ARMY TM 9-2815-256-24
AIR FORCE TO 38G1-96-2
MARINE CORPS TM 2815-24/5
Install injection nozzles (with new seals) and injection lines, refer to paragraph 3-29.4.
Install fuel filter, fuel supply pump, and fuel lines, refer to paragraphs 3-24.4., 3-25.3. and 3-26.3.
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.)
Install water manifold/thermostat housing with thermostat, refer to paragraph 3-9.4
Install exhaust manifold and turbocharger, refer to paragraphs 3-14.3 and 3-13.4 Prelube the turbocharger.
Install oil cooler piping, water pump, and hoses, refer to paragraph 3-10.4
Install crankshaft pulley, refer to paragraph 3-38.3.
Install battery charging alternator, refer to paragraph 3-11.7, and fan, and fan belts, refer to end item
Adjust valves, refer to paragraph 3-32.1.
Install valve cover, refer to paragraph 3-31.2.
Fill engine with proper oil and coolant, refer to end item maintenance manual.
Perform engine break-in and perform normal standard performance checks.
3-5. TEST ENGINE COMPRESSION PRESSURE.
Before beginning test, ensure that batteries are fully charged and injection nozzle area is thoroughly
Run engine to bring up to normal operating temperature.(From a cold start, operate engine 10 to 15 minutes at
Remove fuel injection nozzles, refer to paragraph 3-29.1.
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
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.
Compare readings from all cylinders.
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).
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.
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.
Place a hose with a standard gas gage in end of crankcase vent tube.
Run engine at rated speed and load (engine at operating temperature and run-in, with at least 100 operating
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)
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.