TM 9-2815-225-34&P
Section IV. ASSEMBLY
3-65. GENERAL
a. This section provides maintenance procedures for assembly of subassemblies, installation of major components, and removal
of engine from maintenance stand. These procedures are for the engine removed from the vehicle.
b. In cases where it may only be necessary, or more time efficient, to assemble the engine while installed in vehicle, follow the
applicable portions of the tasks contained in this section to install the part or component.
c. In the task summary listed below, a complete list of special tools, test equipment, materials, parts, and related information
required to perform a complete engine assembly is provided. To find a specific engine assembly procedure contained in this section,
see list of tasks.
3-66. TASK SUMMARY
INITIAL SETUP:
APPLICABLE MODELS
Compound, antiseize (Appendix C, Item 7)
All
MATERIALS/PARTS (Contd)
SPECIAL TOOLS
Sealant, thread (liquid) (Appendix C, Item 27)
Piston ring expander (15434) ST-763
Main bearing set, standard: (15434) AR-7110
Two connecting rod guide pins (15434) 3375601
0.010 under: (15434) AR-711
Piston ring compressor (15434) 3375162
0.020 under: (15434) 157282
Oil seal installer (15434) ST-1259
Thrust ring, standard: (15434) 157280
Oil seal expander (15434) 3375151
0.010 under: (15434) 157281
Fuel pump drive oil seal mandrel (15434) ST-
0.020 under: (15434) 157282
1173
Piston ring set (15434) 3014149
Pulley installation assembly tool (15434)
Cam follower housing gasket (15434) 3020000
3376326
Cam follower housing gasket (as required) (15434)
Air compressor wrench (15434) 3375159
3020001,3020002, 3020003,3020004
Crankshaft rear oil seal driver (15434) ST-997
Cylinder head gasket (15434) 3001667
Dial gauge attachment (15434) ST-1325
Four O-ring seals (15434) 131026
Dial indicator and sleeve assembly (15434)
Housing gasket (15434) 200809
3376050
Pump mounting gasket (15434) 3031434
Injector puller (15434) 3375161
Crankshaft oil seal (15434) 3006736
Torque wrench adapter (15434) ST-669
Accessory drive oil seal (15434) 3004316
Compressor gasket (15434) 3005962
TEST EQUIPMENT
Four lockwashers (15434) S-609
Injection timing fixture (15434) 3375522
Fuel pump mounting gasket (15434) 200817
Rear cover gasket (15434) 40662-A
MATERIALS/PARTS
Rear main seal (15434) 211253
Oil, lubricating, OE/HDO 30
Suction tube gasket (15434) 157551
(Appendix C, Item 21)
Oil pan gasket (15434) 3027983
Oil, lubricating gear, 60-80/140
O-ring seal (15434) 3029846
(Appendix C, Item 22)
O-ring seal (15434) 3029847
Lubricant, high-pressure (Appendix C, Item 15)
Gasket, rocker housing (15434) 3017750
Lubricant, rust preventative
Gasket, brake housing (75078) 010279
(Appendix C, Item 16)
Three intake manifold gaskets (15434) 3008591
Sealant, pipe (Appendix C, Item 26)
Three lockwashers (15434) S-602
Solvent, SD-3 (Appendix C, Item 30)
Two water header cover gaskets (15434) 70089-1
Grease, GAA (Appendix C, Item 13)
Six piston cooling nozzle O-rings (15434) 3007442
Oil, lubricating, OE/HDO 10
Support gasket (15434) 3031858
(Appendix C, Item 20)
Two grommets (15434) S-1003-A
Six exhaust manifold gaskets (15434) 3020943
Turbocharger mounting gasket (15434) 190849
3-539
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