TM-9-2815-204-35

• FIELD AND DEPOT MAINTENANCE FOR ENGINE, DIESEL (MULTIFUEL):TURBOSUPERCHARGED, FUEL INJECTED, WATER COOLED, 6-CYLINDER, ASSEMBLY2815-897-5061 (CONTINENTAL MODEL LDS-427-2) AND CLUTCH, ASSEMBLY (ORD 7748995) (LONG MODEL 13CF)
• Table of Contents
• Table of Contents-continued
• VISUAL GUIDE TO CONTENTS (1 of 3).
• VISUAL GUIDE TO CONTENTS (2 of 3).
• VISUAL GUIDE TO CONTENTS (3 of 3).
• FIGURE 1. LATE MODEL LDS-427-2 ENGINE - 3/4 FRONT VIEW
• CHAPTER 1. INTRODUCTION
• FIGURE 5. LATE MODEL LDS-427-2 ENGINE ASSEMBLY-3/4 RIGHT REAR VIEW
• FIGURE 7. LATE MODEL LDS-427-2 ENGINE ASSEMBLY - 3/4 LEFT REAR VIEW
• Section II. OPERATION AND DESCRIPTION
• PRINCIPLE OF HYPERCYCLE OPERATION
• Compression and Power Stroke
• CYLINDER AND CRANKCASE
• CRANKSHAFT ASSEMBLY
• CONNECTING ROD BEARINGS
• PISTON RINGS
• CYLINDER HEAD WATER OUTLET MANIFOLDS
• LUBRICATION SYSTEM
• COOLING SYSTEM
• FIGURE 21. ENGINE FUEL SYSTEM DIAGRAM
• FUEL SYSTEM
• FIGURE 22. ENGINE FLAME HEATER FUEL SYSTEM DIAGRAM
• AIR INDUCTION AND EXHAUST SYSTEM (TURBOSUPERCHARGER)
• ENGINE ASSEMBLY
• ENGINE ASSEMBLY-continued
• DRIVE RATIOS AND ROTATION (FROM FRONT)
• CHAPTER 2. PARTS, SPECIAL TOOLS, AND EQUIPMENT FOR FIELD AND DEPOT MAINTENANCE
• FIGURE 23. SPECIAL TOOLS.
• Table I. Special Tools and Equipment for Field and Depot Maintenance-continued
• FIGURE 24. HYDRAULIC RAM KIT -10912249 AND CYLINDER LINER REMOVER AND REPLACER KIT -8722925.
• Table I. Special Tools and Equipment for Field and Depot Maintenance-continued
• FIGURE 26. MECHANICAL PULLER KIT -8708724.
• Table I. Special Tools and Equipment for Field and Depot Maintenance-continued
• FIGURE 28. ENGINE OVERHAUL STAND -7950189, CRADLE ASSEMBLY - 7950198, AND ENGINE MOUNTING BRACKETS
• Table I. Special Tools and Equipment for Field and Depot Maintenance-continued
• FIGURE 29. ENGINE LIFTING SLING-8715107
• FIGURE 33. IMPROVISED TOOL - INTAKE AND EXHAUST VALVE SEAT INSERT REPLACER
• IMPROVISED TOOLS
• FIGURE 37. IMPROVISED TOOL - CYLINDER HEAD INNER NUT WRENCH
• CHAPTER 2. TROUBLESHOOTING
• TROUBLESHOOTING ENGINE ASSEMBLY
• Engine cranks but will not start.
• Engine runs rough, one or more cylinders not firing.
• Engine low on power
• Excess engine power or engine overspeeds
• Engine will not idle but runs well under load
• Engine exhaust smokes-continued
• Engine noises.
• Tapping noise.
• Grinding or squealing noise
• Grinding or squealing noise-continued
• Rough or poor engine idling
• Poor fuel economy.
• TROUBLESHOOTING STARTING SYSTEM
• TROUBLESHOOTING GENERATOR SYSTEM
• TROUBLESHOOTING FUEL SYSTEM
• Engine runs hot, misfires, or runs rough
• TROUBLESHOOTING LUBRICATION SYSTEM
• High engine oil pressure
• High engine oil temperature
• Excessive oil consumption
• Loss of coolant.
