change 2
14-55/(14-56 blank)
TM 9-2815-224-34&P
CHAPTER15
ENGINE GOVERNOR MAINTENANCE
Page
15-1
15-1
15-3
15-15
15-20
15-22
15-22.5
15-27
15-30
15-33
15-35
Para
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Governor Housing Assembly Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . 15-2
Governor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
Governor Cover Removal/Repair/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Throttle Delay Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Fuel Modulator Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5.1
Variable, Low Speed Limiting Governor Removal/Installation . . . . . . . . . . . . . 15-6
Buffer Screw Switch Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . 15-7
Throttle Air Cylinder Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8
Throttle Control Solenoid Removal/Repair/Installation . . . . . . . . . . . . . . . . . . 15-9
Engine Stop Solenoid Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
SectionI.INTRODUCTION
15-1. GENERAL
This chapter covers removal, installation, and repair of the engine governor. The
subassemblies and parts which must be removed before the governor components can be removed will be
referenced to other paragraphs or chapters of this manual, TM 9-2320-279-10, TM 9-2320-279-20, or
TM 9-2320-279-34.
Section II. ENGINE GOVERNOR ASSEMBLY
Engine Governor Maintenance Instructions
15-2.
GOVERNOR HOUSING ASSEMBLY REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Condition Description
TM or Par-a
Blower removed.
Para 14-3
Special Tools
None
Special Environmental Conditions
None
Supplies
Grease, automotive and artillery, Item 26,
Appendix C
General Safety Instructions
None
Personnel Required
MOS 63W, Wheel vehicle repairer
Level of Maintenance
Direct Support
Change 2
15-1
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-2. GOVERNOR HOUSING ASSEMBLY REMOVAL/INSTALLATION (CONT).
(1) Remove screw (1), copper washer (2), and bracket (3) .
(2) Remove screw (4) and copper washer (5).
(3) Remove eight screws (6), lockwashers (7), and washers (8).
(4) Remove governor (9) and gasket (10) from blower (11).
b. Installation.
(1)
(2)
(3)
(4)
Apply grease to face of blower (11) and governor (9) and install gasket (10) and governor.
Install screw (4) with copper washer (5).
Install screw (1),copper washer (2) and bracket (3).
Install eight screws (6), lockwashers (7), and washer (8).
(5) Tighten ten screws (4,1,and 6) to 15 lb-ft 934 N•m).
c. Follow-on Maintenance. Install blower (para 14-3).
END OF TASK
15-2
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cent)
15-3. GOVERNOR REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
TM or Para
Para 14-3
Para 15-6
Special Tools
None
Supplies
Compound, sealing, pipe thread, Item 32,
Appendix C
Solvent, dry cleaning, Item 60, Appendix C
Tags, identification, Item 61, Appendix C
oil, lubricating, Item 48, Appendix C
Grease, automotive and artillery, Item 36,
Appendix C
Condition Description
Blower removed.
Variable low speed limiting
governor removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
Personnel Required
MOS 63W, Wheel vehicle repairer
a. Disassembly.
NOTE
Engines after serial number 8VF- 106635 will not have starting aid screw and
locknut.
(1)
(2)
(3)
(4)
Mount governor housing (1) in vise with soft jaws.
Remove plug (2) and gasket (3) from governor housing (1).
Bend tang of lockwasher (4) away from head of bearing retaining screw (5).
Remove bearing retaining screw (5), lockwasher (4), and washer (6).
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
115-3. GOVERNOR REPAIR (CONT).
(5) Remove governor housing (1) from vise and support in
press.
(6) Press governor weight shaft (7) out of governor housing
bearing (8).
(7) Remove bearing assembly (9) and governor riser (10)
from governor weight shaft (7).
(8) Remove bearing (8) from governor housing (l).
(9) Remove four retaining rings (11) and
washers (12).
(10) Remove two washers (13) and pins (14).
(11) Remove two weights (15).
NOTE
Bearings are removed from both weights in same manner. Remove
only if damaged.
(12) Press two bearings (16) from weight (15).
15-4
TM
9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
(13) Press shaft (7) from weight carrier (17).
(14) Remove spring clip (18) and
(15)
(16)
(17)
(18)
(19)
washer (19) from operating lever
connecting link (20).
Remove operating lever
connecting link (20).
Remove spring clip (21) and
washer (22) from differential
lever (23).
Remove differential lever (23).
Remove pin (24).
Press pin (25) out.
(20) Remove two springs (26) and retainer
clips (27).
(21) Separate governor links (28 and 29).
(22) Remove pin (30) from link (29).
15-5
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-3. GOVERNOR REPAIR (CONT).
(23) Remove expansion plug (31) from governor housing (1).
(24) Remove upper bearing retaining screw (32),
lockwasher (33), and washer (34).
(25) Press operating shaft and spacer (35) from lower
bearing (36).
15-6
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
(26) Support operating fork (37) with wrench.
(27) Press operating shaft spacer (38) from
operating fork (37). Remove operating fork.
(28) Remove operating shaft spacer (38), operating
shaft (35), upper bearing (39), and operating
lever (40) from governor housing (1).
(29) Press operating shaft (35) from upper
bearing- (39)
-.
. . and
operating lever (40).
NOTE
Measure and note length of gap adjusting screw to aid in
assembly.
(30) Loosen jamnut (41) and remove gap adjusting
screw (42).
(31) Press pin (43) from operating lever (40).
(32) Press lower bearing (44) from governor housing (1).
15-7
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-30 GOVERNOR REPAIR (CONT).
(33) Remove screw (45), lockwasher (46), and
locking clip (47).
(34) Remove operating lever shaft (48), control
link operating lever (49), and two
washers (50).
NOTE
Replace needle bearings only if damaged.
(35) Remove pin (51).
(36) Press two bearings (52) from control link operating lever (49).
NOTE
Engine after serial number 8VF-106635
will not have starting aid screw and
locknut.
(37) Measure and note length starting aid
screw (53) extends from governor
housing (l).
(38) Remove locknut (54) and screw (53)
from housing (l).
(39) Remove four clamps (55) and two
hoses (56).
(40) Press two tubes (57) from governor
housing (1).
15-8
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
b . Cleaning/lnspection.
WARNING
. Adhesives, solvents, and sealing compounds can burn easily, can give off
harmful vapors, and are harmful to skin and clothing. To avoid injury or death,
keep away from open fire and use in well-ventilated area. If adhesive, solvent,
or sealing compound gets on skin or clothing, wash immediately with soap and
water.
l Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa).
Use only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(1)
(2)
(3’)
(4)
(5)
(6)
(7’)
c
Scrape old sealant from parts.
Clean all metal parts with dry cleaning solvent.
Dry metal parts, except bearings, with compressed air. Let bearings air dry.
Inspect housing for cracks, warpage and damages threads.
Inspect bearings for pitting, corrosion, or rough spots.
Inspect mechanical parts for nicks and burrs.
Replace all damaged parts.
Assembly.
(1) Press twO tubes (1) into governor
housing (2).
(2) Install two hoses (3) with four
clamps (4).
NOTE
—
Screw must be installed from inside
housing.
(3) Install screw (5) and locknut (6).
NOTE
Press bearings flush with operating lever,
(4) Lubricate two bearings (7) with grease. Press bearings, numbered
side up, into control link operating lever (8).
(5) Install pin (9).
15-9
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-3. GOVERNOR REPAIR (CONT).
(6) Mount governor housing (2) in vise with soft
jaws.
(7) Place control link operating lever (8) inside
governor housing (2).
(8) Insert washer (10) on each side of lever (8).
(9) Install operating lever shaft (11 ) with slot up.
(lo) Install locking clip (12), lockwasher (13), and
screw (14).
(11)
(12)
(13)
(14)
(15)
15-10
Install gap adjusting screw (15) and jamnut (16) into operating lever (17).
Tighten jamnut. (16) so length of gap adjusting screw (15) is same as noted at disassembly.
Press pin (18) into operating lever (17).
Press upper bearing (19) with bearings (20) facing up onto operating shaft.
Press operating lever (17) and bearing (19) on operating shaft (21) until flush with top of shaft.
.
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
(16) Install shaft (21 ) and position lever (17) so gap
adjusting screw (15) contacts low speed limiting
screw (22).
NOTE
Flat on shaft goes on flat in fork.
(17) Place shaft (21 ) into spacer (23) and position
operating fork (24) with finished cam surfaces
of fork fingers facing rear of governor
housing.
(18) Place tool between housing (2) and operating
fork (24) and press shaft (21) until spacer (23)
does not move up or down.
(19) Seat upper bearing (19).
(20) Install upper bearing retaining screw (25),
lockwasher (26), and washer (27).
15-11
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-3. GOVERNOR REPAIR (CONT).
(21) Lubricate inside lower bearing (28) with grease, and
lubricate outside with lubricating oil.
(22) Start lower bearing (28) closed side up into governor
housing (2) over shaft (21).
(23) Press lower bearing (28) on shaft (21) until it seats on
shoulder in governor housing (2).
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful to
skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and water.
(24) Apply small amount of pipe thread sealing compound
to edge of expansion plug (29).
(25) Install expansion plug (29), curved side up, in
governor housing (2).
(26) Tap center of expansion plug (29) to seal.
(27) Install pin (30) into link (31).
(28) Connect link (31) and (32).
(29) Install two retainer clips (33) and
springs (34).
(30) Install pin (35).
(31) Install differential lever (36),
washer (37), and spring clip (38)
on operating shaft lever (17).
(32) Install short end of connecting
link (31), washer (39), and spring
clip (40) on operating shaft
lever (17).
15-12
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
(33) Support weight earner (42) in center and press shaft (41) into
weight carrier.
(34) Press two bearings (43) in weight (44).
NOTE
Repeat steps (35) and (36) for other weight.
(35) Install weight (45) and two washers (46).
(36) Install pin (47), two washers (48), and two
retaining rings (49).
(37) Install governor housing
bearing (50) in governor
housing (2).
(38) Install governor riser (51) on
governor weight shaft (41).
(39) Install governor riser thrust
bearing (52), smaller inside
diameter first, against governor
riser (51).
(40) Support spline end of governor
weight shaft (41) on bed of press.
Set governor housing (2) over
governor weight shaft and press
housing on shaft.
15-13
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-3. GOVERNOR REPAIR (CONT).
(41) Position lockwasher (53) with tab facing
into housing (2).
(42) Install washer (54) into housing (2).
(43) Position lockwasher (53) and screw (55).
(4-4) Install bearing retaining screw (55).
(45) Tighten bearing retaining screw (55) to
20 lb-ft (27 N-m). Bend tang on
lockwasher (53) against head of bearing
retaining screw.
(46) Install gasket (56) inside governor
—
housing (2).
CAUTION
Apply small amount of sealing compound.
Excess could get in bearing causing bearing
failure.
(47) Apply pipe thread sealing compound to
threads of plug (57) and install plug in
governor housing (2). Tighten plug to
45 lb-ft (61 N.m).
(48) Install pin (58).
d. Follow-on Maintenance.
(1) Install variable low speed limiting governor (para 15-6).
(2) Install blower (para 14-3).
END OF TASK
15-14
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-4. GOVERNOR COVER REMOVAL/REPAIR/INSTALLATION.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
Preferences
None
Test Equipment
None
Equipment Condition
Special Tools
None
Supplies
Grease, automotive, artillery, Item 36,
Appendix C
Solvent, dry cleaning, Item 60, Appendix C
Oil, lubricating, Item 48, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
TM or Para
Para 15-8
Condition Description
Thottle air cylinder removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
(1) Remove nut (1), lockwasher (2), and washer (3) from engine stop solenoid (4),
15-15
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-4. GOVERNOR COVER REMOVAL/REPAIR/iNSTALLATION (CONT).
WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. To avoid injury or
death, keep away from open fire and use in
well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash
immediately with soap and water.
(2) Clean governor cover assembly (5) with dry
cleaning solvent and wipe dry.
(3) Remove five screws (6), lockwashers (7),
governor cover assembly (5), and gasket (8).
b. D i s a s s e m b l y .
(1) Matchmark stop lever (1) and stop lever shaft (2).
(2) Loosen screw (3) and remove stop lever (1) from governor cover (4).
15-16
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cent)
(3) Remove retaining ring (5), two washers (6), and preformed
packing (7).
(4) Remove stop lever shaft (2) and return spring (8) from
governor cover (4).
(5) Remove retaining ring (9), washer (10), copper
washer (11 ), preformed packing (12), and two
bushings (13) from speed control lever shaft (14).
(6) Remove speed control lever shaft (14) from governor
cover (4).
(7’) Remove pin (15) from speed control lever shaft (14).
c. Cleaning/lnspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily,
can give off harmful vapors, and are harmful to skin and
clothing. To avoid injury or death, keep away from open fire
and use in well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash immediately
with soap and water.
(1) Clean cover assembly (1) with dry cleaning solvent and dry
with clean rag.
(2) Inspect speed control lever shaft (2) and stop lever
shaft (3) for wear or damage. Replace if damaged.
(3) Inspect return spring (4) for cracks, breaks, or damage.
Replace if damaged, cracked, or broken.
(4) Inspect bushings (5) for scoring or out-of-round condition.
If bushings are deeply scored (0.0312 in. (0.79 mm)) or if more than 0.005 in. (0.15 mm)
out-of-round, replace cover.
d. Assembly.
NOTE
Spring arm goes behind stop pin. Spring tang goes over
stop lever shaft.
(1) Install return spring (1) on governor cover (2).
NOTE
Lever end of shaft is positioned against stop pin on side
opposite speed control lever shaft.
(2) Install stop lever shaft (3) in return spring (1) in
governor cover (2).
15-17
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-4. GOVERNOR COVER REMOVAL/REPAIR/INSTALLATION (CONT).
(3) Install preformed packing (4), two washers (5), and retaining ring (6) on stop lever shaft (3).
(4) Aline matchmarks and install stop lever (7) on stop lever shaft (3). Tighten screw (8).
(5) Install pin (9) in speed control lever shaft (10).
(6) Install speed control lever shaft (10).
15-18
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
(7’) Install two bushings (11), preformed packing (12),
washer (13), copper washer (14), and retaining ring (15)
on speed control lever shaft (10).
e. Installation.
NOTE
Apply a light coat of grease to both sides of
gasket before installing.
(1) Install gasket (1) on governor housing (2).
NOTE
When installing governor cover assembly,
speed control lever shaft pin fits into fork of
lever.
(2) Install governor cover assembly (3) with
five screws (4) and lockwashers (5).
(3) Install engine stop solenoid (6)
with washer (7), Iockwasher (8),
and nut (9).
f. Follow-on Maintenance. Install
throttle control air cylinder (para 15-8).
END OF TASK
15-19
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-5. THROTTLE DELAY REMOVAL/lNSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
TM o r Pam
Para 11-2
Condition Description
Right front engine brake
retarder and drone removed.
Special Tools
None
Supplies
None
General Safety Instruct ions
None
Personnel Required
MOS 63W, Wheel vehicle repairer
Level of Maintenance
Direct Support
References
None
a. Removal.
(1) Remove two nuts (1), lockwashers (2), and U-bolt (3).
(2) Remove throttle delay cylinder (4).
15-20
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
(3) Remove cotter pin (5) pin (6), and
lever (7) from connecting link (8).
(4) Remove spring pin (9), connecting
link (8) and throttle piston (10).
(5) Remove check valve (11) and
plug (12) from cylinder (4).
b. Installation.
(I) Install plug (1) and check valve (2) in
cylinder (3).
(2) Install connecting link (4) and spring
pin (5) to throttle piston (6).
(3) Install lever (7), pin (8), and cotter
pin (9) to connecting link (4).
(4) Install throttle piston (6) in
cylinder (3).
(5) Install cylinder (3) in cylinder head (10).
(6) Install U-bolt (11), two nuts (12), and
lockwasher (13).
c. Follow-on Maintenance.
(1) Install right front engine brake retarder and drone (para 11-2).
(2) Adjust injector rack control levers (para 19-6).
(3) Adjust throttle delay (para 19-8).
END OF TASK
15-21
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-5.1 FUEL MODULATOR AND TUBE REMOVAL/lNSTALLATlON
This task covers:
a. Removal
b. Cleaning/Inspection
c. Installation
d. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer
Equipment Condition
Condition Description
TM or Para
Left rear engine brake
Para 11-2
retarder and drone removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
References
None
a Removal.
(1)
(2)
(3)
15-22
Disconnect tube (1) from elbow (2) and fuel modulator (3).
Remove screw (4), lockwasher (5), clamp (6), and lever (7).
Remove two screws (8) and fuel modulator (3).
Change 2
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
(4)
(5)
(6)
Disconnect hose (9) from elbow (10).
Remove elbows (2) and (10) from adapter (11).
Remove two screws (12), lockwashers (13), adapter (11),
and gasket (14).
(7)
Remove pin (15), from cam (16), and bracket and
cylinder housing (17).
Change 2
15-22.1
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
155.1
FUEL MODULATOR REMOVAL/INSTALLATION (CONT).
