TM 5-2420-230-24-2
Index
Page 2
General Information .................................................................. 2-5
Engine Storage - Long Term ................................................. 14-31
Exhaust Manifold .................................................................... 11-3
Removing the Engine from Long-Term Storage .................... 14-34
Flywheel and Ring Gear ......................................................... 16-2
Engine Storage - Short Term ................................................ 14-29
Flywheel Housing ................................................................... 16-2
Removing the Engine from Short-Term Storage ................... 14-31
Front Support ......................................................................... 16-2
Engine Testing - Engine Side Views ............................. 14-4 , 14-5
General Information - Injectors ................................................. 6-4
Engine Testing - General Information ..................................... 14-6
General Information - Lubrication System................................ 7-6
General Engine Test Specifications......................................... 14-6
Oil Cooler Core ........................................................................ 7-6
Engine Testing - Service Tools................................................ 14-2
General Information About Fans ............................................. 8-14
Engine Weight ........................................................................... 0-8
General Repair Instructions ..................................................... i-10
Exhaust Manifold - Exploded View.......................................... 11-2
General Safety Instructions ....................................................... i-9
Exhaust Manifold - Installation .............................................. 0-105
Important Safety Notice ............................................................. i-9
Exhaust Manifold - Removal.................................................... 0-14
Generic Symbols ....................................................................... i-4
Exhaust Manifold Inspection ................................................... 11-4
Glossary of Terms .................................................................... i-12
Expansion and Pipe Plug - Installation................................... 1-20
How To Use The Manual............................................................. i-3
Exploded View........................................................................... 2-3
Group Contents ......................................................................... i-3
Exploded View - Fuel System ................................................... 5-3
Index ......................................................................................... i-3
Fan Hub - Disassembly ............................................................. 8-7
Metric Information ..................................................................... i-3
Fan Hub - Inspection ................................................................. 8-7
Table of Contents....................................................................... i-3
Fan Hub - Installation ............................................................. 0-110
Illustrations................................................................................. i-8
Fan Hub - Removal................................................................... 0-11
Injection Pump - General Information ...................................... 5-4
Fan Hub Assembly .................................................................... 8-8
Injection Pump - Identification ................................................. 5-4
Fan Pulley - Removal ............................................................... 0-10
Injection Pump - Installation ................................................... 0-71
Filter Bypass Valve - Replace ................................................... 7-8
Injection Pumps - Unlocking ................................................... 0-74
Flywheel - Installation ............................................................. 0-89
Locked Timed Injection Pump - Installation............................. 0-72
Flywheel - Removal ................................................................. 0-23
Unlocked Bosch VE and P7100 Injection Pump - Installation .. 0-80
Flywheel and Ring Gear Inspection........................................ 16-3
Unlocked CAV Injection Pump - Installation ............................ 0-76
Flywheel Housing - Installation............................................... 0-89
Unlocked Stanadyne DB4 Injection Pump - Installation........... 0-77
Flywheel Housing - Removal................................................... 0-23
Injection Pump - Removal (In-Line) ........................................ 0-26
Flywheel Housing Assembly ................................................... 16-4
Injection Pump - Removal (Rotary Type Pumps) .................... 0-24
Wet Clutch Application ........................................................... 16-5
Drive Gear - Removal ............................................................. 0-26
Flywheel Housing Inspection.................................................. 16-4
Gear Lash - Check ................................................................. 0-24
Front Cover - Installation......................................................... 0-91
Locking the Pump .................................................................. 0-25
Front Cover - Removal............................................................. 0-22
Injection Pump Dataplate ......................................................... E-4
Front Support - Cleaning and Inspection ............................... 16-6
Lucas CAV DPA dataplate location. .......................................... E-4
Fuel Filter - Removal ............................................................... 0-14
Robert Bosch VE dataplate location. ........................................ E-4
Fuel Filter Head - Installation ................................................ 0-104
Injection Pump Repairs - Bosch VE........................................ 5-15