• TROUBLESHOOTING INTAKE MANIFOLD FLAME HEATER FUEL SYSTEM
• Fuel to intake manifold flame heater will not operate (ignite).
• CHAPTER 4. REPLACEMENT OF ENGINE ACCESSORIES, COMPONENTS, AND RELATED SERVICE OPERATIONS
• Section II. REPLACEMENT OF ENGINE ACCESSORIES
• FIGURE 42. REMOVING OR INSTALLING GENERATOR PULLEY.
• TURBOSUPERCHARGER
• FIGURE 46. REMOVING ORINSTALLING TURBOSUPERCHARGE REXHAUSTEL BOW AND SUPPORT (LATE MODEL ENGINES).
• FIGURE 49. DISCONNECTING OR CONNECTING TURBOSUPERCHARGER-TO-INTAKE MANIFOLD HOSE AND OIL DRAIN TUBE (LATE MODEL ENGINES)
• FIGURE 51. REMOVING OR INSTALLING TURBOSUPERCHARGER ASSEMBLY (LATE MODEL ENGINES)
• FUEL INJECTION PUMP ASSEMBLY
• FIGURE 58. DISCONNECTING OR CONNECTING CYLINDER NO. 4, 5, AND 6 FUEL INJECTION TUBES.
• FIGURE 59. DISCONNECTING OR CONNECTING FUEL HOSES FROM FUEL INJECTION PUMP (LATE MODEL ENGINES).
• FIGURE 61. REMOVING OR INSTALLING INJECTION PUMP ACCESS COVERS
• FIGURE 62. REMOVING OR INSTALLING FRONT CYLINDER HEAD COVER.
• FIGURE 66. REMOVING OR INSTALLING FUEL INJECTION PUMP DRIVEN GEAR RETAINING PLATE
• FIGURE 67. REMOVING OR INSTALLING FUEL INJECTION PUMP DRIVEN GEAR
• FIGURE 71. REMOVING OR INSTALLING FUEL INJECTION PUMP ASSEMBLY.
• FIGURE 74. REMOVING OR INSTALLING PUMP FITTINGS (LATE MODEL ENGINES)
• FIGURE 75. REMOVING OR INSTALLING PUMP FITTINGS (EARLY MODEL ENGINES)
• Preparation of Fuel Injection Pump for Installation
• FLAME HEATER FUEL PUMP ASSEMBLY
• FIGURE 79. FLAME HEATER FUEL PUMP ASSEMBLY
• FIGURE 82. REMOVING OR INSTALLING AIR COMPRESSOR DRIVE BELT.
• FIGURE 84. REMOVING OR INSTALLING AIR COMPRESSOR ADJUSTING FLANGE AND PULLEY
• Section III. REPLACEMENT AND REPAIR OF ENGINE COMPONENTS ALLOCATED TO THIRD ECHELON MAINTENANCE
• FIGURE 88. CLUTCH ASSEMBLY - INSTALLED VIEW
• FIGURE 90. CLUTCH ASSEMBLY - PARTIAL EXPLODED VIEW.
• FIGURE 93. INSTALLING NEW CLUTCH FACINGS AND/OR CHECKING DRIVEN MEMBER RUNOUT
• FIGURE 95. BUSHING- TYPE PILOT BEARING INSTALLATION INSTRUCTIONS
• OIL FILTER BYPASS VALVE
• OIL COOLER BYPASS VALVE
• OIL PRESSURE REGULATOR VALVE
• OIL FILTER ELEMENTS
• OIL PRESSURE SENDING UNIT
• WATER TEMPERATURE SENDING UNIT
• WATER PUMP ASSEMBLY
• FIGURE 115. DISCONNECTING OR CONNECTING WATER PUMP ASSEMBLY.
• FIGURE 116. REMOVING OR INSTALLING WATER PUMP ASSEMBLY
• FIGURE 119. REMOVING OR INSTALLING WATER PUMP PULLEY RETAINING RING
• FIGURE 124. REMOVING WATER SEAL FROM WATER PUMP HOUSING
• FIGURE 126. REMOVING PIPE PLUG FROM WATER PUMP BODY ASSEMBLY.
