ARMY TM 9-2815-256-24
AIR FORCE TO 38G1-96-2
MARINE CORPS TM 2815-24/5
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, refer to end item maintenance manual and battery charging alternator, refer to paragraph 3-
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 3-9.1.
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.
Remove starter, refer to paragraph 3-12.2.
Remove rocker arm assembly and pushrods, refer to paragraph 3-33.1. Keep rods in sequence. Check for bent
pushrods and condition of wear pad contact surfaces on rockers.
Remove cylinder head and cylinder head gasket, refer to paragraph 3-34.1. Check piston protrusion.
Remove cam followers, refer to paragraph 3-34.1. Keep in same sequence as removed.
Remove flywheel, rear oil seal, and flywheel housing, refer to paragraphs 3-35.1., 3-36.1., and 3-37.1.
Remove oil pan, refer to paragraph 3-20.1.