ARMY TM 9-2815-255-24
AIR FORCE TO 38G1-95-2
MARINE CORPS TM 2815-24/4
Replace all nuts, bolts, capscrews, and studs with damaged threads. Do not use a tap or die to repair damaged
threads which may impair the strength and closeness of the threads and is not recommended.
Do not allow grease or oil to enter a blind threaded hole as hydraulic action present when bolt or stud is screwed
in could split or stress housing.
To check or re-torque a bolt or nut, item is slackened a quarter of a turn and then tightened to specified value.
A steel ISO metric bolt, capscrew, or nut can be identified by the letter M either on head or one hexagon flat.
The strength grade will also be marked on top or one flat.
On nuts with identification marks on one face the frictional area of that surface will be reduced, therefore nut
should be installed with unmarked face towards component.
Service tools are designed to aid disassembly and assembly procedures and their use will prevent possible
unnecessary damage to components. It is recommended that service tools are always used, some operations
cannot be safely carried out without aid of relevant tool.
When removing/disconnecting fuel and lubrication lines and coolant hoses, cover/cap all openings to prevent
entry of foreign material. Remove covers and caps upon installation.
3-4. DISASSEMBLY AND ASSEMBLY SEQUENCE FOR OVERHAUL
The following paragraphs provide the sequence of disassembly and assembly for complete overhaul of the engine. Step-
by-step procedures can be found in remaining sections of Chapter 3.
If the engine has been operating and coolant Is hot, allow engine to cool before you slowly
loosen filler cap and relieve pressure from cooling system. Failure to observe this warning could
result in severe personal Injury.
Use care when rotating engine on engine maintenance stand. If necessary, use a lifting device to
avoid severe personal Injury.
Drain all coolant and engine oil, refer to end item maintenance manual. Check engine oil for metal
Remove fan belt and battery charging alternator, refer to paragraph 3-11.1.
Remove turbocharger and exhaust manifold, refer to paragraphs 3-13.1. and 3-14.1.
Remove valve cover, refer to paragraph 3-31.1.
Remove water manifold/thermostat housing with thermostat, refer to paragraph 39. 1.
Remove oil cooler piping, water pump, and hoses, refer to paragraph 3-10.1.
Remove dipstick, oil filter, and engine oil cooler, refer to paragraphs 3-19.1. and 3-16.1. Discard oil cooler if oil
contained metal particles.
Remove oil pressure regulating valve assembly, refer to paragraph 3-17.1.
Remove fuel filter, fuel supply pump, and fuel lines, refer to paragraphs 3-24.2., 3-25.1., and 3-26.1.
Remove injection lines, injection pump, and injection nozzles, refer to paragraph 3-27.1.