• FIGURE 127. WATER PUMP ASSEMBLY - EXPLODED VIEW.
• FIGURE 129. INSTALLING WATER PUMP DRIVE SHAFT IN WATER PUMP HOUSING ASSEMBLY.
• OIL COOLER
• FIGURE 134. REMOVING OR INSTALLING OIL COOLER COVER.
• FIGURE 137. REMOVING OR INSTALLING INTAKE MANIFOLD FLAME HEATER ASSEMBLY.
• INTAKE MANIFOLD HEATER ASSEMBLY
• FLAME HEATER IGNITION UNIT
• FIGURE 142. FLAME HEATER FUEL FILTER - EXPLODED VIEW.
• FLAME HEATER SOLENOID VALVES
• FUEL INJECTOR NOZZLE AND HOLDER ASSEMBLIES
• FIGURE 151. TESTING FUEL INJECTOR NOZZLE AND HOLDER ASSEMBLY.
• FIGURE 152. REMOVING OR INSTALLING NOZZLE AND HOLDER ASSEMBLY CAP
• FIGURE 155. REMOVING OR INSTALLING VALVE
• FIGURE 157. FUEL INJECTOR NOZZLE AND HOLDER ASSEMBLY-SECTIONAL VIEW
• DRIVE BELTS
• TRANSMISSION ADAPTER AND FLYWHEEL
• FIGURE 161. CHECKING FLYWHEEL RUN USING A DIAL INDICATOR.
• CRANKSHAFT REAR OIL SEAL
• FIGURE 165. REMOVING CRANKSHAFT REAR OIL SEAL FROM HOUSING
• EXHAUST MANIFOLD
• FIGURE 169. DISCONNECTING OR CONNECTING MANIFOLDS-BOTTOM VIEW
• FIGURE 173. EXHAUST MANIFOLD ASSEMBLY SHOWING HEAT APPLICATION POINTS FOR SEPARATION OF SECTIONS
• INTAKE MANIFOLD
• FIGURE 175. REMOVING OR INSTALLING CYLINDER HEAD WATER OUTLET MANIFOLDS
• FRONT AND/OR REAR CYLINDER HEAD WATER OUTLET MANIFOLDS
• VALVE ROCKER ARM ADJUSTING SCREWS
• VALVE ROCKER ARM SHAFTS AND/OR ROCKER ARM ASSEMBLIES
• FIGURE 186. DISASSEMBLING OR ASSEMBLING FRONT VALVE ROCKER ARMS.
• VALVE ROCKER ARM PUSH RODS
• CYLINDER HEAD ASSEMBLY OR CYLINDER HEAD GASKET
• FIGURE 191. REMOVING OR INSTALLING FRONT CYLINDER HEAD ASSEMBLY.
• FIGURE 193. REMOVING OR INSTALLING ENGINE FRONT LIFTING BRACKET AND FUEL RETURN TUBES
• Cleaning and Inspection.
• FIGURE 195. TORQUE TIGHTENING SEQUENCE FOR CYLINDER HEAD NUTS
• OIL PAN AND/OR OIL PAN GASKET
• CRANKSHAFT DAMPER AND PULLEY ASSEMBLY
• FIGURE 202. REMOVING OR INSTALLING CRANKSHAFT DAMPER AND PULLEY RETAINING BOLT AND PLATE
• FIGURE 205. DISASSEMBLING, ASSEMBLING, AND INSPECTING CRANKSHAFT DAMPER AND PULLEY ASSEMBLY.
• CRANKSHAFT FRONT OIL SEAL
• FIGURE 209. REMOVING OR INSTALLING TACHOMETER ADAPTER.
• CRANKSHAFT GEAR, INJECTION PUMP DRIVEN GEAR, AND CAMSHAFT GEAR
• FIGURE 214. CRANKSHAFT AND CAMSHAFT GEAR TIMING MARKS ALINED
• FIGURE 217. REMOVING CAMSHAFT GEAR USING MECHANICAL PULLER KIT - 8708724.
• FIGURE 220. CHECKING CAMSHAFT END PLAY USING A DIAL INDICATOR.
