ARMY TM 92815-256-24
AIR FORCE TO 38G1-96-2
MARINE CORPS TM 2815-24/5
Remove all covers.
When using gaskets with one steel-backed side, the non steel-backed side must face
towards the cylinder head.
Using six new gaskets (5, FIGURE 3-44) position exhaust manifold (4) on cylinder head. Coat all twelve
capscrews (1 and 3) with antiseize compound (CP-8) and install with washers (2) in locations as noted during
removal. Tighten capscrews to 35 ft-lbs (47 Nm).
Install turbocharger, refer to paragraph 3-13.4.
3-15. INTAKF MANIFOLD.
Loosen two clamps (1, FIGURE 3-45) securing hose (2) to turbocharger and air inlet elbow (5). Remove
clamps and hose.
Disconnect cold weather starting aid.
Remove two capscrews (3) and lockwashers (4) securing air inlet elbow (5) to cylinder head. Remove elbow
and gasket (6); discard lockwashers (4) and gasket (6).
Cover all openings.
Intake manifold hose and capscrew connections should be inspected periodically for tightness and kept tight.
Inspect intake manifold for serviceability. Replace, if it is cracked or otherwise damaged.
Compressed air used for cleaning can create airborne particles that may enter the eyes.
Pressure will not exceed 30 psig (207 kPa). Eye protection required.
Inspect machined mating surfaces of cylinder head and intake manifold. Clean as required, using a scraper
and/or wire brush and compressed air.
Remove all covers.
Position new gasket (6, FIGURE 3-45) and air intake elbow (5) on cylinder head and secure with two capscrews
(3) and new lockwashers (4). Tighten capscrews to 35 ft-lbs (47 Nm).
Ensure hose (2) is in good condition and install it between turbocharger and air intake elbow (5) and secure
with two clamps (1).
All intake manifold connections at the turbocharger and engine cylinder head must be
tight to prevent loss of power resulting from lower manifold pressure.
If applicable, connect cold weather starting aid.