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ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 s. Install injection nozzles (with new seals) and injection lines, refer to paragraph 3-29.4. t. Install fuel filter, fuel supply pump, and fuel lines, refer to paragraphs 3-24.4., 3-25.3.  and 3-26.3. u. Install engine standard flow oil cooler, new oil filter, and dipstick, refer to paragraphs 3-16.3 and 3-19.2 (Never clean or reuse a contaminated engine oil cooler. Install a new one.) v. Install water manifold/thermostat housing with thermostat, refer to paragraph 3-9.4 w. Install exhaust manifold and turbocharger, refer to paragraphs 3-14.3 and 3-13.4 Prelube the turbocharger. x. Install oil cooler piping, water pump, and hoses, refer to paragraph 3-10.4 y. Install crankshaft pulley, refer to paragraph 3-38.3. z. Install   battery   charging   alternator,   refer   to   paragraph   3-11.7,   and   fan,   and   fan   belts,   refer   to   end   item maintenance manual. aa. Adjust valves, refer to paragraph 3-32.1. ab. Install valve cover, refer to paragraph 3-31.2. ac. Fill engine with proper oil and coolant, refer to end item maintenance manual. ad. Perform engine break-in and perform normal standard performance checks. 3-5.  TEST ENGINE COMPRESSION PRESSURE. NOTE Before beginning test, ensure that batteries are fully charged and injection nozzle area is thoroughly cleaned. a. Run engine to bring up to normal operating temperature.(From a cold start, operate engine 10 to 15 minutes at slow idle.) b. Remove fuel injection nozzles, refer to paragraph 3-29.1. c. Install adapter (JT01679) with O-ring in injection nozzle bore.  Use holding clamp (JT02017) to hold adapter in position.  Install hold down screw in clamp and tighten screw to 27 ft-lbs (37 Nm).  Attach test gage (JT01682) to adapter. d. Refer  to  end  item  maintenance  manual,  and  using  DEAD  CRANK  switch,  (or  other  applicable  device),  turn crankshaft for 10 to 15 seconds with starter (150 rpm minimum cranking speed).  Record pressure reading. e. Compare readings from all cylinders. f. Compression pressure must be 350 psi (2400 kPa) minimum.  The difference between the highest and lowest cylinder must be less than 50 psi (350 kPa). g. If pressure is much lower than shown, remove gage and apply oil to ring area of piston through injection nozzle bore.  Do not use too much oil.  Do not get oil on the valves. h. Test  compression  again.    If  pressure  is  high,  worn  or  stuck  rings  are  indicated.    If  pressure  is  still  low,  it  is possible that valves are worn or sticking. 3-6.  MEASURE ENGINE BLOW-BY. a. Place a hose with a standard gas gage in end of crankcase vent tube. b. Run  engine  at  rated  speed  and  load  (engine  at  operating  temperature  and  run-in,  with  at  least  100  operating hours). c. Measure blow-by over a period of 5 minutes.  Multiply figure obtained by 12 (hourly rate).  Maximum  allowable below-by is 225 cu ft/h (6.0 cu m/h) d. If blow-by is lower, there probably is no undue wear between piston rings and liners.  If blow-by is higher, there could be excessive wear between piston rings and liners, resulting in loss of engine power. 3-18


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