• CRANKCAUSE BREATHER TUBE AND ADAPTER
• Section IV. SERVICE OPERATIONS
• CHECKING NOZZLE OPENING BREAK PRESSURE AND SPRAY PATTERN
• CHECKING VALVE TIMING
• FUEL INJECTION PUMP IDLE ADJUSTMENT
• FIGURE 222. REVERSE FLUSHING ENGINE COOLING SYSTEM
• CHAPTER 5. DISASSEMBLY OF ENGINE
• DRAINING OF ENGINE AND COMPONENTS
• REMOVAL OF ENGINE ACCESSORIES DURING ENGINE DISASSEMBLY
• REMOVAL OF FUEL FILTER ASSEMBLY
• REMOVAL OF FUEL INJECTION TUBE ASSEMBLIES AND FUEL INJECTOR NOZZLE AND HOLDER ASSEMBLIES
• FIGURE 230. REMOVING FUEL INJECTION TUBES AND CLAMPS.
• REMOVAL OF OIL FILTER ELEMENTS
• FIGURE 235. REMOVING OR INSTALLING OIL COOLER WATER INLET TUBE.
• REMOVAL OF AIR COMPRESSOR SUPPORT AND FUEL INJECTION PUMP ADAPTER ASSEMBLIES
• REMOVAL OF COMPONENTS FROM RIGHT SIDE OF ENGINE
• FIGURE 246. REMOVING OR INSTALLING FLAME HEATER IGNITION UNIT.
• REMOVAL OF FLAME HEATER FUEL PUMP AND FUEL FILTER BRACKET
• REMOVAL OF OIL GAGE ROD SUPPORT AND GENERATOR MOUNTING BRACKET
• REMOVAL OF OIL PRESSURE SENDING UNIT AND STARTER ADAPTER
• REMOVAL OF ENGINE FAN, THERMOSTAT HOUSING, AND WATER PUMP ASSEMBLY
• FIGURE 257. REMOVING ENGINE FAN.
• REMOVAL OF ENGINE FRONT AND REAR LIFTING BRACKETS
• REMOVAL OF CRANKCASE BREATHER ADAPTER AND  CYLINDER HEAD COVERS
• REMOVAL OF CYLINDER HEAD WATER OUTLET, INTAKE, AND EXHAUST MANIFOLDS
• FIGURE 267. REMOVING OR INSTALLING INTAKE AND EXHAUST MANIFOLDS AS A UNIT
• REMOVAL OF ROCKER ARMS, ROCKER ARM PUSH RODS, AND VALVE TAPPETS
• REMOVAL OF CYLINDER HEAD ASSEMBLIES
• REMOVAL OF TRANSMISSION ADAPTER, CLUTCH ASSEMBLY, AND FLYWHEEL
• REMOVAL OF OIL PAN
• FIGURE 279. REMOVING OR INSTALLING SCAVE-NGER PUMP INLET TUBE.
• REMOVAL OF PISTON AND CONNECTING ROD ASSEMBLIES
• REMOVAL OF CRANKSHAFT DAMPER AND PULLEY ASSEMBLY
• REMOVAL OF TACHOMETER DRIVE ADAPTER
• REMOVAL OF TIMING GEAR COVER ASSEMBLY
• REMOVAL OF ENGINE MOUNTING BRACKETS
• REMOVAL OF ENGINE FROM OVERHAUL STAND FOR COMPLETION OF DISASSEMBLY
• REMOVAL OF FLYWHEEL HOUSING
• REMOVAL OF CRANKSHAFT REAR OIL SEAL AND HOUSING
• REMOVAL OF ENGINE FRONT PLATE
• REMOVAL OF MAIN BEARING CAPS, CRANKSHAFT ASSEMBLY, AND MAIN BEARINGS
• FIGURE 307. REMOVING OR INSTALLING CRANKSHAFT ASSEMBLY
• REMOVAL OF PISTON COOLING NOZZLES
• FIGURE 311. REMOVING OR INSTALLING CAMSHAFT ASSEMBLY.
• CHAPTER 6. REBUILD OF ENGINE COMPONENTS
• Castings.