Use care when removing snap and retaining rings. Snap and retaining rings are
under spring tension and can act as projectiles when released and could cause
severe eye injury,
(8)
(9)
(10)
(11)
Remove retainer ring (18), retainer (19), spring (20), and piston (21) with cam (16) from bracket
and cylinder housing (17).
Remove pin (22) from piston (21) and cam (16).
Remove cam (16), retainer ring (18), retainer (19), and spring (20) from piston (21).
Remove connector (23) from bracket and cylinder housing (17).
b. Cleaning/inspection
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1)
(2)
(3)
(4)
(5)
15-22.2
Clean all metal parts with drycleaning solvent.
Inspect parts for defects.
Inspect roller and piston outer diameter and cylinder bore inner diameter for wear. Inspect
operating surfaces, lever roller, roller pins at the cam pivot, and cam attachment to the piston.
Replace defective parts.
Coat all metal parts with oil.
Change 2
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
c.
Installation.
WARNING
Use care when installing snap and retaining rings. Snap and retaining rings are
under spring tension and can act as projectiles when released and could cause
severe eye injury.
(1)
(2)
(3)
(4)
(5)
Position cam (1) through retainer ring (2), retainer (3), and spring (4).
Install cam (1) in piston (5) with pin (6).
Install piston (5), spring (4), and retainer (3) in bracket and cylinder housing (7) with retainer
ring (2).
Install cam (1) in bracket and cylinder
housing (7) with pin (8).
Install connector (9) in bracket and
cylinder housing (7).
Change 2
15-22.3
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-5.1
(6)
(7)
(8)
(9)
(10)
(11)
d.
FUEL MODULATOR REMOVAL/INSTALLATION (CONT).
Install gasket (10) and adapter (11) with two screws (12)
and lockwashers (13).
Install elbows (14) and (15) on adapter (11).
Connect hose (16) on elbow (14).
Install fuel modulator (17) with two screws (18).
Install lever (19) and clamp (20) with
screw (21) and lockwasher (22).
Connect tube (23) to fuel modulator (17)
and elbow (15).
Follow-on Maintenance.
(1)
(2)
(3)
Install left rear engine brake retarder and drone (para 11-2).
Adjust injector rack control levers (para 19-6).
Adjust fuel modulator (para 19-8.1).
END OF TASK
15-22.4
Change 2
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-6.
VARIABLE, LOW SPEED LIMITING GOVERNOR REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-20 Batteries disconnected.
TM 9-2320-279-20 Air intake ducting removed.
Special Tools
None
Supplies
Solvent, drycleaning, Item 60, Appendix C
Grease automotive and artillery, Item 36,
Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
a.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Removal.
(1)
(2)
Remove air hose (1) and fitting (2) from limiting governor housing (3).
Remove two screws (4), lockwashers (5), and limiting governor housing (3) from governor
housing (6).
Change 2
15-22.5/(15-22.6 blank)
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
(3) Remove seal (7) from idle
adjusting screw (8).
(4) Remove jamnut (9) and idle
adjusting screw (8) from air
cylinder (10).
(5) Remove air cylinder (10) from
plunger (11).
(6) Remove nut (12) from plunger (1 1).
(7) Loosen locknut (13).
WARNING
Spring retainer holds back three
springs. Remove retainer slowly.
Springs can eject parts with force and
cause injury.
(8) Remove spring retainer
assembly (14) from governor
housing (6).
(9) Remove gasket (15) from governor
housing (6).
(10) Remove spring cap (16), two springs (17 and 18), two plungers (19 and 20), spring (21), and
locknut (13) from spring retainer (14).
15-23
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
(11) Remove pin (22) from air cylinder (10) and air
cap (23).
(12) Remove retaining ring (24), air cap (23), and
piston (25) from air cylinder (10).
(13) Remove seal ring (26) from piston (25).
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful
to skin and clothing. To avoid injury or death, keep
away from open fire and use in well-ventilated area.
If adhesive, solvent, or sealing compound gets on skin
or clothing, wash immediately with soap and water.
Compressed air used for cleaning purposes will not
exceed 30 psi (207 kPa). Use only with effective
chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(14) Clean low speed limiting governor in dry cleaning solvent. Dry parts with compressed air.
b. Installation.
NOTE
All metal parts must be lubricated with grease.
(1) Install seal ring (1) on piston (2).
(2) Install piston (2) and air cap (3) in air cylinder (4).
(3) Install pin (5) flush with edge of air cylinder (4) and
air cap (3).
(4) Install retaining ring (6) on air cylinder (4).
NOTE
Locknut is installed 1-1/2 in. (38,1 mm) on spring retainer. Only for clearance
when installing spring retainer.
(5) Install locknut (7) on spring retainer (8).
(6) Install spring (9) and plunger (10) in spring retainer (8).
(7) Install spring (12), plunger (11), spring (13), and spring cap (14) in plunger (10).
15-24
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
WARNING
Spring retainer holds down three
springs. Install retainer carefully.
Springs can eject parts with force
and cause injury.
Spring retainer is installed
approximately 1 in. (25 mm) in
governor housing.
(8) Install gasket (15) on governor
housing (16).
(9) Install spring retainer assembly (8)
through gasket (15) and governor
housing (16). Tighten locknut (7).
NOTE
Nut is installed 1/2 in. (12.7 mm) on
plunger.
(10) Install nut (17) on plunger (10).
(11)
(12)
(13)
(14)
Install air cylinder assembly (18) on plunger (10).
Install idle adjusting screw (19) on air cylinder assembly (18) finger tight.
Loosen idle adjusting screw (19) one turn and install jamnut (20).
Install seal (21 ) on idle adjusting screw (19).
15-25
TM9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-6.
VARIABLE, LOW SPEED LIMITING GOVERNOR REMOVAL/lNSTALLATION (CONT).
(15) Install limiting governor housing (22) on governor housing (16) with two screws (23) and
lockwashers (24).
(16) Install fitting (25) and hose (26) on limiting governor housing (22).
c. Follow-on Maintenance.
(1) Install air intake ducting (TM 9-2320-279-20).
(2) Connect batteries (TM 9-2320-279-20).
(3) Adjust governor gap (para 19-5).
END OF TASK
15-26
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-7.
BUFFER SCREW SWITCH REMOVAL/REPAIR/INSTALLATION.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Tags, identification, Item 61, Appendix C
Solvent, drycleaning, Item 60, Appendix C
Oil, lubricating, Item 48, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
d. Assembly
e. Installation
f. Follow-on Maintenance
References
None
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-20 Batteries disconnected.
TM 9-2320-279-10 Parking brake set.
TM 9-2320-279-10 Engine cover open.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
(1)
(2)
(3)
(4)
(5)
NOTE
There are three models of buffer switches. Model A is square and has removable
parts. Model B is round and has no removable parts. Model C is square and has no
removable parts.
For Models B and C, do steps (l) and (5) only.
Tag and mark wires before disconnecting.
Disconnect two wires (1).
Loosen nut (2) and remove switch and bracket (3).
Measure and record distance buffer switch nut (2) extends from governor (4).
Loosen locknut (5) and remove screw (6).
Loosen locknut (7) and remove buffer switch (8) from governor (9).
Change 2
15-27
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-7.
BUFFER SCREW SWITCH REMOVAL/REPAIR/INSTALLATION (CONT).
b. Disassembly,
NOTE
Disassembly pertains to Model A switch
only.
(1)
(2)
(3)
(4)
C.
Remove retaining ring (1),
washer (2), plunger (3),
spring (4), and preformed
packing (5) from plunger
assembly (6).
Remove locknut (7), locking
ring (8), and nut (9) from plunger
assembly (6).
Remove two screws (10), clamp (11),
bracket (12), clamp (13), and two
washers (14).
Remove two screws (15) and lockwashers (16)
with two terminals (17), diode wire (18), and
lockwasher (19) from switch (20).
Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. ‘lb avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1)
(2)
(3)
(4)
Clean all metal parts with drycleaning solvent.
Inspect parts for defects.
Replace defective parts and all packings.
Coat all metal parts with oil.
15-28 Change 2
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
d. Assembly.
NOTE
Assembly pertains to Model A switch
only.
Silver end of wire is installed on
center screw on switch.
(1)
Install two screws (1), lockwashers (2),
diode wire (3), lockwasher (4), and two
terminals (5) on switch (6).
(2)
Install two screws (7), washers (8),
clamp (9), diode wire (10), switch (6),
bracket (11), and clamp (12) finger-tight.
NOTE
The switch should close when the gage is
inserted.
(3)
(4)
(5)
(6)
(7)
Adjust gap between bracket (11) and
switch (13). Gap between bracket and
switch must be 0.010 in. (0.254 mm).
Tighten two screws (7).
Install plunger (14) in plunger
assembly (15).
Install spring (16), washer (17), and
retaining ring (18).
Install nut (19), locknut (2O)
locking ring (21), and preformed
packing (22).
Change 2
15-29
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-7.
e.
BUFFER SCREW SWITCH REMOVAL/REPAIR/INSTALLATlON (CONT).
Installation.
CAUTION
Installing screw in deeper than recorded
distance can cause engine to overspeed at
start-up.
NOTE
There are three models of buffer switches.
Model A is square and has removable parts.
Model B is round and has no removable
parts. Model C is square and has no
removable parts. For Models B and C, do
steps (1.1) and (3) only.
(1)
f.
Install buffer screw (1) with nut (2)
and locknut (3) on governor (4).
(1.1) Install buffer switch (7) with locknut (8) on governor (9).
(2) Install bracket and switch (5) and tighten nut (2).
(3) Install two wires (6).
Follow-on Maintenance.
(1) Connect batteries (TM 9-2320-279-20).
(2) Adjust buffer switch (para 19-9).
END OF TASK
15-8. THROTTLE AIR CYLINDER REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Disassembly
c. Assembly
d. Installation
e. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Solvent, drycleaning, Item 60, Appendix C
Grease, automotive and artillery, Item 36,
Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
15-30 Change 2
References
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Batteries disconnected.
TM 9-2320-279-10 Engine side cover opened.
Special.Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2815-2I24-34&P
Engine Governor Maintenance Instructions (Cont)
a. Removal.
(1) Remove air lines (1 and 2) from throttle air cylinder (3).
(2) Disconnect spring (4) from air cylinder bracket (5) and speed control lever (6).
(3) Remove three screws (7), lockwashers (8), and two washers (9) from air cylinder mounting
plate (10).
(4) Loosen two speed control lever screws (11). .
(5) Remove throttle air cylinder (3), speed control lever (6), and spacer (12) from speed control lever
shaft (13).
15-31
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-8. THROTTLE AIR CYLINDER REMOVAL/INSTALLATION (CONT).
b. Disassembly.
(1)
(2)
(3)
(4)
(5)
Remove remote control lever (1) from rod end assembly (2).
Remove two nuts (3), two screws (4), and spring pin (5) from remote control lever (1),
Remove heat shield (6) from shaft of cylinder assembly (7).
Remove rod end assembly (2) from shaft of cylinder assembly (7).
Remove two nuts (8), lockwasher-s (9), screws (10), washers (11), and cylinder assembly (7) from
air cylinder mounting plate (12).
15-32 Change 2
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
c. Assembly.
(1)
(2)
(3)
(4)
(5)
Install cylinder assembly (1) on air cylinder mounting plate (2) with two screws (3), washers (4)
lockwashers (5), and nuts (6).
Install extension stud (7) on shaft of cylinder assembly (1).
Position heat shield (8) on shaft of cylinder assembly (1).
Install spring pin (9), two screws (10), and nuts (11) in remote control lever (12). Do not tighten
nuts.
Place remote control lever (12) on extension stud (7).
d. Installation.
(1)
(2)
Install spacer (1) and speed control lever (2)
on speed control lever shaft (3).
Install throttle air cylinder (4) with three
screws (5), lockwashers (6), and two
washers (7).
Change 2
15-32.1
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-8.
(3)
(4)
(5)
(6)
e.
THROTTLE AIR CYLINDER REMOVAL/INSTALLATION (CONT).
Adjust link adapter (8) so that distance from
center of screw (9) to center of link adapter
pivot point (3) is 7 in. (177.8 mm).
Tighten two speed control lever screws (10).
Connect air lines (11 and 12) to throttle
air cylinder (4).
Connect spring (13) from air cylinder
bracket (14) to speed control lever (15).
Follow-on Maintenance.
(1)
(2)
Connect batteries (TM 9-2320-279-20).
Start engine and check engine operation of throttle air cylinder (TM 9-2320-279-10).
END OF TASK
15-32.2
Change 4
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-9. THROTTLE CONTROL SOLENOID REMOVAL/INSTALLATION.
This task covers:
c. Follow-on Maintenance
a. Removal
b. Installation
INITIAL SETUP
Equipment Condition
Models
All
Condition Description
TM or Para
TM 9-2320-279-10 Parking brake set.
TM 9-2320-279-10 Front cargo panel removed.
(M977 and M985 only).
TM 9-2320-279-20 Batteries disconnected.
TM 9-2320-279-10 Air system drained.
Test Equipment
None
Special TooLs
None
Supplies
Compound, sealing, pipe thread, Item 32,
Appendix C
Tags, identification, Item 61, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
NOTE
Tag and mark wires and air lines before disconnecting.
(1) Disconnect wires (1 and 2).
(2) Disconnect two air lines (3).
15-33
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-9. THROTTLE CONTROL SOLENOID REMOVAL/INSTALLATION (CONT).
(3) Remove two fittings (4).
(4) Remove solenoid (5).
(5) Remove screw (6), lockwasher (7), and ground
wire (8).
(6) Remove two screws (9) and lockwashers (10) to
separate brackets (11 and 12).
b . Installation.
(1) Install two screws (1) and lockwashers (2) to
brackets (3 and 4).
(2) Install screw (5), lockwasher (6), and ground wire (7).
(3) Slide solenoid (8) in position.
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful to
skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and water.
(4) Apply pipe thread sealing compound on two
fittings (9). Install fittings.
(5) Connect two air lines (10).
(6) Connect two wires (11 and 12).
c. Follow-on Maintenance.
(1) Connect batteries (TM 9-2320-279-20).
(2) Close air drains (TM 9-2320-279-20).
(3) Start engine and build air pressure to
operating pressure
(TM 9-2320-279-10).
(4) Adjust engine speed control
(para 19-9).
(5) Install front cargo panel (M977 and M985 only) (TM 9-2320-279-10).
END OF TASK
15-34
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-10. ENGINE STOP SOLENOID REMOVAL/INSTALLATION/ADJUSTMENT
This task covers:
a. Removal
b. Installation
c. Adjustment
d. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Tags, identification, Item 61, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
Equipment Condition
TM or Para
TM 9-2320-279-20
TM 9-2320-279-10
TM 9-2320-279-20
Condition Description
Batteries disconnected.
Parking brake on.
Engine side panel
removed.
TM 9-2320-279-10 Engine top cover
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Change 2
15-35
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-10.
ENGINE STOP SOLENOID REMOVAL/INSTALLATION /ADJUSTMENT (CONT).
a. Removal.
NOTE
There are two models of engine stop solenoids. Model A works by electrical signal
only. Model B has a manual shutdown cable.
Some older model engines have one washer and do not have a bracket,
Screw that goes through bracket is longer than others.
(1)
(2)
Remove nut (1) and washer (2) from shaft (3).
Remove four nuts (4) lockwashers (5) three washers (6) spacer washer (6.1), and four srews (7)
from solenoid (8) and plate (9).
NOTE
Tag and mark wires before removal.
(3)
15-36
Remove screw (10), lockwasher (11), and ground wire (12).
Change 2
TM 9-2815-224-34&P
Engine Governor Miaintenance Instructions (Cont)
(4)
Remove two nuts (13), lockwashers (14), two wires (15), and ground wire (12).
NOTE
Model B has a manual shutdown cable. Do steps (4.1) through (4.6) for Model B
(4.1) Remove locknut (15.1). Pull up on shutdown link (15.2) and remove bracket (15.3) and stop
lever (15.4) from screw (15.5).
(4.2) Remove locknut (15.6), two washers (15.7), and screw (15.5).
(4.3) Remove locknut (15.8) and shutdown link (15.2) from shutdown cable (15.9).
(4.4) Loosen two nuts (15.10) and remove shutdown cable (15.9) from cable bracket (15.11).
(4.5) Remove two nuts (15.12), lockwashers (15.13), washers (15.14), screws (15.15), and cable
bracket (15.11).
NOTE
Matchmark stop lever and stop lever shaft.
(4.6) Loosen screw (15.16) and remove stop lever (15.4).
(5) Remove solenoid (8).
(5.1) Remove washer (16) and nut (17) from solenoid (8).
(6) Remove screw (18), lockwasher (19), and plate (9).
Change 2
15-37
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
15-10. ENGINE STOP SOLENOID REMOVAL/INSTALLATION/ADJUSTMENT (CONT).
NOTE
Matchmark stop lever and stop lever
shaft.
