Quantcast 3-4.2.  Assembly - TM-9-2815-256-24_41

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ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 q. Remove crankshaft pulley, refer to paragraph 3-38.1. r. Remove timing gear cover, refer to paragraph 3-39.1. s. Remove oil pump drive gear, oil outlet tube, (and its O-ring in block), and pump body, refer to paragraph 3-21.1. t. Remove oil slinger, timing gears, and camshaft, refer to paragraphs 3-40.1.  and 3-41.1.  Perform wear checks. u. Remove engine front plate, refer to paragraph 3-42.1. v. Remove lube oil system by-pass valve, refer to paragraph 3-22.1. w. Stamp cylinder number on rod (if required).  Remove pistons and rods, refer to paragraph 3-44.1.  Perform wear checks with bearing gage (PLASTIGAGEPR1).  Remove two at a time. x. Remove crankshaft and main bearings, refer to paragraph 3-43.1.  Perform wear checks with bearing gage. y. Remove cylinder liners and mark each one with cylinder number from which removed, refer to paragraph 3-44.2. z. Remove piston cooling orifices, refer to paragraph 3-44.1. aa. Remove cylinder block plugs and serial number plate (as required) when block is to be put in a "hot tank". ab. Clean out liner bores (upper and lower areas) with nylon brush. ac. Measure cylinder block, refer to paragraph 3-46.3. ad. Cap/cover all openings to prevent entry of foreign material. 3-4.2.  Assembly. NOTE Remove all caps/covers. a. Install all plugs (and serial number plates) in cylinder block that were removed to service block. b. Install clean piston cooling orifices. c. Install cylinder liners without O-rings and measure stand-out.  Install liners with O-rings, refer to  paragraph  3- 49.2. d. Install crankshaft and main bearings, refer to paragraph 3-43.4.  Bearing gage bearings. e. Install flywheel housing, rear oil seal, and flywheel, refer to paragraphs 3-37.3., 3-36.2., and 3-35.3. f. Install pistons and rods, refer to paragraph 3-49.3.  Measure piston protrusion for proper piston selection. g. Install lube oil system by-pass valve, refer to paragraph 3-22.3. h. Install engine front plate, refer to paragraph 3-42.5. i. Install oil outlet tube, O-ring in block, and oil pump, refer to paragraph 3-21.3. j. Install injection pump on front plate, refer to paragraph 3-27.8. k. Install camshaft, timing gears, and oil slinger, refer to paragraph 3-40.3. I. Time all gears Top Dead Center (TDC), No.1 cylinder on compression stroke. m. Install timing gear cover (with new front seal), refer to paragraph 3-39.3. n. Install oil pan, refer to paragraph 3-20.3. o. Install oil pressure regulating valve, refer to paragraph 3-17.3. p. Install cam followers in the same sequence as removed, refer to paragraph 3-34. q. Install cylinder head gasket, cylinder head, pushrods, and rocker arm assembly, refer to paragraphs 3-34.7. and 3-33.5. r. Install starter, refer to paragraph 3-12.7. 3-17


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