• REPAIR
• FIGURE 313. CYLINDER AND CRANKCASE STUDDING - LEFT REAR VIEW.
• Table III. Stud Identification
• Table III. Stud Identification-continued
• REPLACEMENT OF HELICAL COIL THREADED INSERTS
• Section II. REBUILD OF CYLINDER AND CRANKCASE ASSEMBLY
• REMOVAL OF MISCELLANEOUS ITEMS FROM CYLINDER AND CRANKCASE
• FIGURE 321. LOCATION OF CORE HOLE PLUGS BEHIND ENGINE NAME PLATE.
• FIGURE 322. CYLINDER AND CRANKCASE, CRANKSHAFT, PISTON, AND RELATED PARTS - EXPLODED VIEW.
• FIGURE 323. POINTS OF MEASUREMENT FOR CHECKING CYLINDER LINER BORES.
• FIGURE 324. CHECKING TAPPET BORE CLEARANCE.
• REPAIR OF CYLINDER AND CRANKCASE AND MISCELLANEOUS ITEMS
• REPLACEMENT OF CAMSHAFT BUSHING-TYPE BEARINGS
• FIGURE 328. REMOVING NO. 2 CAMSHAFT BUSHING-TYPE BEARING.
• REPLACEMENT OF CYLINDER LINERS
• FIGURE 331. CYLINDER LINER REMOVER AND REPLACER KIT - 8722925 SHOWING POSITION OF SHOE AGAINST LINER DURING LINER REMOVAL - SECTIONAL VIEW.
• FIGURE 332. CYLINDER SLEEVE REMOVER AND REPLACER KIT - 8722925 AND RAM KIT - 10912249 SHOWING PROPER METHOD OF CYLINDER LINER INSTALLATION.
• INSTALLATION OF MISCELLANEOUS ITEMS ON CYLINDER AND CRANKCASE
• Section III. REBUILD OF CRANKSHAFT ASSEMBLY
• CLEANING AND INSPECTION
• REPAIR
• Section V. REBUILD OF PISTONS, RINGS, PISTON PINS, AND CONNECTING RODS
• FIGURE 340. REMOVING OR INSTALLING OIL CONTROL EXPANDER SPRING.
• CLEANING AND INSPECTION
• FIGURE 344. INSPECTION POINTS FOR PISTON.
• REPAIR
• ASSEMBLY
• Section VI. REBUILD OF MISCELLANEOUS ENGINE COMPONENTS
• TAPPET CHAMBER COVER
• CYLINDER AND CRANKCASE WATER BAFFLE
• FIGURE 351. CYLINDER AND CRANKCASE, TIMING GEARS, OIL PAN, AND RELATED PARTS - EXPLODED VIEW.
• FUEL INJECTION PUMP DRIVE GEAR ACCESS COVER
• OIL PUMP IDLER GEAR
• FIGURE 353. ENGINE FRONT PLATE AS REMOVED FROM ENGINE
• CRANKSHAFT GEAR
• COOLANT DRAIN COCK AND OIL PRESSURE SENDING UNIT
• OIL PRESSURE RELIEF VALVE HOUSING
• Section VII. REBUILD OF OIL PUMP ASSEMBLY AND RELATED PARTS
• FIGURE 362. REMOVING OR INSTALLING OIL PUMP PRESSURE RELIEF VALVE.
• FIGURE 365. REMOVING OR INSTALLING SCAVENGER OIL PUMP DRIVEN IMPELLER.
• FIGURE 367. REMOVING OR INSTALLING PRESSURE OIL PUMP DRIVEN IMPELLER.
• FIGURE 370. REMOVING OR INSTALLING DRIVE SHAFT IMPELLER WOODRUFF KEYS.
• FIGURE 371. OIL PUMP ASSEMBLY AND RELATED PARTS - EXPLODED VIEW.
• FIGURE 372. REPLACING SCAVENGER OIL PUMP HOUSING BUSHING-TYPE BEARING.
• FIGURE 374. REPLACING OIL PUMP COVER BUSHING-TYPE BEARING.