Fuel Filter Head - Removal...................................................... 0-15
Delivery Valve Holder/Sealing Washer - Replacement............. 5-16
Fuel Lines - Clean and Inspect ............................................... 6-16
Fuel Inlet Adapter/Seal - Replacement.................................... 5-20
Fuel Drain Manifold ................................................................ 6-17
Overflow Adapter/Sealing Ring - Replacement........................ 5-19
High Pressure Fuel Lines ....................................................... 6-16
Shaft Seal - Replacement....................................................... 5-15
Low Pressure Fuel Lines ........................................................ 6-18
Shutdown Lever/Spring - Replacement ................................... 5-18
Fuel Lines - Installation ......................................................... 0-101
Shutdown Solenoid - Replacement ......................................... 5-17
Fuel Drain Manifold - Installation........................................... 0-102
Injection Pump Repairs - Lucas CAV DPA ............................. 5-25
High Pressure Fuel Lines - Installation .................................. 0-103
Automatic Timing Advance - Disassembly............................... 5-33
Injection Pump Supply Line - Installation............................... 0-101
Back Leakage Valve - Replacement/Inspection ....................... 5-26
Injection Pump Vent Line - Installation .................................. 0-102
Bleed Screws/Sealing Washers - Replacement ....................... 5-28
Fuel Lines - Removal............................................................... 0-16
Control Lever - Replacement .................................................. 5-30
Fuel Drain Manifold - Removal................................................ 0-17
Fuel Inlet Fitting/Sealing Washer - Replacement..................... 5-30
High Pressure Fuel Line - Removal ........................................ 0-16
Locking Screw/O-Ring - Replacement..................................... 5-25
Low Pressure Fuel Lines - Removal........................................ 0-18
Shutdown Lever/Spring - Replacement ................................... 5-31
Fuel Pump Stud - Replacement .............................................. 1-58
Shutdown Solenoid - Replacement ......................................... 5-27
Fuel Transfer Pump - Cleaning and Inspecting ...................... 6-13
Timing Advance - Assembly.................................................... 5-35
Fuel Transfer Pump - General Information ............................... 6-5
Timing Advance Components - Inspection .............................. 5-34
Fuel Transfer Pump - Identification .......................................... 6-5
Vent Fitting/Sealing Washer - Inspection/Replacement ........... 5-29
Fuel Transfer Pump - Installation............................................ 0-69
Injection Pump Repairs ........................................................... 5-39
Fuel Transfer Pump - Piston Style Rebuild............................. 6-14
Fuel Inlet Banjo Connector Replacement, Bosch P7100 ......... 5-50
Assembly................................................................................ 6-15
Fuel Pump Shut Off Lever Replacement, Bosch P7100........... 5-52
Cleaning................................................................................. 6-15
Fuel Shut Off Solenoid Adjustment, Bosch P7100 ................... 5-51
Fuel Transfer Pump - Removal................................................ 0-28
Fuel Shut Off Solenoid Bracket Replacement, Bosch P7100 ... 5-52
Gear Housing - Disassembly .................................................. 1-58
Fuel Shut Off Solenoid Replacement, Bosch P7100 ................ 5-51
Gear Housing - Installation ..................................................... 0-54
Injection Pump Timing - Nippondenso EP9 ............................ 5-44
Gear Housing - Removal ......................................................... 0-34
Injection Pump Timing - Stanadyne DB4 ................................ 5-39
Gear Housing and Timing Pin Assembly - Inspection ........... 1-57
Pressure Relief Valve and Sealing Washer Replacement,
General Cleaning Instructions .................................................. i-11
Bosch P7100 .......................................................................... 5-48
Glass or Plastic Bead Cleaning................................................ i-11
Return Connection Replacement, Stanadyne DB4 .................. 5-40
Solvent and Acid Cleaning ....................................................... i-11
Seal Replacement, Bosch P7100 ............................................ 5-50
Steam Cleaning ....................................................................... i-11
Seals Replacement, Nippondenso EP9 .................................. 5-46
General Engine Specifications ................................................. E-6
Shut Down Lever or Spring Replacement, Nippondenso EP9 . 5-46
Batteries (Specific Gravity) ....................................................... E-8
Shutdown Solenoid Inspection, Bosch P7100 ........................ 5-54
Cooling System........................................................................ E-7
Shutoff Solenoid Replacement, Stanadyne DB4...................... 5-41
Electrical System ..................................................................... E-8
Speed Droop Adjustment Off Engine - Stanadyne DB4........... 5-43
Fuel System............................................................................. E-7
Throttle Lever Replacement, Bosch P7100 ............................. 5-53
General Engine Data................................................................ E-6
Injection Pump Timing - Bosch VE ......................................... 5-21
Intake Air and Exhaust System ................................................ E-7
Injector - Assembly.................................................................. 6-10
Lubrication System .................................................................. E-6
Injector - Clean and Inspect...................................................... 6-8
General Engine Test Procedures - (Chassis Dynamometer). 14-22
L-529