Do steps (7) through (9) for Model A.
(7)
(8)
(9)
(10)
Loosen screw (20) and raise lever (21).
Remove locknut (22) and screw (23).
Remove lever (24).
Remove screw (25), copper washer (26), and bracket (27).
NOTE
Model B has a manual shutdown cable. Do steps (10.1) through (10.3) for Model B.
(10.1) Remove three ties connecting shutdown
cable (15.9) to heater hoses, horizontal
tube of cab, and transmission shift
cable.
(10.2) Loosen nut (28) and unscrew
handle (29) from shutdown cable (15.9).
(10.3) Remove nut (30) and pull shutdown
cable (15.9) downward through opening
in cab.
15-38
Change 2
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
b.
Installaton.
NOTE
Model B has a manual shutdown cable. Do
steps (1) through (1.2) for Model B.
(1)
Route shutdown cable (1) upward
through opening in cab. Secure using
nut (1.1).
(1.1) Screw handle (1.2) on shutdown cable (1)
and tighten nut (1.3).
(1.2) Secure shutdown cable (1) to
transmission shift cable, horizontal tube
of cab, and heater hoses using three ties.
(1.3) Install bracket (1.4), copper washer (2), and screw (3).
NOTE
Do steps (2) through (7) for Model A.
Model B has a manual shutdown
cable. Do steps (7.1) through (7.11)
for Model B.
(2)
Install bracket (4) to lever (5) with
screw (6) and nut (7). Do not tighten.
(3) Tighten nut (7) leaving lever (4) loose.
(4) Aline and install lever (5).
(5) Tighten screw (8).
Change 2
15-39
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
(6)
(6.1)
(7)
(7.1)
(7.2)
(7.3)
(7.4)
(7.5)
Install plate (9) with screw (10) and lockwasher (11).
Install nut (11.1) and washer (11.2) onto solenoid (12).
Install solenoid (12) with actuating screw (13) in hole of bracket (4).
Aline matchmarks and install stop lever (5).
Tighten screw (8).
Install plate (9) with screw (10) and lockwasher (11).
Position solenoid (12) on plate (9).
Install cable bracket (13.1) with two screws (13.2), washers (13.3), lockwashers (13.4), and
nuts (13.5).
(7.6) Install shutdown cable (1) on cable bracket (13.1) and tighten two nuts (13.6).
(7.7) InstaIl shutdown link (13.7) on shutdown cable (1) and locknut (13.8). Do not tighten locknut.
(7.8) Install bracket (4) on actuating screw (13).
(7.9) Install screw (13.9) in shutdown link (13.7) with two washers (13.10) and locknut (13 11)
Tighten locknut to provide 0.03 in. (0.76 mm) clearance above and below shutdown link (‘137).
(7.10) InstaIl stop lever (5) and bracket (4) on screw (13.9) with locknut (13.12). Tighten locknut to
provide 0.03 in. (0.76 mm) clearance above and below bracket (4).
(7.) Adjust locknuts (13.8) until shutdown link (13.7) has approximately 0.38 in. (9.65 mm) free
play in slot before shutdown link contacts screw (13.9). Tighten locknuts.
(8) Install washer (14), two nuts (15), wires (16), and ground wire (17).
15-40
Change 2
TM 9-2815-224-34&P
Engine Governor Maintenance Instructions (Cont)
NOTE
Some older model engines have one washer and do not have a bracket.
Screw that goes through bracket is longer than the others.
(9)
(10)
(11)
(12)
Install two screws (20), three washers (21), spacer washer (21.11, four lockwashers (22), and
nuts (23).
Install screw (24), lockwasher (25), and ground wire (17).
Install washer (26) and nut (27) finger tight and take slack out of bracket (4).
Tighten nuts (27) and (29) against bracket (4).
c. Adjustment.
(1)
(2)
(3)
(4)
d.
Hold lever (1) in run position.
Adjust nut (2) to touch bracket (3).
Tighten nuts (2 and 4) against
bracket (3).
Move lever (1) to stop position; if it
binds, loosen mounting bolts and realine
solenoid (5).
Follow-on Maintenance.
(I)
(2)
(3)
(4)
(5)
Connect batteries (TM 9-2320-279-20).
Start engine and check operation of
engine stop switch (TM 9-2320-279-10).
Shut off engine (TM 9-2320-279-10).
Install engine cover (TM 9-2320-279-20).
Install engine side panel
(TM 9-2320-279-10).
END OF TASK
Change 2
15-41/(15-42 blank)
TM 9-2815-224-34&P
CHAPTER 16
AFTERCOOLER MAINTENANCE
Contents
Para
Page
General, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aftercooler Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16-1
16-2
16-1
16-1
Section I. INTRODUCTION
GENERAL. This chapter covers the removal and installation of the aftercooler assembly.
Subassemblies and Parts which must be removed before the aftercooler can be removed will be referenced
to TM 9-2320-279-10, TM9-232O-279-2O, or TM 9-2320-279-34, or to other paragraphs of this manual.
116-1.
Section Il.
AFTERCOOLER ASSEMBLY
Aftercooler
Maintenance
Instructions
16-2. AFTERCOOLER REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
None
Supplies
Oil, lubricating, Item 48, Appendix C
Adhesive-sealant, silicone, Item 6, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
TM or Para
Para 14-3
Condition Description
Blower removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2815-224-34&P
Aftercooler Maintenance Instructions (Cont)
16-2.
a.
AFTERCOOLER REMOVAL/INSTALLATION (CONT).
Removal.
NOTE
Some engines have two bolts,
lockwashers, and washers. Others
have two flanged head bolts.
(1)
(2)
(3)
Loosen clamps (1), remove
two bolts (2), lockwashers (3),
and washers (4) from
elbow (5).
Remove connector (6),
hose (7), elbow (5), and
gasket (8) from engine
block (9).
Remove eight lock screws (10)
from after-cooler (11).
CAUTION
Remove aftercooler carefully Fins are delicate and can be easily damaged.
(4)
(5)
16-2
Remove after-cooler (11) from engine block (9) and inspect water openings for blockage,
Remove four seal rings (12).
Change 2
TM 9-2815-224-34&P
Aftercooler Maintenance Instructions (Cont)
(I) Apply lubricating oil to four seal rings (1).
(2) Install seal rings (1) on after-cooler (2).
(3) Position aftercooler (2) in engine block (3) so inlet tube (4) fits into adapter (5).
16-3
TM 9-2815-224-34&P
Aftercooler Maintenance Instructions (Cont)
16-2.
(4)
AFTERCOOLER REMOVAL/INSTALLATION (CONT).
Secure aftercooler (2) with eight lock bolts (6). Do not tighten.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(5)
Apply silicone adhesive-sealant to flange to elbow (7), hose (8), and connector (9).
NOTE
Some engines have two bolts, lockwashers, and washers. Others have two flanged
head bolts. Refer to TM 9-2320-279-24P
(6)
(7)
(8)
(9)
(10)
C.
Install elbow (7) and gasket (10) with two bolts (11), lockwashers (12), and washers (13). Do not
tighten bolts (11).
Install hose (8) and connector (9) on elbow (7).
Tighten hose clamps (14).
Tighten two bolts (11) to 15 lb-ft (20 N•m).
Tighten eight lock bolts (6) to 15 lb-ft (20 N•m).
Follow-on Maintenance.
(1)
(2)
Install blower (para 14-3).
Start engine and check engine operation (TM 9-2320-279-10)
END OF TASK
16-4
Change 2
TM 9-2815-224-34&P
CHAPTER 17
WATER PUMP MAINTENANCE
Contents
G e n e r a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section I.
Para Page
17-1
17-1
17-1
17-2
INTRODUCTION
1 7 - 1 . GENERAL. This chapter includes removal, installation, and repair of the water pump. The
subassemblies and parts which must be removed before the water pump components can be removed will
be referenced to other paragraphs or chapters of this manual, TM 9-2320-279-10, TM 9-2320-279-20, or
TM 92330-279-34.
Section II.
WATER PUMP ASSEMBLY
Water Pump Maintenance Instructions
17-2. WATER PUMP REMOVAL/REPAIR/INSTALLATON.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
Presonnel Required
MOS 63W, Wheel vehicle repairer (2)
TEST Equipment
N o n e
Reference
None
Special Tools
Installer. water pump drive gear, J25257
Remover, water pump seal, J22150-B
Gage, feeler FB310B
Set, dial indicator J7872
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-20 Cooling system drained.
TM 9-2320-279-20 Fan removed.
Special
Supplies
None
Solvent, dry cleaning, Item 60. Appendix C
Compound, sealing, pipe thread, Item 32,
General
Appendix C
None
Adhesive-sealant, silicone, Item 6, Appendix C
Level of
Oil, lubricating, Item 48, Appendix C
Direct
Tags, identification, Item 61, Appendix C
Compound, International No. 2, Item 26.
Appendix C
Screw, 5 16-18 x 2 in., Item 58. Appendix C
Environmental Conditions
Safety Instructions
Maintenance
Support
17-1
TM 9-2815-224-34&P
Water Pump Maintenance Instructions (Cont)
17-2.
WATER PUMP REMOVAL/REPAIR/INSTALLATiON (CONT).
a. Removal.
(1)
(2)
(3)
(4)
(5)
Loosen two screws (1), lockwashers (2), and washers (3). Move secondary fuel filter (4) out of
way.
Loosen two hose clamps (5) and slide
hose (6) up.
Loosen two hose clamps (7) and slide
hose (8) down.
Loosen two hose clamps (9) and slide
hose (10) down.
Loosen hose clamp (11) and remove
hose (12).
NOTE
Some engines do not have screw, lockwashers,
and clip.
(6)
17-2
Remove screw (13), lockwasher (14), and
clip (15).
Change 2
TM9-2815-224-34&P
Water Pump Maintenance Instructions (Cont)
(7) Remove screw (16) and lockwasher (17).
(8) Remove screw (18), lockwasher (19), and
washer (20).
(9) Remove water pump (21) and preformed
packing (22).
(10) Remove preformed packing (22) from water
pump (21).
b. Disassembly.
(1) Place pump body (1) gear-side down on a clean work surface.
(2) Remove retaining ring (2), pump cover (3), and preformed
packing (4).
(3) Soldier A removes locknut (5), washer (6), and impeller (7)
while Soldier B holds pump gear (8) with strap wrench.
28
(4) Place pump body (1), gear side up, on work surface.
NOTE
Tag and mark elbow before removal.
(5) Remove elbow (9).
17-3
TM9-2815-224-34&P
Water Pump Maintenance Instructions (Cont)
17-2. WATER PUMP REMOVAL/REPAIR/INSTALLATION (CONT).
(6) Turn pump gear (8) until ends of retaining ring (1()) can be seen.
(7) Move retaining ring (10) out of groove in pump body (1).
(8) Press pump gear (8) and shaft assembly (11) out of pump body (1).
(9) Press shaft (12) out of pump gear (8).
(10) Remove retaining ring (10).
(11) Press shaft (12) out of bearing ( 13).
(12) Press shaft (12) out of bearing ( 14).
17-4
TM9-2815-224-34&P
Water Pump Maintenance Instructions (Cont)
(13) Remove water seal (15) and oil seal (16) from pump body (l).
(14) Remove plug (17).
c. Cleaning/lnspection.
WARNING
Adhesives, solvents, and sealing compounds car burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Clean all metal parts with dry cleaning solvent.
(2) Inspect passages of housing for obstructions, deposits, and cracks. Clean out any obstruction or
deposits. Replace housing if cracked.
(3) Inspect bearings for damage and rough turning. Replace both bearings if either bearing is
damaged.
(4) Inspect impeller and replace if damaged.
d. Assembly.
(1) Lubricate bearings (1 and 2) and shaft (3) with oil.
NOTE
Bearings are installed so that numbered side of each bearing
faces in toward numbered side of other bearing.
(2) Press shaft (3), threaded end down, into small bearing (2)
using water pump drive gear installer to support bearing.
(3) Press shaft (3), threaded end up, into large bearing (1)
using water pump drive gear installer to support bearing.
CAUTION
When installing shaft assembly, make sure that shaft
assembly is installed straight into pump body otherwise
shaft assembly and pump body may be damaged.
NOTE
When installing shaft assembly, press against outer race of
large bearing.
(4) Install shaft assembly (4) into pump body (5) by pressing
on outer race of larger bearing (1).
17-5
TM9-2815-224-34&P
Water Pump Maintenance Instructions (Cont)
17-2. WATER PUMP REMOVAL/REPAIR/INSTALLATION (CONT).
(5) Install retaining ring (6).
CAUTION
Gear must be installed straight onto shaft or gear will be
damaged.
(6) Press pump gear (7) onto shaft assembly (4) using water
pump drive gear installer to support shaft assembly from
beneath.
WARNING
Adhesives, solvents, and sealing compounds can burn easily,
can give off harmful vapors, and are harmful to skin and clothing.
To avoid injury or death, keep away from open fire and use in
well-ventilated area. If adhesive, solvent, or sealing compound gets
on skin or clothing, wash immediately with soap and water.
(7) Apply pipe thread sealing compound to threads and install elbow fitting (8) into pump body (5).
(8) Apply pipe thread sealing compound to threads and install
plug (9).
CAUTION
Oil seal must be installed flush with water seal counter bore.
Pump will not operate if oil seal is not properly installed.
(9)
(lo)
(11)
(12)
(13)
Support pump body (5), gear side down, with suitable blocking.
Apply lubricating oil to shaft (3) and lip of oil seal (10).
Install oil seal (10), with lip toward bearing (2).
Apply silicone adhesive-sealant to outside of water seal (11).
Position water seal (11) into pump body (5).
NOTE
Water pump seal remover comes with teeth for cutting and
removing seals. Remove these teeth before using to install water
seal.
(14) Attach water pump seal remover to pump body (5) with
retaining ring (12) beveled edge out.
(15) Seat water seal (11) by turning shaft of water pump seal
remover clockwise until tight.
NOTE
After removing tool wipe excess sealant off water seal.
(16) Remove retaining ring (12) and water pump seal remover.
17-6
TM 9-2815-224-34&P
Water Pump Maintenance Instructions (Cont)
(17)
(18)
Apply compound No. 2 to threads of shaft (3).
Soldier A installs impeller (13), washer (14), and locknut (15).
(19)
Hold 0.015 in. (0.38 mm) feeler gage between impeller (13)
and corner (16) of pump body (5).
While holding feeler gage in position described in step (19),
turn impeller (13) and wall of pump body (5).
If clearance is wrong, repeat section b. Disassembly and
section c. Cleaning/Inspection of this procedure.
(20)
(21)
e.
Installtion.
(1)
(2)
(3)
(4)
Install ring seal (1) on water pump (2).
Install water pump (2) on front cover (3) and into
two hoses (4) and (5).
Install screw (6) and washer (7). Tighten screw to
20 to 25 lb-ft (27 to 34 N•m).
Install screw (8), lockwasher (9), and washer (10).
Tighten screw to 20 to 25 lb-ft (27 to 34 N•m).
NOTE
Some engines do not have screw, lockwasher,
and clip. Refer to TM 9-2320-279-24P.
(5)
Install screw (11), lockwasher (12), and clip (13).
Change 2
17-7
TM 9-2815-224-34&p
Water Pump Maintenance Instructions (Cont)
17-2. WATER PUMP REMOVAL/REPAlR/lNSTALLATlON (CONT).
(6) Install 5/16-18 x 2 in. screw (14) into impeller (15).
NOTE
Limits for gear backlash are 0.001-in. to 0.006-in.
(0.025 mm to 0.15 mm). If backlash cannot be fixed,
replace pump.
(7) Place plunger of dial indicator against screw (14). Move
impeller (15) and read backlash.
(8) If backlash is outside limits, loosen two screws (6 and 8)
and pivot pump to obtain proper backlash.
(9) Tighten screws (6 and 8) to 25 lb-ft (27 N-m).
(10) Remove screw (14).
(11) Tighten screws (6, 8, and 11) to 45 to 50 lb-ft (61 to
67 N.m).
(12) Install preformed packing (16), pump
cover (17), and retaining ring (18).
(13) Install three hoses (19, 20 and 21).
(14) Tighten six hose clamps (22).
(15) Install hose (23).
(16) Tighten hose clamp (24).
(17) Aline secondary fuel filter (25) with mounting holes
and tighten two screws (26) lockwashers (27), and
washers (28).
f. Follow-on Maintenanca.
(1) Install fan (TM 9-2320-279-20).
(2) Fill cooling system (LO 9-2320-279- 12)
END OF TASK
17-8
TM 9-2815-224-34&P
CHAPTER 18
FAN CLUTCH MAINTENANCE
Para
Contents
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........
18-1
Fan Clutch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2
Page
18-1
18-2
Section I. INTRODUCTION
18-1. GENERAL. This chapter covers repair of the fan clutch. The subassemblies and parts which must be
removed before the fan clutch can be removed will be referenced to other paragraphs or chapters of this manual
or TM 9-2320-279-10, TM 9-2320-279-20, or TM 9-2320-279-34.
