TM 5-2420-230-24-2
Index
Page 1
About the Manual ....................................................................... i-2
Engine Testing - Test Specifications ....................................... V-35
Accessories - Installation ....................................................... 0-88
Fan Hub - Specifications ........................................................ V-31
Accessories - Removal ............................................................ 0-24
Fuel System ........................................................................... V-26
Accessory Drive - Cleaning....................................................... 9-4
Lubricating Oil System - Specifications .................................. V-29
Accessory Drive - Inspection .................................................... 9-4
Rocker Levers and Pedestals ................................................. V-25
Accessory Drive Adapter - Exploded View ............................... 9-2
Tappet and Push Rods ........................................................... V-26
Accessory Drive Adaptor - Assembly ....................................... 9-5
Thermostat, Coolant 0perating Temperature ........................... V-31
Accessory Drive Adaptor - Disassembly................................... 9-4
Connecting Rod - Inspection .................................................. 1-44
Additional Service Literature .................................................... L-2
Crankshaft - Cleaning.............................................................. 1-26
Aftercooler Assembly - Cleaning and Inspection for Reuse .. 10-6
Crankshaft - Inspection ........................................................... 1-26
Inspection............................................................................... 10-6
Crankshaft - Installation .......................................................... 0-42
Aftercooler Assembly - Rebuild .............................................. 10-7
Crankshaft - Removal .............................................................. 0-39
Air Compressor - Cleaning and Inspection for Reuse............ 12-3
Crankshaft End Play - Measuring............................................ 0-66
Inspection............................................................................... 12-3
Crankshaft Gear - Replacement .............................................. 1-27
Air Crossover Tube - Cleaning and Inspection for Reuse ...... 10-8
Cup Plug Replacement............................................................ 2-13
Cleaning ................................................................................. 10-8
Cylinder Block - Cleaning ....................................................... 1-12
Inspection............................................................................... 10-8
Cylinder Block - De-Glazing .................................................... 1-17
Air Equipment - General Information...................................... 12-2
Cylinder Block - Disassembly ................................................. 1-10
Air Compressor ...................................................................... 12-2
Cylinder Block - Exploded View ............................................... 1-4
Air Intake System - Exploded View ......................................... 10-2
Cylinder Block - General Information ....................................... 1-7
Air Intake System - General Information................................. 10-4
Camshaft: ................................................................................ 1-7
Air Transfer Pipe - Cleaning and Inspection for Reuse .......... 10-7
Crankshaft:............................................................................... 1-7
Cleaning ................................................................................. 10-7
Cylinder Block .......................................................................... 1-7
Inspection............................................................................... 10-8
Oil Seals .................................................................................. 1-7
Alternator - Installation .......................................................... 0-111
Pistons ..................................................................................... 1-7
Alternator - Removal................................................................ 0-11
Vibration Damper ..................................................................... 1-7
Alternator Inspection .............................................................. 13-3
Cylinder Block - Inspection..................................................... 1-15
Balancer - Assembly................................................................ 1-51
Cylinder Block - Precheck Before Disassembly ..................... 1-10
Balancer - Disassembly........................................................... 1-48
Cylinder Block - Prepare for Assembly ................................... 0-41
Balancer - Installation ............................................................. 0-62
Cylinder Block - Removing From the Rollover Stand ............. 0-41
Balancer - Removal ................................................................. 0-35
Cylinder Block - Service Tools.................................................. 1-8
Locking the Balancer.............................................................. 0-35
Cylinder Block - Storing .......................................................... 1-25
Measuring Backlash ............................................................... 0-35
Cylinder Block Group Inspection Checklist ............................. 1-9
Measuring the End Play ......................................................... 0-35
Cylinder Head - Assembly ....................................................... 2-21
Removing the Balancer .......................................................... 0-36
Cylinder Head - Cleaning .......................................................... 2-7
Belt Tensioner - Inspection ..................................................... 8-10
Cylinder Head - Disassembly .................................................... 2-6
Belt Tensioner - Installation ................................................... 0-111
Cylinder Head - Installation..................................................... 0-92
