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ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 n. 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. o. 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. 3-4.1.  Disassembly. Warning 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. Warning Use  care  when  rotating  engine  on  engine  maintenance  stand.    If  necessary,  use  a  lifting  device  to avoid severe personal injury. a. Drain   all   coolant   and   engine   oil,   refer   to   end   item   maintenance   manual.      Check   engine   oil   for   metal contaminates. b. Remove fan belt, refer to end item maintenance manual and battery charging alternator, refer to paragraph 3- 11.2. c. Remove turbocharger and exhaust manifold, refer to paragraphs 3-13.1. and 3-14.1. d. Remove valve cover, refer to paragraph 3-31.1. e. Remove water manifold/thermostat housing with thermostat, refer to paragraph 3-9.1. f. Remove oil cooler piping, water pump, and hoses, refer to paragraph 3-10.1. g. 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. h. Remove oil pressure regulating valve assembly, refer to paragraph 3-17.1. i. Remove fuel filter, fuel supply pump, and fuel lines, refer to paragraphs 3-24.2., 3-25.1., and 3-26.1. j. Remove injection lines, injection pump, and injection nozzles, refer to paragraph 3-27.1. k. Remove starter, refer to paragraph 3-12.2. I. 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. m. Remove cylinder head and cylinder head gasket, refer to paragraph 3-34.1.  Check piston protrusion. n. Remove cam followers, refer to paragraph 3-34.1.  Keep in same sequence as removed. o. Remove flywheel, rear oil seal, and flywheel housing, refer to paragraphs 3-35.1., 3-36.1., and 3-37.1. p. Remove oil pan, refer to paragraph 3-20.1. 3-16


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