Section II. FAN CLUTCH ASSEMBLY
Fan Clutch Maintenance Instructions
18-2.
FAN CLUTCH REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
Personnel Required
MOS 63W, Wheel vehicle repairer
Test Equipment
None
References
None
Special Tools
Kit, tool, overhaul 3-462-902-24460
Gage, feeler FB310B
Fabricated Tools
Wear sleeve installation tool
Supplies
Oil, lubricating, Item 48, Appendix C
Solvent, drycleaning, Item 60, Appendix C
Grease, automotive and artillery, Item 36,
Appendix C
Compound, sealing, lubricating, Item 31,
Appendix C
Adhesive-sealant, silicone, Item 6, Appendix C
Compound, sealing, pipe thread, Item 32,
Appendix C
Gasket, loctite plastic, Item 35.1, Appendix C
Equipment Condition
Condition Description
TM or Para
Fan clutch on clean work
surface.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Change 2
18-1
TM 9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
18-2. FAN CLUTCH REPAIR (CONT). 1
a. Disassembly.
NOTE
Shim may or may not be installed on fan mounting hub.
(1) Remove eight screws (1), bearing retainer (2), and shim (3).
(2) Remove preformed packing (4) from bearing retainer (2).
CAUTlON
Be sure that supports are under fan hub and not under bearing retainer, or
damage to fan hub may result.
(3)
(4)
(5)
(6)
18-2
Support fan hub (5) with suitable blocking.
Press bearing (6) down l/16-in. (1.5 mm), using tool No. 10.
Remove retaining ring (7) and spacer (8).
Remove retaining ring (9) from inside fan hub (5).
TM 9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
(7) Support bearing retainer (2) with suitable blocking.
(8) Press fan hub (5) out of bearing retainer (2) using short
end of tool No. 1.
(9) Remove bearing (6).
(10) Support bearing retainer (2) with suitable blocking.
(11) Press out bearing race ( 10) and oil seal (11) using tool NO. 3
and tool No. 8.
(12) Support fan hub (5) with suitable blocking.
(13) Press out expansion plug (12) using tool No. 9.
(14) Remove retaining ring (13) from fan hub (5).
18-3
TM 9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
18-2. FAN CLUTCH REPAIR (CONT).
(1.5)
Support fan hub (5) with suitable blocking.
NOTE
Number and type of shims may vary among fan
clutches.
(16)
Press out two roller bearings (14), thrust
washers (15), one needle bearing (16), and
shims (17) using small end of tool No. 9.
NOTE
There are two models of fan hubs. Model A has no
wear sleeve. Model B is a smaller diameter and uses a
wear sleeve. Model B fan hub replaces Model A and is
supplied with wear sleeve already installed. If a new
Model B fan hub is being installed, skip step (16.1). To
replace wear sleeve on Model B fan hub, do step (16.1).
(16.1) Using a hammer and chisel, split wear
sleeve ( 17.1) and remove wear sleeve from
shoulder of fan hub (5).
(17) Remove splined hub (18) with back plate (19)
from fan pulley (20).
(18) Remove six spline plates (21), five clutch
plates (22), and pressure plate (23).
(19) Remove retaining ring (24) and back
plate (19) from splined hub (18).
18-4 Change 2
Fan Clutch Maintenance Instructions (Cont)
(20) Remove needle bearing (25).
(21) Loosen setscrew (26) until 1/4-in. (6 mm) of setscrew is sticking
out of load cell assembly (27).
(22) Remove load cell assembly (27) from fan pulley (20). Remove
setscrew (26).
CAUTION
Make sure tool No. 6 is centered on thrust washer, or retaining
ring and thrust washer may be damaged.
(23) Support load cell assembly (27) with suitable blocking.
CAUTION
Pressing thrust washer more than 1/32-in. (0.8 mm) may damage
parts in load cell.
(24) Press thrust washer (28) down 1/32-in. (0.8 mm) using tool
No. 6 and remove retaining ring (29).
(25) Remove thrust washer (28) and two springs (30).
(26) Remove four screws (31) and two oilers (32).
(27’) Remove piston housing (33) from clutch body (34).
(28) Remove two preformed packings (35 and 36) from clutch
body (34).
18-5
Fan Clutch Maintenance Instructions (Cont)
18-2. FAN CLUTCH REPAIR (CONT).
CAUTION
Be sure support is placed beneath bracket and shaft assembly,
and not fan pulley, or fan pulley may be damaged during
removal of bearing.
(29) Support bracket and shaft assembly (37) with suitable
blocking.
(30) Press bearing (38) down 1/16-in. (1.5 mm) using tool No. 5.
(31) Remove two preformed packings (39), retaining ring (40) and
spacer (41).
(32)
(33)
(34)
(35)
Support fan pulley (20) with suitable blocking.
Press out bracket and shaft assembly (37) using tool No. 8.
Remove bearing (38).
Remove two screws (42) and washers (43).
CAUTION
Be sure tool No. 8 and tool No. 3 are centered on top of oil
seal, or damage to fan pulley and oil seal may result.
(36) Support fan pulley (20) with suitable blocking.
(37) Press out bearing race (44) and oil seal (45), using tool
No. 8 and tool No. 3.
18-6
TM 9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
NOTE
Tag fittings before removal.
(38)
Remove three fittings (46,47, and 48) from
bracket and shaft assembly (37).
NOTE
There are two models of bracket and shaft assemblies.
Model A has no wear sleeve. Model B is a smaller
diameter and uses a wear sleeve. Model B bracket
and shaft assembly replaces Model A and is supplied
with wear sleeve already installed. If new Model B
bracket and shaft assembly is being installed, skip
step (39). To replace wear sleeve on Model B bracket
and shaft assembly, do step (39).
(39)
Using a hammer and chisel, split wear sleeve (49) and remove wear sleeve from shoulder of
bracket and shaft assembly (37).
b. Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1)
Clean all metal parts with drycleaning solvent.
WARNING
Compressed air used for cleaning must not exceed 30 psi (207 kPa) and must be
used only with chip guarding and personnel protective equipment such as goggles,
shield, gloves, etc.
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Dry all parts, except bearings, with compressed air.
Blow air through passageways in shaft and bracket assembly to make sure passageways are not
blocked.
Remove burrs from setscrew contact point.
Replace any spline plates or clutch plates that look or smell burned.
Inspect clutch plates for wear spots. Replace clutch plates if wear spots exceed 0.010 in. (0.25
mm), or if clutch plate is bent.
Inspect spline plates for wear. Replace spline plates if worn to bottom of wear grooves on surface
of plate.
Inspect all metal parts for scratches, grooves, scoring, dents, nicks, and burrs. Replace damaged
parts.
Change 2
18-6.1(18-6.2blank)
TM 9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
c. Assembly.
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing.To avoid
injury or death, keep away from open fire and
use in well-ventilated area. If adhesive,
solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and
water.
(1)
Coat three fittings (1, 2, and 3) with pipe
thread sealing compound and install on
bracket and shaft assembly (4).
NOTE
There are two models of bracket and shaft assemblies. Model A has no wear
sleeve. Model B has a wear sleeve. Model B replaces Model A and is supplied with
wear sleeve already installed. If installing a new Model B bracket and shaft
assembly, skip steps (1.1) through (1.3). If replacing wear sleeve on existing Model
B bracket and shaft assembly, do steps (1.1) through (1.3).
(1.1) Apply plastic gasket to outside diameter of shoulder of bracket and shaft assembly (4) and inside
diameter of wear sleeve (4.1).
(1.2) Support bracket and shaft assembly (4) with suitable blocking.
(1.3) Press wear sleeve (4.1) on shoulder of bracket and shaft assembly (4) using wear sleeve
installation tool.
Change 2
18-7
TM 9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
18-2. FAN CLUTCH REPAIR (CONT).
(2) Install tool No. 2 on tool No. 5.
(3) Support fan pulley (5) with tool No. 2 and tool No. 5.
(4) Apply lubricating oil to oil seal (6) and tool No. 4.
CAUTION
All tools should be centered and oil seal properly alined with
fan pulley to prevent improper installation or damage to oil seal
during installation.
(5) Press oil seal (6) flat side up. into fan pulley (5) until tool
No. 4 contacts tool No. 2.
(6) Support fan pulley (5) with
suitable blocking.
(7) Apply lubricating oil to
bearing race (7).
(8) Press bearing race (7), thin
edge up, into fan pulley (5)
using tool No. 2 until tool
No. 2 contacts fan pulley.
(9) Apply lubricating oil to
bearing (8).
(10) Install bearing (8), numbered
side up, in bearing race (7).
(11) Attach tool No. 5 to fan
pulley (5) using 3/8-16 x 2 in.
(51 mm) screws from fan drive
overhaul tool kit. Finger
tighten screws.
18-8
TM9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
(12) Support fan pulley (5) and tool No. 5 with suitable
blocking.
(13) Place two screws (9) and washers (10), threads up, on
fan pulley (5).
(14) Apply lubricating oil to bracket and shaft assembly (4).
(15) Press bracket and shaft assembly (4) into fan pulley (5)
over two screws (9) using tool No. 8,
(16) Remove tool No. 5.
(17) Install spacer (11) and retaining ring (12) on bracket and
shaft assembly (4).
CAUTION
Make sure blocks are placed under pulley, not under bracket
and shaft assembly, or bracket and shaft-assembly may be
damaged.
(18) Support fan pulley (5) with suitable blocking.
(19) Press bracket and shaft assembly (4) down 1/16-in.
(1.5 mm) with tool No. 8 to seat spacer (11) and
retaining ring (12) on bearing (8).
(20) Apply lubricating oil to two preformed packings (13)
and install on bracket and shaft assembly (4).
(21) Apply lubricating oil to two preformed packings (14 and 15) and install
on clutch body (16).
(22) Install clutch body (16) in piston housing (17).
18-9
TM9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cent)
18-2. FAN CLUTCH REPAIR (CONT).
(23) Apply lubricating oil to two springs (18) and install springs,
concave side up, on clutch body (16).
(24) Apply oil to thrust washer (19) and install, flat side up, on
springs (18).
NOTE
Be sure blocking does not touch clutch body.
(25) Support piston housing (17) with suitable blocking.
CAUTION
Do not press thrust washer down more than 1/32-in. (0.8 mm) or
thrust washer and springs may be damaged.
(26) Press thrust washer (19) down 1/32-in. (0.8 mm) using tool
No. 6 and install retaining ring (20) in piston housing (17).
(27) Apply sealing compound to threads of four screws (21).
(28) Install two oilers (22) with four screws (21). Tighten screws to
45 lb-in (5.1 N°m).
(29) Install setscrew (23) but do not tighten.
(30) Install load cell assembly (24) until upper surface of
clutch body (16) is flush with, or just below shoulder
of shaft.
(31) Aline setscrew (23) with oil holes (25) and setscrew
hole (26) on bracket and shaft assembly (4).
CAUTION
Setscrew must rest in center of hole. Make sure setscrew
is centered when tightened or damage to shaft may
result.
(32) Tighten setscrew (23) to 50 lb-in (5.4 N°m).
18-10
TM 9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
(33)
Support fan hub (27) with suitable
blocking.
NOTE
There are two models of fan hubs. Model A has no
wear sleeve. Model B has a wear sleeve. Model B
replaces Model A and is supplied with wear sleeve
already installed. If installing a new Model B fan hub,
skip steps (33.1) and (33.2). If replacing wear sleeve on
existing Model B fan hub, do steps (33.1) and (33.2).
(33.1) Apply plastic gasket to inside diameter of
wear sleeve (27.1) and mating surface of fan
hub (27).
(33.2) Press wear sleeve (27.1) on shoulder of fan
hub (27).
(34) Apply lubricating oil to 0.75 in. long (19 mm)
straight roller bearing (28).
(35) Press 0.75 in. long (19 mm) straight roller
bearing (28), numbered side up, into fan
hub (27), using long end of tool No. 1 until
shoulder of tool No. 1 contacts fan hub.
(36)
Apply lubricating oil to 1 in. long (25 mm)
straight roller bearing (29).
NOTE
Roller bearing is correctly installed when
shoulder of tool No. 1 contacts fan hub.
(37)
(38)
(39)
(40)
(41)
(42)
Press l-in. long (25 mm) roller bearing (29)
numbered side up, into fan hub (27) using
short end of tool No. 1 until shoulder of tool
No. 1 contacts fan hub.
Install retainer ring (30) in fan hub (27).
Install tool No. 2 on tool No. 5.
Support bearing retainer (31) with tool
No. 2 and tool No. 5.
Apply lubricating oil to oil seal (32).
Press oil seal (32) into bearing retainer
(31) using tool No. 4 until tool No. 4
bottoms out against tool No. 2.
Change 2
18-11
TM 9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
18-2. FAN CLUTCH REPAIR (CONT).
(43) Support bearing retainer (31) with suitable blocking.
(44) Apply lubricating oil to bearing race (33).
(45) Press bearing race (33), thin edge up, into place using
tool No. (2) until tool No. 2 contacts bearing retainer (31).
(46) Apply lubricating oil to oil seal (32) and install fan
hub (27) in bearing retainer (31).
CAUTION
Before installing bearing, make sure blocking is under fan
hub or damage to bearing retainer may result.
(47) Support fan hub (27) with suitable blocking.
(48) Apply lubricating oil to bearing (34).
(49) Press bearing (34), numbered side up, over fan hub (27)
into bearing retainer (31) using tool No. 10 until tool
No. 10 contacts bearing retainer.
(50) Install spacer (35) and retaining ring (36).
CAUTION
Before pressing fan hub, make sure blocking is installed under
bearing retainer. not fan hub, or damage to fan hub may result.
(51) Support bearing retainer (31) with suitable blocking.
(52) Press fan hub (27) down l/16-in. (1.5 mm) using tool No. 3 to
seat bearing (34) against spacer (35) and retaining ring (36).
18-12
TM9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
CAUTION
Make sure retaining ring fits completely in groove of splined hub
and groove of back plate or retaining ring, splined hub, and back
plate may be damaged.
(53) Install back plate (37), flat side down, on splined hub (38).
(54) Install retaining ring (39) on splined hub (38).
CAUTION
Oil holes in fan hub must aline with oil ducts in splined hub or
clutch may be damaged.
(55) Aline oil holes (40) with ducts (41) and install splined
hub (38) on bearing retainer (31).
(56) Install six internally splined plates (42) alternating with five
clutch plates (43).
(57) Install pressure plate (44) flat side down.
(58) Support bearing retainer (31) with suitable blocking.
(59) Apply light pressure against pressure plate (44) using
tool No. 5.
CAUTION
Do not touch pressure plate with hands while taking
measurements or measurements will be wrong,
(60) Measure and write down distance from pressure
plate (44) to outer flange of bearing retainer (31).
(61) Measure and write down distance from pressure
plate (44) and bearing retainer (31 ) on opposite side of bearing retainer from first measurement,
(62) Add measurements from step (60 and (61) and write down answer.
(63) Add 0.250-in. (6.35 mm) to result from step (62) and write down answer. This is measurement A.
18-13
TM9-2815-224-34&P
Fan Clutch Maintenance Instructions
18-2. FAN CLUTCH REPAIR (CONT).
(64) Support fan pulley (5) with suitable blocking.
CAUTION
Apply only slight pressure on shaft when alining shaft straight
up and down, or parts on fan hub may be damaged or
improperly alined.
(65) Aline bracket and shaft assembly (4) straight up and down
using tool No. 8.
CAUTION
Do not place tool No. 7 over screw holes or
improper measurements may result and cause
damage to clutch parts.
(66) Place tool No. 7 on fan pulley (5).
(67) Measure and write down distance between top
side of tool No. 7 and thrust washer (19), Take
measurement next to retaining ring (20).
(68) Move tool No. 7 and repeat step (67) on opposite
side of fan pulley (5).
(69) Add measurement from step (67) to measurement from step (68) and write down answer.
(70) Subtract 2.00-in. (50.8 mm) from result in step (69) and write down answer. This is
measurement B.
(71) Subtract measurement B from measurement A, step (63), and write down answer.
(72) Subtract answer in step (71) from 0. 136-in. (3.45 mm). This answer is shim gap indicator.
(73) If shim gap indicator is 0.000 to 0.008 in. (0.00 to 0.20 mm), shim is not required. If gap is
0.009 to 0.028 in. (0.23 to 0.71 mm), use 0.010 in. (0,25 mm) shim. If gap is 0.029 to 0.048 in.
(0.74 to 1.22 mm), use 0.020 in. (0.51 mm) shim. If gap is 0.049 to 0.068 in. (1.25 to 1.73 mm),
use 0.030 in. (0.76 mm) shim. If gap is 0,069 to 0.088 in. (1.75 to 2.23 mm), use 0.040 in.
(1.02 mm) shim, and if gap is 0.089 to 0.108 in. (2.26 to 2.74 mm), use 0.050 in. (1.27 mm) shim.