Belt Tensioner - Removal......................................................... 0-10
Cylinder Head - Precheck Before Disassembly ........................ 2-6
Belt Tensioner and Fan Hub - Exploded View .......................... 8-5
Cylinder Head - Removal......................................................... 0-22
Belt Tensioner and Fan Hub - General Information .................. 8-6
Cylinder Head - Service Tools................................................... 2-2
Belt Tensioner .......................................................................... 8-6
Cylinder Head - Tightening ..................................................... 0-95
Blowby Measurement .............................................................. 14-7
Cylinder Head Combustion Face Inspection........................... 2-11
Blowby Conversion Chart (5.613 mm [0.221 in] Orifice)........... 14-7
Cylinder Head Cracks - Reuse Guidelines .............................. 2-12
Camshaft - Cleaning................................................................ 1-29
Data Plate - Replacement........................................................ 1-59
Camshaft - Installation ............................................................ 0-56
Dipstick - Removal .................................................................. 0-19
Camshaft End Play - Measuring ............................................. 0-58
Dipstick Tube - Replacement .................................................. 1-25
Camshaft Gear Backlash - Measuring .................................... 0-59
Drive Belt - Installation .......................................................... 0-113
Camshaft - Removal ................................................................ 0-31
Drive Belt - Removal.................................................................. 0-9
Measuring Gear Lash ............................................................. 0-31
Drive Belt Tension ................................................................... V-36
Camshaft and Gear - Inspection ............................................. 1-29
Drive Units - General Information ............................................. 9-3
Camshaft Lobe Edge Deterioration (Breakdown) Criteria ......... 1-31
Accessory Drive Adapter .......................................................... 9-3
Camshaft Lobe Pitting Reuse Criteria..................................... 1-30
Electrical Equipment - General Information ........................... 13-2
Camshaft Bushing - Installation.............................................. 1-23
Engine - Painting .................................................................. 14-28
Camshaft Capscrew - Installation ........................................... 1-38
Engine Assembly ..................................................................... 0-41
Camshaft Expansion Plug - Installation.................................. 1-22
Engine Component Torque Values .......................... V-3 , V-4 , V-5
Camshaft Gear - Replacement ................................................ 1-34
Engine Diagram - Automotive Engine ...................................... E-9
Camshaft Gear - Installation (Heated Gear Method)................ 1-34
Engine Disassembly ................................................................. 0-8
Camshaft Gear - Installation (With Special Tool 3823589) ....... 1-36
Engine Disassembly and Assembly.......................................... 0-4
Camshaft Gear - Removal ...................................................... 1-34
Assembly ................................................................................ 0-4
Capscrew Markings and Torque Values .................................. V-41
Disassembly ............................................................................ 0-4
Charge Air Cooler (CAC) - Cleaning and Inspection for Reuse. 10-8
General Information ................................................................. 0-4
Cleaning ................................................................................. 10-8
Engine Disassembly and Assembly - Service Tools................. 0-5
Inspection............................................................................... 10-9
Engine Disassembly Check List ............................................... 0-7
Charge Air Cooler (CAC) - Pressure Testing ........................... 10-9
Engine Dynamometer Test - Engine Run-In ......................... 14-14
Chassis Dynamometer - Operation ...................................... 14-20
Engine Dynamometer Test - Performance Checking ............ 14-18
Component Specifications and Torque Values ........................ V-6
Engine Dynamometer Test - Installation of the Engine ........ 14-8
Air Intake System ................................................................... V-32
Engine Identification................................................................. E-2
Combustion Air System .......................................................... V-31
Automotive Engine Dataplate ................................................... E-2
Compressed Air System Torque Values .................................. V-33
Automotive Engine Nomenclature ........................................... E-3
Cylinder Block - Rebuild Specifications .................................. V-16
Engine Dataplate ..................................................................... E-2
Cylinder Block - Torque Values............................................... V-22
Industrial Engine Nomenclature .............................................. E-3
Cylinder Head - Rebuild Specifications .................................. V-23
Engine Run-In Procedure - (Chassis Dynamometer) ........... 14-25
Cylinder Head - Torque Values ............................................... V-25
Engine Run-In Procedure ``In Chassis'' - (On- and
Electrical System ................................................................... V-34
Off-Highway Vehicles) ........................................................... 14-27
Engine Assembly - Capscrew Torque Values........................... V-10
Off-Highway ......................................................................... 14-27
Engine Assembly - Specifications............................................. V-6
On-Highway ......................................................................... 14-27
L-528