• FIGURE 375. REPLACING PRESSURE OIL OR SCAVENGER OIL PUMP DRIVEN IMPELLER BUSHING-TYPE BEARINGS.
• PRESSURE OIL PUMP PICKUP TUBE
• SCAVENGER OIL PUMP INLET TUBE
• Section VIII. REBUILD OF CYLINDER HEAD ASSEMBLY
• FIGURE 382. REMOVING OR INSTALLING EXHAUST VALVE AND VALVE ROTATOR.
• FIGURE 385. CYLINDER HEAD ASSEMBLY AND RELATED PARTS - EXPLODED VIEW.
• CLEANING AND INSPECTION
• REPAIR
• FIGURE 387. INTAKE AND EXHAUST VALVE FACE AND VALVE SEAT GRINDING DIAGRAM
• FIGURE 389. REMOVING VALVE GUIDE FROM CYLINDER HEAD USING VALVE GUIDE REMOVER - 10899157.
• Section IX. REBUILD OF VALVE ROCKER ARMS, SHAFTS, PUSH RODS, TAPPETS, AND RELATED CYLINDER HEAD PARTS.
• VALVE ROCKER ARM PUSH RODS AND TAPPETS
• FIGURE 393. CYLINDER HEAD COVERS, CRANKCASE BREATHER, AND RELATED PARTS - EXPLODED VIEW
• Section X. REBUILS OF CYLINDER HEAD COVERS, BREATHER TUBE ADAPTER, CRANKCASE BREATHER TUBE , AND RELATED PARTS
• FIGURE 395. FLYWHEEL HOUSING, FLYWHEEL, TRANSMISSION ADAPTER, AND RELATED PARTS - EXPLODED VIEW.
• Section XI. REBUILD OF FLYWHEEL HOUSING, FLYWHEEL ASSEMBLY AND TRANSMISSION ADAPTER
• TRANSMISSION ADAPTER
• FIGURE 402. OIL FILTERS, OIL COOLER, AND OIL FILTER HOUSING-EXPLODED VIEW
• Section XII. REBUILD OF OIL FILTERS, OIL COOLER AND OIL FILTER HOUSING, AND OIL COOLER
• Section XIII. REBUILD OF FUEL FILTER ASSEMBLY, FUEL FILTER HOSES, FUEL INJECTION TUBES, FUEL INJECTION PUMP ATTACHING PARTS, AND FUEL INJECTOR NOZZLE AND HOLDER ASSEMBLIES
• FIGURE 404. FUEL FILTER ASSEMBLY - EXPLODED VIEW.
• FIGURE 407. FUEL INJECTION TUBE ASSEMBLIES, FUEL INJECTION PUMP ASSEMBLY, FUEL HOSES, AND RELATED PARTS - EXPLODED VIEW.
• FIGURE 407. FUEL INJECTION TUBE ASSEMBLIES, FUEL INJECTION PUMP ASSEMBLY, FUEL HOSES, AND RELATED PARTS - EXPLODED VIEW-continued
• FUEL FILTER HOSES
• Section XIV. REBUILD OF THERMOSTAT HOUSING, INTAKE MANIFOLD, WATER PUMP AND RELATED PARTS
• FIGURE 408. INTAKE MANIFOLD, CYLINDER HEAD WATER OUTLET MANIFOLDS, AND RELATED PARTS - EXPLODED VIEW.
• INTAKE MANIFOLD
• Section XV. REBUILD OF EXHAUST MANIFOLD ASSEMBLY, FLAME HEATER, AND RELATED PARTS
• IGNITION UNIT
• FIGURE 410. EXHAUST MANIFOLD, FLAME HEATER, AND RELATED PARTS - EXPLODED VIEW.
• Section XVI. REBUILD OF FLAME HEATER FUEL SYSTEM COMPONENTS
• FIGURE 411. FLAME HEATER FUEL SYSTEM COMPONENTS - EXPLODED VIEW
• FLAME HEATER FUEL FILTER ASSEMBLY
• TUBES AND CLAMPS
• FIGURE 413. REMOVING OR INSTALLING RELIEF VALVE.
• FIGURE 416. REMOVING OR INSTALLING SPUR GEAR AND SPUR GEARSHAFT.