NOTE
When removing clutch assembly, carefully lift out
assembly so all parts remain together for easy
installation.
(74) Remove clutch assembly (45) from bearing
retainer (31).
(75) Apply grease to shim (46).
(76) Install shim (46) on fan hub (27).
18-14
TM9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
CAUTION
Oil holes in fan hub must line up with oil ducts in
splined hub or clutch may be damaged during
operation.
(77) Aline oil holes (40) with ducts (41) and install clutch
assembly (45) on bearing retainer (31).
NOTE
If clutch assembly has come apart, it must be installed
following steps (53) through (57).
(78) Apply lubricating oil to preformed packing (47) and
needle bearing (48).
(79) Install preformed packing (47).
(80) Install needle bearing (48).
(81) Install fan pulley (5) on bearing retainer (31).
18-15
Fan Clutch Maintenance Instructions (Cont)
18-2. FAN CLUTCH REPAIR (CONT).
NOTE
Clutch assembly will fall apart if not held together
while turning over fan clutch.
(82) Install eight screws (49) and tighten to 20 lb-ft
(27 N°m).
(83) Install 0.095-in. (2.4 mm) thick thrust washer (50),
needle bearing (51 ), and second 0.095-in. (2.4 mm)
thick thrust washer (50).
WARNING
When using compressed air, be sure to use chip guarding and personal protective
equipment, (goggles/shield, gloves, etc. ) to avoid personal injury.
CAUTION
Do not turn fan clutch upside down, thrust washers and needle bearing will fall
out.
(84) Apply compressed air four times, at 100 psi (690 kPa), into port (52) on bracket and shaft
assembly (4).
18-16
TM9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
(85) Keep air pressure applied at 100 psi
(690 kPa) and install shims (53) between
thrust washers (50) and retaining ring
groove (54).
(86) Install retaining ring (55). If retaining
ring cannot be installed, remove one
shim (53).
(87) Release air pressure.
CAUTION
Screws must go through holes on opposite
sides of fan hub or improper adjustment
may result and cause damage to fan clutch
during operation.
(88) Install two 1/2-13 x 2 in. (51 mm)
screws from fan drive overhaul tool kit
through fan hub (27) and finger-tighten
against bearing retainer (31 ).
(89) Rotate fan pulley (5) four turns.
CAUTION
Screws in fan hub must be finger tight and retaining ring must
be against top of groove or incorrect measurement will be
taken and result in improper shim adjustment and possible
damage to fan clutch during operation.
(90) Using feeler gage, measure gap between shims (53) and
retaining ring (55).
NOTE
Shim stack should be arranged so that thickest shims are
against thrust washer and retaining ring, with thinner shims
between.
(91) Add or remove shims (53) as needed, to leave 0.001-in. (0.025 mm) gap between shim and
retaining ring (55).
WARNING
When using compressed air, be sure to use chip guarding and personal protective
equipment, (goggles/shield, gloves, etc. ), to avoid personal injury.
(92) Apply air pressure at 100 psi (690 kPa).
NOTE
If 0.001-in. to 0.003-in. (0.025 to 0.076 mm) gap cannot be reached, perform
steps (94) through (98),
(93) Add or remove shims (53) as needed, to leave 0.003-in. (0.076 mm) gap between shim and
retaining ring (55) with air pressure applied.
18-17
TM9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
18-2. FAN CLUTCH REPAIR (CONT).
(94) Release air pressure and remove two 1/2-13
x 2 in. (51 mm) screws.
(95) Loosen eight screws (49),
(96) Add shims (53), as needed, to leave 0.001 to
0.003-in. (0.025 to 0.076 mm) gap.
(97) Tighten eight screws (49) evenly to 20 lb-ft
(27.12 N°m).
(98) Install two 1/2- 13 x 2 in. (51 mm) screws
through fan hub (27) and finger-tighten
screws against bearing retainer (31).
(99) Apply adhesive-sealant to expansion plug (56).
CAUTION
Insure screws from fan drive overhaul tool kit are installed while installing
expansion plug to prevent damage to bearings.
(100) Install expansion plug (56), numbered side down, in fan hub (27) using tool No. 1.
(101) Remove two 1/2-13 x 2 in. (51 mm) screws from fan hub (27).
18-18
TM9-2815-224-34&P
Fan Clutch Maintenance Instructions (Cont)
(102) Install tool No. 5 and two
tools No. 11 on fan
hub (27) with two 1/2-13
x 2 in. (51 mm) screws.
CAUTION
Jaws of vise must not touch
fan mounting hub or fan
mounting hub and attaching
parts may be damaged.
(103) Clamp clutch assembly (45)
in vise with soft jaws.
WARNING
When using compressed air, be sure to
use chip guarding and personal
protective equipment, (goggles/shield,
gloves, etc.) to avoid personal injury.
(104) Apply compressed air at 100 psi
(690 kPa) and spin fan hub (27)
four times. Fan hub should turn
easily.
(105) Remove compressed air. Turn fan
hub (27) with socket extension
installed in 1/2 in. drive hole (57)
in tool No. 5. Fan hub should
require 140 lb-ft (189.84 N°m) to
turn.
(106) Remove tool No. 5, two tools
No. 11, and two 1/2-13 x 2 in. (51 mm) screws from fan hub (27).
d. Follow-on Maintenance. None.
END OF TASK
18-19/(18-20 blank)
TM 9-2815-224-34&P
CHAPTER 19
ENGINE
TUNE-UP
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Brake Retarder Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector Timing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Gap Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector Rack Control Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Aid Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Delay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Modulator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Speed Control Adjustment (M984) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EngineCompressionCheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
19-1
19-1
19-4
19-6
19-8
19-9
19-19
19-21
19-22.1
19-22.4
19-27
19-31
Para
19-1
19-2
19-3
19-4
19-5
19-6
19-7
19-8
19-8.1
19-9
19-10
19-11
Section I. INTRODUCTION
19-1. GENERAL. This chapter covers tune-up instructions for the 8V92TA engine. Adjustments are given
for exhaust valve clearance, brake retarder adjustment, fuel injector timing, governor adjustments, injector rack
control lever, starting aid screw, throttle delay, engine speed adjustments, and compression check. The
subassemblies and parts which must be removed before engine tune-up will be referenced to other paragraphs
of this manual, TM 9-2320-279-10, TM 9-2320-279-20, or TM 9-2320-279-34.
Section II. ENGINE TUNE-UP ADJUSTMENTS
Engine Tune-Up Instructions
19-2.
EXHAUST VALVE CLEARANCE ADJUSTMENT.
This task covers:
a. Adjustment
b. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Gage, feeler 007958
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-10 Valve rocker covers
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
References
None
Change 2
19-1
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
1 9 - 2 . EXHAUST VALVE CLEARANCE ADJUSTMENT (CONT).
a. Adjustment.
NOTE
Pull control lever fully toward operator for no fuel position.
(1) Soldier A rotates crankshaft by turning pulley (1) clockwise while Soldier B holds rack control
lever (2) in the no-fuel position and tells Soldier A when injector follower (3) is fully depressed.
(2) Loosen locknut (4) on exhaust valve rocker arm push rod (5).
19-2
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
NOTE
Use 0.016 in. feeler gage for cold setting.
(3)
Insert feeler gage between valve bridge (6) and valve rocker arm pallet (7).
(4)
(5)
Adjust push rod (5) until slight drag is felt on feeler gage.
Remove feeler gage and tighten push rod locknut (4). Recheck clearance.
Change 2
19-3
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-2. EXHAUST VALVE CLEARANCE ADJUSTMENT (CONT).
NOTE
Final exhaust valve clearance
check is done after engine has
been running.
(6) Repeat steps (1) through (5) to
adjust exhaust valves (8) on
remaining seven cylinders.
(7) Start engine and operate for
15 minutes
(TM 9-2320-279-10).
(8) Stop engine and check exhaust
valve (8) clearance. Follow
steps (1) through (5) if further
adjustment is necessary.
b. Follow-on Maintenance. Adjust engine brake retarders (para 19-3).
END OF TASK
19-3. ENGINE BRAKE RETARDER ADJUSTMENT.
This task covers:
a. Adjustment
b. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Equipment Condition
TM or Para
Para 19-2
Condition Description
Exhaust valve clearance
adjusted.
Special Tools
Gage, feeler 007958
Special Environmental Conditions
None
Supplies
None
General Safety Instructions
None
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
Level of Maintenance
Direct Support
References
None
19-4
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
a. Adjustment.
CAUTION
To prevent engine damage make sure exhaust valves are closed and injector
follower is fully depressed.
(1)
(2)
(3)
(4)
Insert 0.059-in. feeler gage between slave piston foot (1) and exhaust valve bridge (2).
Loosen locknut (3) and turn adjusting screw (4) until a slight drag is felt on feeler gage.
Check both feet of slave piston (5).
Hold adjusting screw (4). Tighten locknut (3) to 15 to 18 lb-ft (20 to 24 N.m) and recheck
clearance.
b. Follow-on Maintenance.
(1) Install valve rocker cover (TM 9-2320-279-20).
(2) Start engine and operate for 10 minutes (TM 9-2320-279-10).
(3) Turn on engine brake switch (TM 9-2320-279-10).
(4) Open throttle to full engine speed and release.
(5) Check brake operation while engine is returning to idle.
(6) Repeat full-throttle and release procedure six to eight times to bleed air from engine brake
system.
(7) Turn off engine (TM 9-2320-279- 10).
(8) Adjust fuel injector timing (para 19-4).
END OF TASK
19-5
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-4.
FUEL INJECTOR TIMING ADJUSTMENT.
This task covers:
a. Adjustment
b. Follow-on Maintenance
INITIAL SETUP
References
Models
None
All
Test Equipment
None
Para 19-3
Special Tools
Gage, injector J34610 (engines equipped
with throttle delay only)
Gage, injector J25502 (engines equipped
with fuel modulator only)
Supplies
Engine brake retarder
adjusted.
TM 9-2320-279-20 Valve rocker covers
removed.
Special Environmental Conditions
None
None
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
19-6
Condition Description
General Safety Instructions
None
a.
Equipment Condition
TM or Para
Adjustment.
Change 3
Level of Maintenance
Direct Support
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
(1)
Soldier B rotates crankshaft by turning pulley (1) clockwise while Soldier A holds fuel rod
clevis (2) in the no-fuel position and tells Soldier B when exhaust valves (3) are fully opened.
NOTE
Flat side of injector gage faces injector
follower.
(2)
(3)
(4)
(5)
(6)
(7)
Insert 1.466 in. injector gage (engines
with throttle delay) or 1.52 in.
injector gage (engines with fuel
modulator) in hole at top of fuel
injector body (4).
Loosen locknut (5) on injector rocker
arm push rod (6).
Turn push rod (6) and adjust injector
rocker arm (7) so flat side of injector
gage passes just over top of injector
follower (8).
Hold push rod (6) and tighten
locknut (5).
Push injector gage into fuel injector
body (4) and recheck clearance of
injector follower (8). If clearance is
wrong repeat steps (2) through (5).
Adjust timing of remaining seven fuel
injectors (9) following steps (1)
through (6).
b. Follow-on Maintenance. Adjust
governor gap (para 19-5).
END OF TASK
Change 3
19-7
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-5. GOVERNOR GAP ADJUSTMENT.
This task covers:
a. Adjustment
b. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Equipment Condition
TM or Para
Para 19-4
Para 15-4
Condition Description
Fuel injector timing adjusted.
Governor cover removed.
Special Tools
Gage, governor gap J23478
Special Environmental Conditions
None
Supplies
None
General Safety Instructions
None
Personnel Required
MOS 63W, Wheel vehicle repairer
Level of Maintenance
Direct Support
References
None
a.
19-8
Adjustment.
PIN: 063616-003
TM 9-2815-224-34&P
Engine Tune-Up Instructions
NOTE
Clearance required is 0.200-m. (5.08 mm).
Be sure starting aid screw is backed out enough to make it ineffective when making
adjustment. Starting aid screw is only used with engines prior to serial number
8VF-106635.
(1)
(2)
Check gap between low speed spring cap (1) and high speed spring plunger (2) using governor
gap gage.
Loosen nut (3) and adjust screw (4) to obtain proper clearance.
b. Follow-on Maintenance.
(1)
(2)
Install governor cover (para 15-4).
Adjust injector rack control lever (para 19-6).
END OF TASK
19-6.
INJECTOR RACK CONTROL LEVER ADJUSTMENT.
This task covers:
a. Adjustment
b. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
None
Equipment Condition
Condition Description
TM or Para
Fuel injection timing
Para 19-4
adjusted.
Governor gap adjusted.
Para 19-5
Buffer screw switch
Para 15-7
removed.
Fuel modulator clamp
Para 15-5.1
removed from injector
control tube (engines
equipped with fuel
modulator only).
I
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Change 2
19-9
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-6.
INJECTOR RACK CONTROL LEVER ADJUSTMENT (CONT).
a. Adjustment.
NOTE
Buffer screw will turn with locknut.
(1) Loosen buffer screw (1) by turning locknut (2) until face (3) of locknut (2) is 5/8-in. (15.89 mm)
from governor housing (4).
NOTE
Adjustment is same for right and
left hand cylinder head banks.
Right hand clevis lever is
disconnected to adjust left
cylinder number one.
(2) Remove cotter pin (5) and
clevis pin (6) from fuel rod (7)
and injector rack clevis
lever (8).
(3) Loosen two nuts (9) from
throttle delay (10).
TA357564
19-10
TM9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
NOTE
False fuel rack setting may result if
idle speed adjusting screw is not
backed out.
(4) Loosen locknut (11) and remove
idle screw (12) half way,
approximately 12 to 14 threads.
(5) Loosen four locknuts (13) and screws (14) on left hand cylinder head
19-11
TM9-2815-224-34&P
Engine Tune-Up Instructions (Cent)
19-6. INJECTOR RACK CONTROL LEVER ADJUSTMENT (CONT).
NOTE
Full fuel position is reached when
injector rack is completely in.
Adjust number one injector rack
control lever (right or left cylinder
head) first to establish guide for
remaining three cylinder control
racks,
Number 1 left and number 1 right
are only two preloaded cylinders.
CAUTION
Do not over tighten injector rack control
lever adjusting screws. Over tightened
screws can damage injector control tube.
(6) Soldier A pulls throttle control arm (16) to full fuel position and holds arm with light pressure
while Soldier B stands by to make adjustment.
(7) While Soldier A maintains full fuel position, Soldier B tightens adjusting screw (14) until injector
control lever (17) starts slight rotation. Tight en additional 1/8 turn, then hold adjusting screw
and tighten locknut (13) to 24 to 35 lb-in (2.712
4.068 N°m).
19-12
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
(8)
(9)
Remove cotter pin (18) and
clevis pin (19).
Disconnect fuel rod (20) from
clevis lever (21).
LEFT
BANK
(10)
Install fuel rod (7) into clevis lever (8) with clevis pin (6).
Change 2
19-13
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
1 9 - 6 . INJECTOR RACK CONTROL LEVER ADJUSTMENT (CONT).
(11) Loosen four locknuts (22) and screws (23) on right cylinder head (24).
TA357572
NOTE
. Full fuel position is reached when the injector rack is completely in.
. Adjust number one injector rack control lever (right or left cylinder head) first
to establish a guide for remaining three cylinder control racks.
(12) Soldier A pulls throttle control arm (16) to full fuel position and holds arm with light pressure
while Soldier B stands by to make adjustment.
19-14
TM9-2815-224-34&P
(13) While Soldier A maintains full fuel position, Soldier B tightens adjusting screw (23) until injector
rack control lever (25) starts slight rotation. Tighten additional 1/8 turn, then hold adjusting
screw and tighten locknut (22) to 25 to 35 lb-in (2.712 to 4.068 N°m).
(14) Connect fuel rod (20) to clevis lever (21) with clevis pin (19).
(15) Check drag on both clevis pins (6 and 19). If drag is not equal, readjust number one right until
drag is equal to number one left.
(16) Remove clevis pin (6) from fuel rod (7) and clevis lever (8).
19-15
TM9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-6. INJECTOR RACK CONTROL LEVER ADJUSTMENT (CONT).
(17) Hold clevis lever (8) out in full fuel position and tighten adjusting screw (23) until injector
rack (25) starts a slight rotation.
(18) Hold adjusting screw (23) and tighten locknut (22) to 25 to 35 lb-in. (92.712 to 4.068 N°m).
(19) Repeat steps (17) and (18) for remaining two injector control levers (26).
19-16
TM9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
(20) Connect fuel rod (7) to clevis lever (8) with clevis pin (6).
(21) Install cotter pin (5).
(22) Hold clevis lever (21) out in full fuel position and tighten adjusting screw (14) until injector
rack (17) starts a slight rotation.
(23) Hold adjusting screw (14) and tighten locknut (13) to 25 to 35 lb-in. (2.712 to 4.068 N°m).
(24) Repeat steps (22) and (23) for remaining two injector control levers (27),
19-17
TM9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-6. INJECTOR RACK CONTROL LEVER ADJUSTMENT (CONT).
