ARMY TM 9-2815-259-24
AIR FORCE TO 38G1-125-2
MARINE CORPS 09249A/09246A-24
Compressed air used for cleaning can create airborne particles that can
enter the eyes. Pressure must not exceed 30 psi (207 kPa). Eye protection
Remove all old sealant material from front plate and engine block.
Clean plate with soapy water and compressed air. Wipe front face of engine block with a cleaning
cloth. Ensure sealant surface on engine block is clean.
Inspect front plate for wear or damage. Replace if necessary.
Apply thread lock (LOCTITE 242) to threads of studs (1, Figure 5-66)
before installing front plate.
Replacement front plates are supplied without injection pump timing mark.
It is extremely important that timing mark be accurately transferred from
original front plate to replacement plate in the exact location for correct
injection pump timing.
Transfer injection pump timing pump mark from original front plate onto replacement plate, as
Position locally manufactured template (Figure F2, Appendix F) on front plate and secure
with three 3/8-16 capscrews.
Transfer injection pump timing mark from previous front plate onto template using a fine tip
marker and straightedge. Remove template from front plate being replaced.
Attach template (with timing mark) to new front plate and tighten capscrews securely.
Transfer timing mark from the template to the new front plate using a scribe. Scribe deep
enough so mark becomes a permanent reference.
Remove template from front plate.
Install oil bypass valve (1, Figure 5-89) and spring (2) in engine block bore.
Apply Flexible Form-In-Place Gasket in a continuous 1.5 to 2.0 mm bead (A) to cylinder block.
Refer to Figure 5-66.
Locate bead in the center of the mating surfaces and completely encircle bolt and bolt holes.