TM 5-3895-382-24
Table of Contents
Disassembly and Assembly
Section
Engine Design ..............................................................................7-4
Fuel Filter Base - Remove and Install ......................................7-5
Fuel Transfer Pump - Remove ...................................................7-7
Fuel Transfer Pump - Disassemble ...........................................7-8
Fuel Transfer Pump - Assemble ................................................7-8
Fuel Transfer Pump - Install .......................................................7-9
Fuel Injection Lines - Remove and Install ............................. 7-10
Fuel Injection Nozzles - Remove
(Type 1 Engines and 9RM Engines) .............................. 7-11
Fuel Injection Nozzles - Install
(Type 1 Engines and 9RM Engines) .............................. 7-12
Fuel Injection Nozzles- Remove
(Type 2 Engines and 7BJ Engines) ............................... 7-13
Fuel Injection Nozzles- Install
(Type 2 Engines and 7BJ Engines) ............................... 7-14
Fuel Injection Pump - Remove
(Type 1 Engines and 9RM Engines) .............................. 7-15
Fuel Injection Pump - Install
(Type 1 Engines and 9RM Engines) .............................. 7-16
Fuel Injection Pump - Remove
(Type 2 Engines and 7BJ Engines) ................................ 7-17
Fuel Injection Pump - Install
(Type 2 Engines and 7BJ Engines) ............................... 7-19
Turbocharger - Remove ........................................................... 7-21
Turbocharger - Disassemble ................................................... 7-22
Turbocharger - Assemble ........................................................ 7-23
Turbocharger - Install ............................................................... 7-24
Exhaust Manifold - Remove and Install
(Type 1 Engines and 9RM Engines) .............................. 7-24
Exhaust Manifold - Remove and Install
(Type 2 Engines and 7BJ Engines) ............................... 7-25
Air Inlet Manifold - Remove
(Type 1 Engines and 9RM Engines) .............................. 7-27
Air Inlet Manifold - Install
(Type 1 Engines and 9RM Engines) .............................. 7-28
Air Inlet Manifold - Remove
(Type 2 Engines and 7BJ Engines) ............................... 7-28
Air Inlet Manifold - Install
(Type 2 Engines and 7BJ Engines) ............................... 7-29
Inlet and Exhaust Valve Springs -
Remove and Install ........................................................... 7-30
Inlet and Exhaust Valves -
Remove and Install ........................................................... 7-31
Inlet and Exhaust Valve Guides -
Remove and Install ........................................................... 7-33
Inlet and Exhaust Valve Seat Inserts -
Remove and Install ........................................................... 7-34
Engine Oil Filter Base - Remove ............................................ 7-35
Engine Oil Filter Base - Disassemble .................................... 7-36
Engine Oil Filter Base - Assemble .......................................... 7-36
Engine Oil Filter Base - Install ................................................. 7-37
Engine Oil Relief Valve - Remove and Install ....................... 7-37
Engine Oil Pump - Remove ..................................................... 7-38
Engine Oil Pump - Install ......................................................... 7-39
Water Pump - Remove ............................................................. 7-40
Water Pump - Disassemble
(Type 1 Engines and 9RM Engines) .............................. 7-41
Water Pump - Assemble
(Type 1 Engines and 9RM Engines) .............................. 7-42
Water Pump - Install ................................................................. 7-44
Water Temperature Regulator -
Remove and Install............................................................ 7-44
Water Outlet Manifold - Remove ............................................ 7-46
Water Outlet Manifold - Install ................................................. 7-47
Flywheel- Remove ..................................................................... 7-47
Flywheel - Install ........................................................................ 7-48
Crankshaft Rear Seal - Remove ............................................. 7-49
Crankshaft Rear Seal - Install ................................................. 7-50
Flywheel Housing - Remove and Install ................................ 7-51
Crankshaft Pulley - Remove and Install ................................ 7-52
Crankshaft Front Seal - Remove ............................................. 7-53
Crankshaft Front Seal - Install ................................................ 7-54
Front Cover - Remove ............................................................... 7-54
Front Cover - Install .................................................................. 7-55
Gear Group (Front) - Remove ................................................. 7-56
Gear Group (Front) - Install ..................................................... 7-57
Housing (Front) - Remove ........................................................ 7-58
Housing (Front) - Install ............................................................ 7-58
Valve Mechanism Cover- Remove and Install ..................... 7-59
Rocker Shaft and Pushrod - Remove .................................... 7-61
Rocker Shaft - Disassemble .................................................... 7-61
Rocker Shaft - Assemble ......................................................... 7-62
Rocker Shaft and Pushrod - Install ........................................ 7-63
Cylinder Head - Remove .......................................................... 7-64
Cylinder Head - Install .............................................................. 7-65
Lifter Group - Remove and Install .......................................... 7-66
Camshaft - Remove and Install .............................................. 7-67
Camshaft Gear- Remove and Install ..................................... 7-68
Camshaft Bearings- Remove and Install ............................... 7-70
Engine Oil Pan - Remove and Install ..................................... 7-71
Cylinder Liner - Remove .......................................................... 7-72
Cylinder Liner - Install ............................................................... 7-73
Piston Cooling Jets - Remove and Install ............................. 7-74
Pistons and Connecting Rods - Remove .............................. 7-75
Pistons and Connecting Rods - Disassemble ...................... 7-75
Pistons and Connecting Rods - Assemble ............................ 7-76
Pistons and Connecting Rods - Install ................................... 7-77
Connecting Rod Bearings- Remove ....................................... 7-78
Connecting Rod Bearings- Install ........................................... 7-80
Crankshaft Main Bearings - Remove ..................................... 7-81
Crankshaft Main Bearings - Install ......................................... 7-82
Crankshaft - Remove ................................................................ 7-83
Crankshaft - Install .................................................................... 7-84
Crankshaft Gear - Remove and Install .................................. 7-87
Bearing Clearance - Check ..................................................... 7-88
V-Belts- Remove and Install .................................................... 7-89
Fan - Remove and Install ......................................................... 7-89
Fan Drive - Remove .................................................................. 7-90
Fan Drive- Install ....................................................................... 7-90
Alternator- Remove and Install ............................................... 7-90
Electric Starting Motor - Remove and Install ........................ 7-91
Dipstick - Remove and Install .................................................. 7-93
Relief Valve - Disassemble & Assemble ............................... 7-93
Index Section
Index............................................................................................. 7-94
7-3