(25) Connect fuel rod (20) to clevis lever (21) with
clevis pin (19).
(26) Install cotter pin (18).
NOTE
When moving from no fuel to full fuel, if injector rack is fully in before full fuel
position is reached, rack setting is too tight. Readjust injectors.
(27) Hold throttle control arm (16) in full fuel position. Using a screwdriver, press downward on
injector rack. Rack should tilt downward. When pressure is released, rack should spring back
upward. If injectors do not spring back, injector rack is too loose.
19-18
TM 9-2815-224-34&P
Engine Tune-Up Instructions
b. Follow-on Maintenance.
(1)
(2)
(3)
(4)
(5)
Install
Adjust
Adjust
Adjust
Install
buffer screw switch (para 15-7).
buffer screw switch (para 15-7).
starting aid screw (para 19-7).
throttle delay (para 19-8).
fuel modulator clamp (engines equipped with fuel modulator only) (para 15-5.1).
END OF TASK
19-7.
STARTING AID SCREW ADJUSTMENT.
This task covers:
a. Starting Aid Screw Adjustment
b. Follow-on Maintenance
INITIAL SETUP
Models
All engines prior to serial number
8VF-106635.
Test Equipment
None
Special Tools
None
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-20 Air intake ducting removed.
Injector rack control levers
Para 19-6
adjusted.
Throttle air cylinder
Para 15-8
removed.
Spring housing removed.
Para 15-6
Engine speed adjusted.
Para 19-9
Special Environmental Conditions
None
General Safely Instructions
None
Level of Maintenance
Direct Support
Change 2
19-19
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
1 9 - 7 . STARTING AID SCREW ADJUSTMENT (CONT).
a. Starting Aid Screw Adjustment.
NOTE
Starting aid screw setting is 0.454-in. (11.53 mm) between injector body and
shoulder of injector rack control clevis.
(1) Loosen locknut (1) and turn screw (2) out until it stops.
(2) Insert gage from tune up kit between injector rack clevis (3) and injector body (4).
(3) Turn starting aid screw (2) until gage pivots freely then tighten locknut (1).
(4) Back idle screw (5) out until it is free from piston,
(5) Turn idle screw (5) in three turns.
(6) Install locknut (6) finger tight.
b. Follow-on Maintenance.
(1) Install air intake ducting (TM 9-2320-279-10).
(2) Install throttle air cylinder (para 15-8).
(3) Adjust engine speed (para 19-9).
END OF TASK
19-20
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-8.
THROTTLE DELAY ADJUSTMENT.
This task covers:
b. Follow-on Maintenance
a. Adjustment
INITIAL SETUP
Equipment Condition
TM or Para
Para 19-7
TM 9-2320-279-20
Para 19-6
Models
All
Test Equipment
None
Para 15-8
Para 15-6
Para 19-9
Special Tools
Gage, pin, throttle, J25558
Gage, throttle delay, J25560
Condition Description
Starting aid screw adjusted.
Air intake ducting removed.
Injector rack control levers
adjusted.
Throttle air cylinder removed.
Spring housing removed.
Engine speed adjusted.
Supplies
None
Special Environmental Conditions
None
Personnel Required
MOS 63W, Wheel vehicle repairer
General Safety Instructions
None
References
None
Level of Maintenance
Direct Support
a. Adjustment
NOTE
Use 0.636 in. gage for throttle delay.
(1)
(2)
Insert throttle delay cylinder gage on injector control rack (1).
Push throttle lever (2) down until gage is held securely.
Change 2
19-21
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-8. THROTTLE DELAY ADJUSTMENT (CONT).
(3)
(4)
Insert throttle delay cylinder pin
gage in fill hole in cylinder (3) using
0.072-in. end of gage. If gage goes
into hole, do steps (4) through (7).
Loosen two nuts (4) on U-bolt (5) and
insert gage.
CAUTION
Do not bend pin gage or use excessive force.
(5)
(6)
(7)
(8)
(9)
Rotate throttle delay lever (6) and
move piston (7) inward to contact
throttle delay cylinder pin gage.
Tighten two nuts (4) while lightly
pressing throttle delay lever (6).
Remove cylinder pin gage.
While keeping a light pressure
against cylinder gage insert 0.072-in.
end of pin gage. If adjusted correctly,
0.072-in. end will not go in, but
0.069-in. end will.
Remove both gages from cylinder
head (8).
b. Follow-on Maintenance.
(1)
(2)
Install throttle air cylinder (para 15-8).
Adjust engine speed (para 19-9).
END OF TASK
19-22
Change 2
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-8.1
FUEL MODULATOR ADJUSTMENT.
This task covers:
a. Adjustment
b. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-20 Air intake ducting removed.
Injector rack control levers
Para 19-6
adjusted.
Throttle air cylinder removed.
Para 15-8
Spring housing removed.
Para 15-6
Para 19-9
Engine speed adjusted.
Special Tools
Gage, injector rack, J34080
Fabricated Tools
Gage, feeler, 0.004 in. (0.102 mm)
Gage, feeler, 0.005 in. (0.127 mm)
Gage, feeler, 0.017 in. (0.432 mm)
Supplies
None
Personnrl Required
MOS 63W, Wheel vehicle repairer
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
NOTE
Use the injector next to and forward of the fuel modulator assembly.
(1)
(2)
Insert injector rack gage on injector control rack (1) so that handle is at approximately 45 degree
angle.
Position governor lever (2) toward maximum speed position and run/stop lever (3) in run
position. The injector rack gage must stand up while being held in place by the rack.
Change 2
19-22.1
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-8.1
(3)
(4)
FUEL MODULATOR ADJUSTMENT (CONT).
Loosen screw (4) and push lever assembly (5) until roller (6) contacts cam (7) with sufficient force
to remove all slack.
Insert a 0.017 inch (0.4318 mm) feeler gage between cam (7) and roller (6).
NOTE
Ensure cam is centered.
(5)
(6)
(7)
19-22.2
Tighten clamp screw (4) until feeler gage falls.
Replace 0.017 inch feeler gage with a 0.004 inch (0.1016 mm) feeler gage.
Tighten clamp screw (4) until 0.004 inch (0.1016 mm) feeler gage falls.
Change 2
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
NOTE
When 0.004 (0.1016 mm) feeler gage is removed from
between cam and roller, injector control rack pressure
should hold injector rack gage at approximately a 45
degree angle. When 0.005 inch (0.127 mm) feeler gage
is placed between cam and roller, injector rack gage
should fall.
(8)
b.
Verify proper adjustment by inserting a 0.005
inch (0.127 mm) feeler gage between cam (7)
and roller (6). If injector rack gage does not
fall, repeat steps (1) through (8).
Follow-on Maintenance.
(1)
(2)
(3)
Install air intake ducting (TM 9-2320-279-20).
Install throttle air cylinder (para 15-8).
Adjust engine speed (para 19-9).
END OF TASK
Change 2
19-22.3
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-9.
ENGINE SPEED ADJUSTMENTS,
This task covers:
a. Maximum No-Load Speed Adjustment
b. Engine Idle Speed and Buffer Screw
Adjustment
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Shield, inlet J26554-A
Equipment Condition
TM or Pam
Condition Description
Para 19-8
Throttle delay adjusted
(engines equipped with
throttle delay only).
Para 19-8.1
Fuel modulator adjusted
(engines equipped with
fuel modulator only).
TM 9-2320-279-20 Fan removed.
Supplies
None
Special Environmental Conditions
None
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
General Safely Instructions
None
References
None
Level of Maintenance
Direct Support
19-22.4
Change 2
TM 9-2815-224-34&P
Engine Tune-Up instructions (Cord)
a. Maximum No-Load Speed Adjustment.
TA357583
(1) Soldier A loosens spring retainer locknut (1) while Soldier B is in cab.
(2) Loosen high speed spring retainer (2) five turns.
(3) Install inlet shield on air inlet port (3).
WARNING
. Wear ear protection when running engine. Noise volume of engine can cause
hearing loss or injury.
. Do not touch hot engine with bare hands. Manifolds and covers are hot and
can cause severe bums if touched.
CAUTION
Run engine in clean area when air intake ducting is removed. Dirt, dust, and
particles in unfiltered air can enter engine intake and damage parts or cause
mechanical failure.
(4) When told by Soldier A, Soldier B starts engine (TM 9-2320-279-10).
(5) Operate engine for 15 minutes.
NOTE
Maximum no-load speed is 2300 rpm.
Tighten high speed spring retainer (2) until engine runs at maximum no-load speed.
Hold high speed spring retainer (2) and tighten locknut (1).
19-23
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-9.
b.
ENGINE SPEED ADJUSTMENTS (CONT).
Engine Idle Speed, Buffer Screw and Buffer Switch Adjustment.
NOTE
l
l
(1)
There are three styles of buffer switches, Model A Model B and Model C.
Buffer screw and buffer switch will turn out with locknut.
Adjust maximum no-load engine speed (para 19-9).
NOTE
Perform step (1.1) for Model B and Model C buffer switches.
(1.1) Tag, mark and remove wires (0.1) from buffer switch (0.2).
NOTE
(3)
(4)
(5)
I
Perform step (2) for Model A buffer switch.
Loosen nut (1) and remove buffer switch (2)and bracket (3).
Loosen locknut (4) and back out to 0.65in. (15.88 mm) from governor housing (5).
Loosen locknut (6) from idle adjusting
screw (7).
When told by Soldier A, Soldier B starts
engine and operates for 15 minutes
(TM 9-2320-279-10).
NOTE
Correct engine idle speed is 675-725 rpm.
(6)
(7)
(8)
Turn idle adjusting screw (7) to correct
engine idle speed.
Tighten locknut (6) when correct engine
idle speed is reached.
When told by Soldier A, Soldier B stops
engine.
NOTE
Gasket is not replaced unless damaged.
(9) Install high speed spring retainer cover (8) with two screws (9) and lockwashers (10).
(10) Install air hose (11) on cover (8).
(11) Remove inlet shield.
19-24 Change 2
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
(12)
(13)
Install air intake ducting (TM 9-2320-279-20).
When told by Soldier A, Soldier B starts engine and operates for 15 minutes.
CAUTION
Do not increase engine speed more than 15 rpm with buffer screw or buffer switch.
Excessive engine speed can damage engine components.
(14)
Soldier A turns buffer screw (12) or buffer switch (0.2) and locknut (4) until it contacts
differential lever (13) as lightly as possible and still remove engine roll. Soldier B remains in cab.
CAUTION
Maximum engine speed cannot exceed 2325 rpm. Excessive engine speed can
damage engine components.
(15)
(16)
(17)
When told by Soldier A, Soldier B increases engine speed to maximum engine speed and notes
rpm reading.
Release throttle and let engine return to idle.
Soldier A holds buffer screw (12), or buffer switch (0.2), tightens locknut (4), and tells Soldier B
to stop engine.
NOTE
Perform step (17.1) for Model B and Model C buffer switches.
(17.1) Connect wires (0.1), as tagged during removal, to buffer switch (0.2)
Change 2
19-25
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-9.
ENGINE SPEED ADJUSTMENTS (CONT).
NOTE
Perform step (18) for Model A buffer switch.
(16)
C.
Install bracket (3) and switch (2).
Follow-on Maintenance.
(1)
(2)
(3)
(4)
(5)
Install
Install
Install
Install
Close
END OF TASK
19-26 Change 2
spring housing (para 15-6).
valve rocker covers (TM 9-2320-279-10).
fan (TM 9-2320-279-20).
engine side panels (TM 9-2320-279-10).
engine covers (TM 9-2320-279-10).
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-10. ENGINE SPEED CONTROL ADJUSTMENT (M984).
This task covers:
a. Maximum Load Speed Adjustment
b. Engine Idle Speed Adjustment
c. Follow-on Maintenance
INITIAL SETUP
Models
Equipment Condition
M984
Test Equipment
None
Special Tools
Shield, inlet J26554-A
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
TM or Para
Condition Description
Para 19-8
Throttle delay adjusted.
TM 9-2320-279-10 Engine side panels removed.
TM 9-2320-279-20 Air intake ducting removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
None
a. Maximum Load Speed
Adjustment.
NOTE
● Engine speed control
adjustment for M984 Heavy
Duty Winch operation.
● Tag and mark wires before
disconnecting.
(1) Disconnect two wires (1)
from connectors (2) and
solenoids (3) on selector
valve (4).
19-27
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-10. ENGINE SPEED CONTROL ADJUSTMENT (M984) (CONT).
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Disconnect air hose (5) from cover (6).
Remove two screws (7), lockwashers (8), cover (6), and gasket (9).
With Soldier B in cab, Soldier A loosens idle speed locknut (10).
Turn idle adjusting screw (11) clockwise until-snug.
Tighten idle speed locknut (10).
Loosen high speed locknut (12).
Install inlet shield on air inlet port (13).
WARNING
• Wear ear protection when running engine. Noise volume of engine can cause
hearing loss or injury.
• Do not touch hot engine with bare hands. Manifolds and covers are hot and
can cause severe burns if touched.
CAUTION
Run engine in clean area when air intake ducting is removed. Dirt, dust, and
particles in unfiltered air can enter engine intake and damage parts or cause
mechanical failure.
(9) When told by Soldier A, Soldier B starts engine (TM 9-2320-279-10).
(10) Operate engine for 15 minutes.
19-28
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
(11) Engage PTO switch (TM 9-2320-279-10).
(12) Activate high idle at either high idle box (14 or 15) (TM 9-2320-279-10).
NOTE
Maximum load speed is 1800 rpm.
(13)
(14)
(15)
(16)
Turn air cylinder (16) clockwise to correct engine speed.
Tighten high speed locknut (12).
Shut off high idle (TM 9-2320-279-10).
Stop engine (TM 9-2320-279- 10).
19-29
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-10. ENGINE SPEED CONTROL ADJUSTMENT (M984) (CONT).
b. Engine Idle Speed Adjustment.
(1) Soldier A loosens idle speed
locknut (1) while Soldier B is in
cab.
(2) When told by Soldier A,
Soldier B starts engine
(TM 9-2320-279-10).
NOTE
Correct engine speed is 700 rpm.
(3) Turn idle adjusting screw (2)
counterclockwise to correct
engine speed.
(4) Tighten idle speed locknut (1).
(5) Soldier B stops engine when told
by Soldier A (TM 9-2320-279-10).
NOTE
Gasket is not replaced unless damaged.
(6) Install high speed spring retainer cover (3) with two screws (4), lockwashers (5), and gasket (6).
(7) Install air hose (7) on cover (3).
(8) Connect two wires (8) to
connectors (9) and
solenoids (10) on selector
valve (11).
c. Follow-on Maintenance.
(1) Air intake ducting installed (TM 9-2320-279-20).
(2) Install engine side panels (TM 9-2320-279-10).
(3) Close engine covers (TM 9-2320-279-20).
END OF TASK
19-30
Change 1
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
19-11. ENGINE COMPRESSION CHECK.
This task covers:
a. Compression Check
b. Follow-on Maintenance
INITlAL SETUP
Models
Ail
References
None
Test Equipment
None
Equipment Condition
Special Tools
Gage, cylinder compression J7334-04
Wrench, fuel line J-8932-01
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer
TM or Pam
Para 11-2
condition Description
Engine brake retarder
removed.
Special Enwvironmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. compression Check.
(1) Start engine and run until normal operating temperature is reached.
(2) Stop engine. Remove fuel pipes (1 and 2) from injector (3) and fuel connectors (4).
19-31
TM 9-2815-224-34&P
Engine Tune-Up instructions (Cont)
19-11. ENGINE COMPRESSION CHECK (Cont).
(3)
(4)
(5)
Remove fuel injector (para 12-2).
Install adapter and gage.
Install bolt, clamp, and convex
washer, tighten to 20-25 ft-lb
(27-34 N•m).
CAUTION
Shorter screws must be used with retarders
off. Check shorter screws for oil passage
hole. If shorter screws are not used,
equipment damage could occur,
(6)
(7)
Secure rocker arm pin and supports
using shorter screws. Tighten
to 45 (61) then 88-92 ft-lb
(119-125 N•m).
Install adapter and gage.
(8)
Install jumper connection (5) between fuel inlet (6) and return manifold connector (7).
NOTE
Engine must be running to obtain compression.
(9)
Start engine and run at 600 to 670 rpm. Record compression pressure shown on gage.
NOTE
The compression pressure in any one cylinder at a given altitude above sea level
must not be less than the minimum shown in Table 19-1. The variation in
compression pressures between cylinders must not exceed 25 psi (172 kPa) at 635
rpm.
(10)
Repeat steps 3 through 9 on each cylinder.
19-32 Change 2
TM 9-2815-224-34&P
Engine Tune-Up Instructions (Cont)
Table 19-1. Compression Pressure Specifications
Minimum Compression
psi
kPa
450
3101
415
385
355
330
2859
2653
2446
2274
I
I
feet
meters
500
2,500
5,000
7,500
10,000
152
762
1,524
2,286
.0715
.0663
.0613
.0567
3,048
.0525
+ Air density at 500 feet altitude based on 85°F (29.4 °C) and 29.38 in. Hg
(99.49 kPa) wet barometer.
b. Follow-on Maintenance.