• FIGURE 420. REMOVING OR INSTALLING SMALL PLAIN SEAL.
• FIGURE 424. REMOVING OR INSTALLING FIELD MAGNETS.
• FIGURE 427. REMOVING SPRING WASHER AND SHIMS
• CLEANING
• FIGURE 431. FLAME HEATER FUEL PUMP ASSEMBLY - EXPLODED VIEW
• FIGURE 432. ROTARY FUEL PUMP - EXPLODED VIEW.
• INSPECTION AND REPAIR
• FIGURE 435. REMOVING OR INSTALLING BRUSH HOLDER.
• FIGURE 439. REMOVING OR INSTALLING ARMATURE BALL BEARINGS.
• ASSEMBLY
• FIGURE 444. FUEL PUMP TEST EQUIPMENT.
• Section XVIII. REBUILD OF AIR COMPRESSOR ADJUSTABLE PULLEY, AIR INTAKE MANIFOLD, AND MISCELLANEOUS ENGINE COMPONENTS
• FIGURE 445. AIR COMPRESSOR AND RELATED PARTS - EXPLODED VIEW.
• AIR COMPRESSOR AIR INTAKE MANIFOLD ASSEMBLY
• FIGURE 446. ENGINE AND MISCELLANEOUS COMPONENTS - EXPLODED VIEW.
• TURBOSUPERCHARGER EXHAUST ELBOW
• ENGINE FAN AND GENERATOR DRIVE BELTS AND AIR COMPRESSOR DRIVE BELT
• CHAPTER 7. CLUTCH ASSEMBLY
• Section II. REBUILD OF CLUTCH ASSEMBLY
• FIGURE 450. REMOVING LOCK PLATES USING CLUTCH SPACER PLATE.
• FIGURE 453. REMOVING OR INSTALLING RELEASE LEVER PIN.
• CLEANING AND INSPECTION
• FIGURE 457. INSPECTING CLUTCH COVER PRESSURE SPRING SEATS AND SCREW HOLES
• REPAIR
• ASSEMBLY
• FIGURE 463. ADJUSTING RELEASE LEVER HEIGHT
• BALANCING PRESSURE PLATE WITH CLUTCH COVER ASSEMBLY
• CHAPTER 8. ASSEMBLY OF ENGINE
• Table V. Engine Components Assembly Guide
• Table V. Engine Components Assembly Guide-continued
• Section II. ASSEMBLY OF ENGINE FROM SUBASSEMBLIES
• FIGURE 467. INSTALLING REAR MAIN BEARING CAP OIL SEALS.
• INSTALLATION OF ENGINE FRONT PLATE, OIL PUMP IDLER GEAR, CRANKSHAFT GEAR, AND CAMSHAFT GEAR
• CHECKING CAMSHAFT END PLAY AND CRANKSHAFT AND CAMSHAFT GEAR BACKLASH
• INSTALLATION OF CAMSHAFT REAR BEARING PLUG, CRANKSHAFT REAR OIL SEAL HOUSING, AND FLYWHEEL HOUSING
• INSTALLATION OF ENGINE MOUNTING BRACKETS AND INSTALLATION OF ENGINE ON OVERHAUL STAND
• INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLIES
• INSTALLATION OF OIL PUMP ASSEMBLY, OIL PUMP TUBES, AND OIL PAN
• INSTALLATION OF FLYWHEEL, CLUTCH ASSEMBLY, AND TRANSMISSION ADAPTER
• FIGURE 484. INSTALLING CLUTCH COVER ASSEMBLY
• ADJUSTING VALVE CLEARANCE
• INSTALLATION OF INTAKE AND EXHAUST MANIFOLDS AND OIL LEVEL GAGE SUPPORT CLAMP BRACKET
• INSTALLATION OF FRONT AND REAR ENGINE LIFTING BRACKETS
• INSTALLATION OF FLAME HEATER FUEL PUMP AND FUEL FILTER BRACKET
• INSTALLATION OF CYLINDER AND CRANKCASE WATER BAFFLE, TAPPET CHAMBER COVER, AND OIL COOLER AND OIL FILTER HOUSING ASSEMBLY
• INSTALLATION OF OIL FILTERS AND FUEL INJECTION PUMP OIL SUPPLY HOSE
• FIGURE 494. CHECKING ENGINE TIMING PRIOR TO FUEL INJECTION PUMP INSTALLATION.
• FIGURE 496. SECURING FUEL INJECTION PUMP ASSEMBLY TO LONG ADAPTER STUD
• FIGURE 499. INSTALLING FUEL INJECTION PUMP DRIVEN GEAR AND RETAINING PLATE.
• INSTALLATION OF INJECTION PUMP DRIVEN GEAR ACCESS COVER, FRONT CYLINDER HEAD COVER, AND CRANKCASE BREATHER ADAPTER
• INSTALLATION OF FUEL INJECTOR NOZZLE AND HOLDER ASSEMBLIES, FUEL RETURN TUBES, AND FUEL INJECTION TUBES
• FIGURE 506. INSTALLING FUEL INJECTOR NOZZLE AND HOLDER FUEL RETURN TUBES.
• FIGURE 507. FUEL INJECTION TUBE AND INJECTION PORT IDENTIFICATION
• FIGURE 508. CONNECTING CYLINDER NO. 1, 2, AND 3 FUEL INJECTION TUBES.
• FIGURE 510. CONNECTING CYLINDER NO. 4, 5, AND 6 FUEL INJECTION TUBES (EARLY MODEL ENGINES).
• INSTALLATION OF FUEL FILTER ASSEMBLY AND FUEL HOSES
• INSTALLATION OF ENGINE ACCESSORIES
• CHAPTER 9. TESTS AND ADJUSTMENTS
• LEAKAGE TEST
• ENGINE RUN-IN
• Table VI. Run-in Schedule (Long)
• TEST, ADJUSTMENT, AND PREPARATION FOR STORAGE
• Oil Consumption Check.
• CHAPTER 10. REPAIR AND REBUILD STANDARDS
• FIGURE 514. REPAIR AND REBUILD STANDARD POINTS OF MEASUREMENT FOR CYLINDER AND CRANKCASE, CAMSHAFT, CRANKSHAFT AND RELATED PARTS.
• Valve Tappets and Tappet Bores in Cylinder and Crankcase.
• Connecting Rods.
• Crankshaft Assembly, Main Bearing Sleeves, and Related Components.
• Crankshaft journal and main bearing sleeves (0.0100-inch undersize).
• FIGURE 515. REPAIR AND REBUILD STANDARD POINTS OF MEASUREMENT FOR CRANKSHAFT GEAR AND OIL PUMP IDLER GEAR.
• FIGURE 516. REPAIR AND REBUID STANDARD POINTS OF MEASUREMENT FOR CRANKSHAFT DAMPER AND PULLEY ASSEMBLY
• OIL PUMP IDLER GEAR, OIL PRESSURE REGULATOR VALVE AND OIL PUMP ASSEMBLY.
• Oil pump impeller shafts, impellers, and bushing-type bearings.
• FIGURE 518. REPAIR AND REBUILD STANDARD POINTS OF MEASUREMENT FOR OIL PUMP ASSEMBLY.
• CYLINDER HEADS, VALVE ROCKER ARMS AND SHAFTS, VALVES, VALVE GUIDE AND ROCKER ARM PUSH RODS
• FIGUR 519. REPAIR AND REBUILD STANDARD POINTS OF MEASUREMENT FOR CYLINDER HEAD ASSEMBLY, VALVES, VALVES GUIDES, ROCKER ARMS, AND ROCKER ARM PUSH RODS
• FLYWHEEL AND RING GEAR
• OIL COOLER AND OIL FILTER HOUSING ASSEMBLY
• WATER PUMP ASSEMBLY
• FIGURE 523. REPAIR AND REBUILD STANDARD POINTS OF MEASUREMENT FOR CLUTCH ASSEMBLY.
• TORQUE SPECIFICATIONS
• APPENDIX
• Repair and Rebuild.
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• THE METRIC SYSTEM AND EQUIVALENTS
• TM-9-2815-204-35
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• DISTRIBUTION
• RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS

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