(1) Install engine brake retarder (para 11-2).
(2) Install valve rocker covers (TM 9-2320-279-20).
END OF TASK
19-33/(19-34
blank)
TM
9-2815-224-34&P
APPENDIX A
REFERENCES
A - l . SCOPE. This appendix lists all forms, field manuals, technical manuals, and other publications
referenced in this manual. Also, those publications that should be consulted for additional information
about vehicle operations are listed.
A-2. PUBLICATION INDEXES.
The following indexes should be consulted frequently for latest
changes or revisions and for new publications relating to material covered in this technical manual.
Consolidated Index of Army Publications and Blank Forms
DA Pam 310-l
A - 3 . FORMS. The following forms pertain to this manual. Refer to DA Pamphlet 310-1 for index of
blank forms.
Equipment Control Record (DA Form 2408-9)).
Equipment Inspection and Maintenance Worksheet (DA Form 2404).
Maintenance Request (DA Form 2407).
Recommended Changes to DA Publications and Blank Forms (DA Form 2028).
Refer to DA PAM 738-750, The Army Maintenance Management Systems (TAMMS), for instructions for
the use of maintenance forms pertaining to this material.
A-4. OTHER PUBLICATIONS.
The following publications contain information pertinent to the M977
series vehicles and associated equipment.
a. Safety.
First Aid for Soldiers
Safety Inspection and Testing of Lifting Devices
Security of ‘Ihctical Wheeled Vehicles
b. Vehicle Operation.
Operator’s Manual. M977 Series Vehicles
c. Maintenance and Repair.
FM 21-11
TB 43-0142
TB 9-2300-422-20
TM g-2320-279-10
TM 9-2320-279-20
Organizational hlaintenance Manual for MH77 Series
L0 9-2320-279-12
Lubrication Order for M977 Series Vehicles
TM 9-2320-279-20P
Organizational Repair Parts and Special Tools List for M977 Series Vehicles
TM 9-2320-279-34
Direct Support and General Support Maintenance for M977 Series Vehicles
TM 750-254
Cooling Systems: Tactical Vehicles
TB 750-651
Use of Antifreeze Solutions and Cleaning Compounds in Engine Cooling Systems
TB ORD 1032
Description, Use. Bonding Techniques, and Properties of Adhesives.
Materials L’sed for Cleaning, Preserving, Abrading, and Cementing Ordnance Materiel and
TM 9-247
Related Materiels Including Chemicals
TM 9-214
Inspection, Care, and Maintenance of Antifriction Bearings
TM 9-243
Care and Use of Handtools and Measuring Tools.
Operator’s Organizational. Direct Support, and General Support Maintenance Manual
TM 9-6140-200-14
for Lead-Acid Storage Batteries
d. Decontamination.
Chemical, Biological, and Radiological (CBR) Decontamination
TM 3-220
A-1
TM 9-2815-224-34&P
References (Cont)
A-4. OTHER PUBLICATIONS (CONT).
e.
General.
Hand Receipt Manual for M977 Series Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-279--10HR
Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use . . . . . . . . . TM 750-244-6
Principles of Automotive Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9--8000
Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF 368
Equipment Improvement Report and Maintenance Digest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0001-39
Equipment Improvement Report and Maintenance Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 43-1043
f.
Warranty.
Warranty Technical Bulletin for M977 Series Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2300-295-15/19
A-2/(B-1 thru B-65 deleted)
Change 4
TM 9-2815-224-34&P
Expendable Supplies and Materials List (Cont)
(1)
(2)
(3)
(4)
(5)
Item
Number
Level
National
Stock
Number
Description
U/M
22
O
6850-00-598-7328
23
24
25
O
C
F
26
F
27
F
28
29
F
F
5970-00-166--5697
5350-01-157-6916
8030-00-181-7603
8030-00-181-7529
30
30.1
F
F
8030-00-656-1426
31
O
32
O
8030-01-166-0675
33
O
5610-00-267-1533
34
35
35.1
36
O
F
F
C
37
38
39
F
F
F
9150-00-065-0029
9150-00-935-1017
9150-00-190-0904
9150-00-190-0905
9150-00-190-0907
9150-01-095-5512
9150-01-091-9336
Compound, Cleaning, Conditioner and Inhibitor for
Engine Cooling System (MIL-C-10597)
Package, Consisting of:
a. Cleaner, Part 1, Oxalic Acid.
b. Cleaner, Part 2, Aluminum Chloride.
c. Sodium Silicate Conditioner.
d. Alkaline Conditioner.
e. Inhibitor.
f. Instruction Sheet
Compound, Cleaning, Creosol Base (MIL-C-5546)
Compound, Corrosion Preventive (77493) NYK-77
Compound, Insulating, Electrical, Embedding
(MIL-C-47233)
Compound, International, No. 2 (5198563)
(FSCM 72582)
Compound, Lapping and Grinding J3179-5
(FSCM 58805) 1 pk No. 1 dry grain
Compound, Polishing 523028 (FSCM 58805)
Compound, Retaining - Loctite RC-620
50-cc
250-cc
Compound, Retaining (MIL-R-46082)
Compound, Sealing, Non-hardening (MIL-S-45180)
Type III, Permatex No. 3 (FSCM 77247)
Formagasket 3
1-pint can
Compound, Sealing, Lubricating, Wicking, Thread
Locking, Anaerobic, Single Component
(MIL-46163) Type I, Grade K
Compound, Sealing, Pipe Thread
(FSCM 05972) (702350-X)
Compound, Walkway, Nonslip
(MIL-W-5044)
Connector, Electrical, Butt 34072 (FSCM 04618)
Gage, Plastic PR 1
Gasket, Loctite Plastic (#56841) (FSCM 05972)
Grease, Automotive and Artillery GAA
(MIL-G-10924)
2-1/4 oz tube
14-oz cartridge
1-lb can
5-lb an
35-lb can
Grease, Ball Bearing, Lithium Base
Grease, General Purpose, Lithium Base
Grease, High Performance, Multi-purpose,
(MIL-G-24508)
Change 4
ea
ea
cc
cc
oz
gal
ea
oz
oz
lb
lb
lb
C-3
TM 9-2815-224-34&P
Expendable Supplier and Materials List (Cont)
(1)
(2)
Item
Number Level
(3)
(4)
(5)
National
Stock
Number
Description
U/M
40
F
9150-00-543-7220
Grease, Molybdenum Disulfide (MIL-2 1164)
41
O
9505-00-191-3680
Lockwire
42
F
6810-00-812-9181
Methyl Ethyl Ketone (MEK) TT-M-261 (MIL-T-27602)
43
C
9140-00-286-5286
9140-00-286-5287
9140-00-286-5288
9140-00-286-5289
44
C
9140-00-286-5294
9140-00-286-5295
9140-00-286-5296
9140-00-286-5297
45
C
9150-01-035-5390
9150-01-035-5393
9150-01-035-5391
46
C
48
5-gal drum
gal
9150-00-189-6727
9150-00-186-6668
1qt can
5-gal drum
55-gal drum, 16 gage
55-gal drum, 18 gage
Oil, Lubricating, OE/HDO 30 (SAE 30) (MIL-L-2104)
qt
gal
C
1qt can
5-gal drum
55-gal drum, 16 gage
55-gal drum, 18 gage
gal
gal
qt
gal
gal
Gil, Lubricating OE/HDO 50 (MIL-L-2104)
C
1qt can
5-gal drum
55-gal drum, 16 gage
Oil, Mineral
qt
gal
gal
Oil, Test, Fuel Injector J26400-5
(FSCM 58805)
5-gal can
C-4
gal
qt
gal
gal
C
O
F
qt
gal
1-qt can
5-gal drum
55-gal drum, 16 gage
Oil, Lubricating, OE/BDG 10 (MIL-L-2104)
9150-00-188-9864
9150-00-188-9865
9150-OO-188-9866
51
52
gal
gal
gal
gal
9150-00-402-4478
9150-00-402-2372
9150-00-491-7197
9150-00-186-6681
9150-00-188-9858
9150-00-265-9436
9150-00-189-6729
50
1-qt can
5-gal drum
55-gal drum
gal
gal
gal
Oil, Lubricating OEA Ice, Subzero (MIL-L-46167)
O
9150-00-191-2772
49
Bulk
5-gal can
55-gal drum, 16 gage
55-gaI drum, 18 gage
Oil, Lubricating Gear, GO 75 (MIL-L-2105C)
gal
Gil, Lubricating, Gear GO 80/90 (MIL-L-2105C)
9150-01-035-5393
47
Oil, Fuel, Diesel DF-1 Winter (W-F-800)
Bulk
5-gal can
55gal drum, 16 gage
55-gal drum, 18 gage
Oil, Fuel, Diesel DF-2 Regular (VV-F-800)
gal
gal
TM 9-2815-224-34&P
Expendable Supplies and Materials List (Cont)
(2)
(3)
(4)
(5)
Item
Number
Level
National
Stock
Number
Description
U/M
53
O
5350-00-186-8818
54
O
5350-00-224-7203
55
56
F
O
57
F
(1)
8030-00-062-5866
8030-00-244-1293
8030-00-244-1294
57.1
58
59
60
61
62
63
64
65
H
F
O
C
O
F
0
6850-00-664-5685
6850-00-281-1985
8135-00-178-9200
8030-00-398-4130
5970-00-644-3167
O
O
8010-00-181-8080
8010-00-181-8079
66
67
68
69
O
O
F
O
8010-01-131-6254
8010-01-131-6261
8010-01-141-2419
Paper, Abrasive, Garnet (Emery Cloth)
P-P-121
Paper, Abrasive, Silicon Carbide, Waterproof
P-P-101
Paper, Abrasive, 600 grit
Primer, Epoxy, 1-qt kit
Rust Preventive
(MIL-C-16173) Texaco Type
19AS436 (FSCM 45152)
1 gal
5 gal
55 gal
Sealant, Teflon (23520676) (FSCM 72582)
Screw, 5116-18 x 2 in.
Solder, Rosin Flux Core ASTM B 284-79
Solvent, Dry Cleaning SD (P-D-680)
1-qt can
l-gal can
Tags, Identification (MIL-T-12755) pk/1000
Tape, Antiseize, Tetrafluoroethylene
(MIL-T-27730)
Tape, Insulation, Electrical (MIL-T-50886)
3/4” 82.5 ft roll
Tape, Masking, A-A-883
Thinner, Aliphatic, Polyurethane Coating
(MIL-T-81772)
1 gal
5-gal drum
Ties, Cable, Plastic (MIL-S-29190)
Trichloroethylene (MIL-T-27602)
Tubing, Heat Shrinkable (MIL-T-47051)
Coating, Chemical Agent Resistant
CARC No. 383 Black (MIL-C-46168B)
1-qt kit
1-gal kit
5-gal kit
Change 2
kit
ea
gal
gal
gal
qt
gal
pk
ea
roll
gal
gal
kit
kit
kit
C-5/(C-6 blank)
TM 9-2815-224-34&P
APPENDIX D
ILLUSTRATED LIST OF MANUFACTURED ITEMS
Section I. INTRODUCTION
This appendix includes complete instructions for making items authorized to be manufactured or fabricated
at direct support and general support maintenance.
A parts number index in alphanumeric order is provided for cross-referencing the part number of the item to
be manufactured to the figure which covers fabrication criteria.
All bulk materials needed for manufacture of an item are listed by part number or specification number in a
tabular list on the illustration.
Section II. MANUFACTURED ITEMS PART NUMBER INDEX
Part No.
2BG623
2BH944
2BH945
2SK742
21021FX24
25351FX7W
2HK392
NSN
5120-00-789-0492
4720-00-676-7936
6145-01-074-7535
Description
Remover, Bearing Shell
Eyes, Lifting
Pliers, Retaining Ring
Holding Fixture, Turbocharger
Hose
Wire Assembly
Installation Tool, Wear Sleeve
Gage, Feeler
I
Fig. No.
D-1
D-2
D-3
D-4
D-5
D-6
D-7
D-8
Change
2
D-1
TM 9-2815-224-34&P
Illustrated list of Manufactured Items (Cont)
Section Ill. MANUFACTURED ITEMS ILLUSTRATION
NOTES:
1. FABRICATE FROM 3/8 INCH (9.52 MM) DLAMETER COLD ROLL STEEL.
2. HEAT AND FLATTEN END OVER 9 INCH (228.6MM) DIAMETER ROUND STOCK UNTIL
END IS 1/8 x 1/2 x 4-1/2 INCHES (3.17 x 12.7 x 114.3 MM).
3. ALL DIMENSIONS ARE IN INCHES (MM).
Figure D-1. Bearing Shell Remover (PIN 2BG623).
D-2
TM9-2815-224-34&P
Illustrated
NOTES:
1. FABRICATE FROM 1/2
2. THREAD SIZE 7/16
X
3. HEAT UNTHREADED
X
14
List of Manufactured
6 INCH (12.7
X
X
1 INCH (11.1
Items (Cont)
152.4 MM) COLD ROLLED STEEL.
X
355.6
X
25.4 MM) LONG.
END AND BEND OVER 1-1/4 INCH (651.5 MM) DIAMETER ROD.
4. ALL DIMENSIONS ARE IN INCHES (MM).
Figure
D-2.
Lifting
Eyes (PIN 2BH944).
D-3
TM9-2815-224-34&P
Illustrated
List of Manufactured
Items (Cont)
NOTES:
1. FABRICATE FROM SNAP RING PLIERS, NSN 5120-00-789-0492.
2. GRIND 1/2 INCH (12.7 MM) FROM END, 1-1/2 INCHES (38.1 MM) DOWN TC A
THICKNESS OF 5/8 INCHES (15.87 MM).
3. ALL DIMENSIONS ARE IN INCHES (MM).
Figure D-3.
D-4
Retaining Ring Pliers (PIN 2BH945).
TM9-2815-224-34&P
Illustrated
List of Manufactured
Items (Cont)
NOTES:
1. FABRICATE FROM 3/4 INCH (19.05 MM) EXTERIOR GRADE PLYWOOD.
2. DRILL 1-1/2 INCH (38. 1 MM) DIAMETER HOLE IN CENTER OF BASE.
3. DRILL FOUR 1/2 INCH (12.7 MM) DIAMETER HOLES IN CORNERS OF BASE.
4. ROUTE FOUR SLOTS 1/2 INCH (12.7 MM) DEEP, 3/4 INCH (38. 1 MM) WIDE, AND 6-5/8
INCHES (153.02 MM) LONG IN BASE.
5. FABRICATE TWO FINGERS FROM PLYWOOD 1-15/16 INCHES (49.2 1 MM) HIGH, 2-1/2
INCHES (63.5 MM) LONG, AND 1-1/4 INCH (31 .75 MM) WIDE.
6. GRIND BOTTOM OF FINGERS 23/32 INCH (18.25 MM) WIDE AND 7/16 INCH(11. 11 MM)
HIGH. CONTUR FRONT SURFACE OF FINGERS TO FIT TURBINE WHEEL BLADES.
7. ALL DIMENSIONS ARE IN INCHES (MM).
Figure D-4.
Turbocharger Holding Fixture (P/N 2SK742)
D-5
TM9-2815-224-34&P
Illustrated
List of Manufactured
Items (Cont)
NOTES:
1. FABRICATE FROM NSN 4720-00-676-7936
STOCK
2. USING SUITABLE KNIFE AND WORKING ON A CLEAN SURFACE, CUT HOSE TO 24
INCHES (610 MM).
3. ALL DIMENSIONS ARE IN INCHES (MM).
NOTES:
1. FABRICATE FROM NSN 6145-01-074-7535
2. USING SUITABLE WIRE CUTTERS
STOCK
CUT WIRE TO 7 INCHES (178 MM).
3. STRIP BOTH ENDS OF WIRE 1/4 INCH (6.3 MM).
4, CRIMP 55008-2 LUG TERMINAL ONTO END OF WIRE.
5. CRIMP 55006-6 LUG TERMINAL ONTO END OF WIRE.
6. ALL DIMENSIONS ARE IN INCHES (MM).
Figure D-6.
Wire Assembly (P/N 25351 FX7W)
U.S. S.
D-6
Change 1
GOVERNMENT
PRINTING
oFFICE:
1989
643-016/00053
TM 9-2815-224-34&P
Illustrated List of Manufactured Items (Cont)
NOTES:
1. FABRICATE FROM 2.50 INCH OUTSIDE DIAMETER X 1.50 INCH DIAMETER
(63.50 MM X 38.10 MM) TUBING.
2. BORE INSIDE DIAMETER TO 1.52-1.53 INCH (38.61-38.86 MM).
3. BORE ONE SIDE OF TUBING TO 1.880-1.885 INCH (47.75-47.88 MM) TO A
DEPTH OF 0.240-0.250 INCH (6.10-6.35 MM).
4. ALL DIMENSIONS ARE IN INCHES (MM).
Figure D-7 Wear Sleeve Installation Tool
Change
2
D-7
TM 9-2815-224-34&P
Illustrated List of Manufactured Items (Cont)
3/16
(4.78)
NOTES:
FABRICATE FROM FEELER GAGE STOCK OF THE FOLLOWING THICKNESSES:
1.
. 0.004 INCH (0.102 MM)
. 0.005 INCH (0.127 MM)
. 0.017 INCH (0.432 MM)
2.
CUT APPROPRIATE THICKNESS FEELER GAGE STOCK TO A SIZE OF 0.38 INCH (9.52 MM)
BY 3 INCH (76.2 MM).
3.
BEND FEELER GAGE AS SHOWN ABOVE.
4.
ALL DIMENSIONS ARE IN INCHES (MM).
Figure D-8. Feeler Gage [0.004 in. (0.102 mm), 0.005 in. (0.127 mm), 0.017 in. (0.432mm)]
D-8
Change 2
*U.S. GOVERNMENT PRNTlNG 0FFICE:1999-746-025/8011
TM9-2815-224-34&P
APPENDIX
TORQUE
E
LIMITS
I E-1. GENERAL. This section provides general torque limits for screws used on the M977 series
vehicles. Special torque limits are indicated in the maintenance procedures for applicable components. The
general torque limits given in this appendix shall be used when specific torque limits are not indicated in
the maintenance procedure. These general torque limits cannot be applied to screws that retain rubber
components. The rubber components will be damaged before the torque limit is reached. If a special torque
limit is not given in the maintenance instructions, tighten the screw or nut until it touches the metal
bracket then tighten it one more turn.
I E-2. TORQUE LIMITS. Table E-1 lists dry torque limits. Dry torque limits are used on screws that do
not have lubricants applied to the threads. Table E-2 lists wet torque limits. Wet torque limits are used on
screws that have high pressure lubricants applied to the threads.
I E-3. HOW TO USE TORQUE TABLE:I
(3) Under the heading SIZE, look down the left hand
column until you find the diameter of the screw you
are installing (there will usually be two lines
beginning with the same size).
(4) In the second column under SIZE, find the number of
threads per inch that matches the number of threads
you counted in step (2). (Not required for metric
screws. )
CAPSCREW
(1) Measure the diameter of the
screw you are installing.
Manufacturer’s marks
may vary. These are all
SAE Grade 5 (3-line).
HEAD MARKINGS
Metric screwsare of three
grades: 8.8, 10.9, and 12.9.
Grades & Manufacturer’s marks
appear on the screw head.
(5) To find the grade screw you are installing, match the
markings on the head to the correct picture of
CAPSCREW HEAD MARKINGS on the torque table.
TA357026
(2) Count the number of threads per
inch.
(6) Look down the column under the picture you found
in step (5) until you find the torque limit (in lb-ft or
N•mthe
for diameter and threads per inch of the
screw you are installing.
E-1
TM9-2815-224-34&P
Torque Limits (Cont)
Table E-l.
Torque Limits for Dry Fasteners
CAPSCREW HEAD MARKINGS
Manufacturer’s marks may vary.
These are all SAE Grade 5
(3-line).
TORQUE
SIZE
DIA.
INCHES
THREADS
PER INCH
SAE GRADE
NO. 5
SAE GRADE
NO. 2
MILLIMETERS
POUNDS
FEET
NEWTON
METERS
POUNDS
FEET
SAE GRADE
NO. 8
SAE GRADE
NO. 6 or 7
NEWTON
METERS
POUNDS
FEET
NEWTON
METERS
POUNDS
FEET
NEWTON
METERS
1/4
20
6.35
5
7
8
11
10
14
12
16
1/4
28
6.35
6
9
10
14
12
16
14
19
5/16
18
7.94
11
15
17
23
21
28
25
34
5/16
24
7.94
12
16
19
26
24
33
25
34
3/8
16
9.53
20
27
30
41
40
54
45
61
3/8
24
9.53
23
31
35
47
45
61
50
68
7/16
14
11.11
30
41
50
68
60
81
70
95
7/16
20
35
47
55
75
70
95
80
108
50
68
75
102
95
129
110
149
55
75
90
122
100
136
120
163
65
88
110
149
135
183
150
203
75
102
120
163
150
203
170
231
90
122
150
203
190
258
220
298
100
136
180
244
210
285
240
325
160
217
260
353
320
434
380
515
180
244
300
407
360
488
420
597
140
190
400
542
520
705
600
814
155
210
440
597
580
786
660
895
220
298
580
786
800
1085
900
1220
240
325
640
868
860
1166
1000
1356
300
407
800
1085
1120
1519
1280
1736
340
461
880
1193
1260
1709
1440
1953
420
570
1120
1519
1580
2142
1820
2468
2712
1/2
13
1/2
20
9/16
12
9/16
18
5/8
11
5/8
18
3/4
10
3/4
16
7/8
9
7/8
14
1
8
1
12
1-1/8
7
1-1/8
12
1-1/4
7
1-1/4
12
1-3/8
6
1-3/8
12
1-1/2
6
1-1/2
E-2
12
12.70
14.29
15.88
19.05
22.23
25.40
25.58
31.75
34.93
38.10
460
624
1240
1681
1760
2387
2000
560
759
1460
1980
2080
2820
2380
3227
640
868
1680
2278
2380
3227
2720
3688
740
1003
1940
2631
2780
3770
3160
4285
840
1139
2200
2983
3100
4204
3560
4827
TM9-2815-224-34&P
Torque Limits (Cont)
Table
E-2.
Torque Limits for Wet Fasteners
CAPSCREW HEAD MARKINGS
Manufacturer’s marks may vary.
These are all SAE Grade 5
(3-line).
SAE GRADE
NO. 2
SIZE
DIA.
INCHES
THREADS
PER INCH
MILLIMETERS
POUNDS
FEET
SAE GRADE
NO. 5
NEWTON
METERS
POUNDS
FEET
SAE GRADE
NO, 6 or 7
NEWTON
METERS
POUNDS
FEET
SAE GRADE
NO. 8
NEWTON
METERS
POUNDS
FEET
NEWTON
METERS
1/4
20
6.35
4
6
6
8
8
11
9
12
1/4
28
6.35
5
7
7
9
9
12
10
14
5/16
18
7.94
8
11
13
18
16
22
18
24
5/16
24
7.94
9
12
14
19
18
24
20
27
3/8
16
9.53
15
20
23
31
30
41
35
47
3/8
24
9.53
17
23
25
34
30
41
35
47
7/16
14
11.11
24
33
35
47
45
61
55
75
7/16
20
25
34
40
54
50
68
60
81
35
47
55
75
70
95
80
108
40
54
65
88
80
108
90
122
50
68
80
108
100
136
110
149
55
75
90
122
110
149
130
176
1/2
13
1/2
20
9/16
12
9/16
18
5/8
11
5/8
18
3/4
10
3/4
16
7/8
9
7/8
14
1
8
1
12
1-1/8
7
1-1/8
12
1-1/4
7
1-1/4
12
1-3/8
6
1-3/8
12
1-1/2
6
1-1/2
12
12.70
14.29
15.88
19.05
22.23
25.40
25.58
31.75
34.93
38.10
70
95
110
149
140
190
170
231
80
108
130
176
160
217
180
244
120
163
200
271
240
325
280
380
140
190
220
298
280
380
320
434
110
149
300
407
400
542
460
624
120
163
320
434
440
597
500
678
160
217
440
597
600
814
680
922
170
231
480
651
660
895
740
1003
220
298
600
814
840
1139
960
1302
260
353
660
895
940
1275
1080
1464
320
434
840
1139
1100
1492
1360
1844
360
488
920
1248
1320
1790
1500
2034
1780
2414
420
570
1100
1492
1560
2115
460
624
1260
1709
1780
2414
2040
2766
560
760
1460
1980
2080
2820
2360
3200
620
841
1640
2224
2320
3146
2660
3607
E-3/( E-4 blank)
TM 9-281 5-224-34&P
INDEX
Paragraph,
Figure, Table
Number
Subject
A
Adapter, air inlet removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aftercooler
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air box covers removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air box drains removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air cylinder, throttle removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air inlet adapter removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arm, rocker removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B
Balance cover, front removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing bushing, camshaft end removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing, main, and crankshaft removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block, engine
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower accessory drive hub removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower drive seal ring removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower drive support removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Box covers,air removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Box drains,air removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake retarder, engine
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake wire harness,engine removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breather tube, cylinder block removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bridge guide,valve removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bridge, exhaust valve removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Buffer screw switch removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, camshaft end bearing removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c
Cam follower repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cam follower/push rod removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Repair/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft end bearing and bushing removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch, fan
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common tools and equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression check, engine... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting rod removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting rod, and liner, piston removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting rod maintenance, and piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-5
16-1
16-2
3-5
3-6
15-8
14-5
7-5
7-12
7-10
4-5
3-1
3-2
14-1
14-3
14-4
10-3
10-4
10-2
3-5
3-6
11-1
11-2
19-3
11-3
11-4
8-2
7-2
7-8
15-7
7-10
7-7
7-6
7-1
7-9
7-10
18-1
18-2
2-2
19-11
6-2
6-2
6-1
TM 9-281 5-224-34&P
INDEX (CONT)
Paragraph,
Figure, Table
Number
19-10
19-6
12-5
3-5
4-6
7-12
15-4
4-6
4-5
4-1
4-2
Subject
Control adjustment, engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control lever, adjustment, injector rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control tube, injector removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, air box removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, crankshaft removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, front balance removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, governor removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft cover removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft, main bearing and removal/repair/installation. ... . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft pulley removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder, throttle air removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D
Damper, vibration removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delay, throttle removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drains, airbox removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive gear.oil pump removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive gear,water pump removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive hub, blower accessory removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive seal ring, blower removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive support, blower removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E
End bearing bushing, camshaft removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End plate,front removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End plate,rear removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine block
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .......
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................
Engine block breather tube removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine brake retarder
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Engine brake wire harness removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine compression check... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Engine disassembly/reassembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine governor maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... ..
Engine idle speed and buffer screw adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine speed adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Engine stop solenoid removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine tune-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... ...
Equipment characteristics, capabilities and features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
Equipment improvement recommendations, reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment improvement report and maintenance digest (EIRMD) and equipment
improvement report and maintenance summary(EIR MS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust manifold
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. .. ............. .......... ................
3-1
3-7
3-8
15-8
4-3
15-5
3-6
4-4
10-5
10-3
10-4
10-2
7-10
3-3
3-4
3-1
3-2
8-2
11-1
11-2
11-3
19-3
11-4
19-11
2-8
15-1
19-7
19-9
15-10
19-1
1-9
1-7
1-2
1-5
9-1
TM 9-281 5-224-34&P
INDEX (CONT)
Paragraph,
Figure, Table
Subject
Exhaust manifold (Cont)
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust valve removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust valve bridge removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expendable supplies and materials list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F
Fan Clutch
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flex plate removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel housing and rear oil seal removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forms, maintenance, records and reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front balance cover removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front end plate removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front seal removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel injector
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pump removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G
Gear, idler removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear, oil pump drive removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear, water pump drive removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor cover removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor gap adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor housing assembly removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor, variable low speed limiting removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide, valve removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide, valve bridge removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H
Harness, engine brake wire removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head, cylinder
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to use torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing assembly, governor removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub, blower accessory drive removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2
7-4
7-8
C-2
18-1
18-2
5-2
5-3
A-2
1-2
7-12
3-3
4-6
12-1
12-2
12-3
12-4
19-3
13-2
13-1
7-11
4-4
10-5
2-1
2-5
15-3
15-4
19-5
15-2
15-6
7-3
7-2
11-4
3-7
3-8
vi
E-3
15-2
10-3
I
Idler gear removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Illustrated list of manufactured items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector control tube removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector, fuel
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-11
D-1
12-5
12-1
INDEX 3
TM 9-281 5-224-34&P
INDEX (CONT)
Subject
Injector, fuel (Cent)
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector rack control lever adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector tube removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insert, valve sea tremoval/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L
Left and right sides of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limiting governor, variable low speed removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liner, piston, connecting rod and removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location and description of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low speed limiting governor, variable removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M
Main bearing and crank shaft removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance forms, records, and reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance instructions, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold, exhaust removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufactured items illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufactured items part number index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Materials list, expendable supplies and . .
Maximum no-load speed adjustment . . . .
Metric System . . . . . . . . . . . . . . . . . . . . . . .
N
National stock number to figure and item numbers cross-reference. . . . . . . . . . . . . . . . . . . . . .
Nozzle, water removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O
Oil pan removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure regulator valve removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure relief valve removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pump
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pump drive gear removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil seal, front, crankshaft cover removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil seal, rear, flywheel housing and removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Organization of removal,installation, and repair procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .
P
Pan,oil removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part number index, manufactured items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part number to figure and item numbers cross-reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts list, repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts, repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston and connecting rod maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, connecting rod, and liner removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, front end removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. . . . . . . .
Index 4
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Paragraph,
Figure, Table
Number
12-2
12-3
12-4
19-3
19-6
3-9
3-10
1-1
2-6
15-6
6-2
1-10
15-6
4-5
1-2
2-5
9-2
D-3
D-2
C-1
19-9
1-2
B-5
3-11
8-3
8-7
8-6
8-4
8-5
4-4
4-6
5-3
8-1
A-3
2-7
8-3
D-2
B-4
B-2
2-4
6-2
6-3
6-1
6-2
3-3
TM 9-2815-224-34&P
INDEX (CONT)
Subject
Plate, rear end removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation for storage or shipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure regulator valveoil removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure relief valve oil removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Publication indexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Publications, other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley, crankshaft removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump, fuel removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump, oil
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump drive gear,oil removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump drive gear, water removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump, water
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Repair/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Push rod removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R
Rear end plate removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear oil seal, flywheel housing and removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Records and reports, maintenance forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulator valve, oil pressure removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief valvel oil pressure removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair parts and special tools list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retarder, engine brake
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker arm removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rod and liner, connecting, piston removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
s
Screw switch, buffer removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal, front removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal, oil, front, crankshaft cover removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal ring,blower drive removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid, engine stop removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid, throttle control removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special tools list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting aid screw adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop solenoid, engine removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplies and materials list, expendable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support, blower drive removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, buffer screw removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T
Tachometer drive removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle air cylinder removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle control solenoid removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle delay removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tool sand equipment,common . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paragraph,
Figure, Table
Number
3-4
1-2
8-7
8-6
A-1
A-3
4-2
13-2
8-4
8-5
4-4
10-5
17-1
17-2
7-6
3-4
5-3
1-2
A-1
8-7
8-6
2-4
B-2
B-1
11-2
11-3
7-5
6-2
15-7
4-6
4-6
10-4
15-10
15-9
2-3
B-3
19-9
19-7
15-10
C-1
10-2
15-7
14-2
15-8
15-9
15-5
2-2
Index 5
TM 9-2815-224-34&P
INDEX (CONT)
Subject
Tools, special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque table, how to use.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trunnion and front oil seal, crankshaft cover removal installation . . . . . . . . . . . . . . . . . . . . . .
Tube, cylinder block breather removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tube injector removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tube, injector control removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tune-up, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V
Valve bridge, exhaust removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve bridge guide removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, exhaust removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve guide removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve mechanism maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, oil pressure relief removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, oil pressure regulator removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve seat insert removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Variable low speed limiting governor removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration damper removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
W
Warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water nozzle removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water pump
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Repair/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water pump drive gear removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire harness, engine brake removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 6
Paragraph,
Figure, Table
‘Number
2-3
E-3
E-2
2-10
4-6
8-2
3-9
12-5
19-1
14-1
14-6
14-7
7-8
7-2
7-4
7-3
7-1
8-6
8-7
3-10
15-6
4-3
1-2
3-11
17-1
17-2
10-5
11-4
By Order of the Secretary of the Army
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
R.L. DILWORTH
Brigadier General United States Amy
The Adjutant General
Distribution
To be distributed in accordance with DA Form 12-38, Direct and General Support
Maintenance requirements for Engine, Diesel, 8-cylinder, Turbocharged, Detroit Diesel
Allison Model 8V92T.
TM9-2815-224-34&P
TM9-2815-224-34&P
TM9-2815-224-34&P
TM9-2815-224-34&P
TM9-2815-224-34&P
TM9-2815-224-34&P
PIN: 063616--000
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