TM 5-3805-281-24-2
Engine Rebuild, Break-In, and Tune-Up
ENGINE DISASSEMBLY SEQUENCE FOR OVERHAUL
NOTE: ALWAYS bolt down liners when rotating
The following sequence is suggested when complete
engine flywheel with cylinder head removed.
disassembly for overhaul is required. Refer to the
appropriate repair group when removing individual
engine components.
14. Remove cylinder head with assembly. Remove
head gasket.
1. Drain all coolant and engine oil. Check engine oil
for metal contaminates.
15. On SAE No. 3 flywheel housings, remove flywheel
housing and then remove flywheel.
2. Remove turbocharger oil inlet line and oil return
line. Remove turbocharger.
16. On SAE No. 1 and 2 flywheel housings, remove
flywheel and then remove flywheel housing.
3. Remove fan pulley and water manifold assembly.
17. Revolve engine on repair stand and remove
4. Remove water pump assembly from timing gear
engine oil pump assembly.
cover.
18. Remove front timing gear cover.
NOTE: DO NOT damage option code label (if
equipped), when removing rocker arm cover.
19. Revolve engine to vertical position. Remove
pistons and connecting rods. Identify for
reassembly. Perform bearing-to-journal wear
5. Remove breather hose from rocker arm cover.
checks with PLASTIGAGE.
Remove rocker arm cover.
6. Remove rocker arm assembly and push rods.
20. Remove main bearing caps and remove
Identify parts for reassembly.
crankshaft. Perform bearing-to-journal wear
checks with PLASTIGAGE.
7. Remove front crankshaft pulley and damper
assembly.
21. Remove camshaft and cam followers. Identify for
reassembly.
8. Remove fuel injection lines and injection nozzles.
22. Revolve engine to horizontal position, remove
9. Remove engine oil filter, filter base, and valve
liners, O-rings, and packings. Mark liners for
housing.
reassembly in same bore from which removed.
10. Remove injection pump gear cover and remove
23. Remove piston cooling orifices from cylinder block.
injection pump. Remove fuel filter and mounting
base.
24. Remove any sensors/gauges, cylinder block plugs
and engine serial number plate, if block is to be
11. Remove engine oil cooler assembly.
put in a "hot tank".
25. Refer to appropriate group for inspection and
repair of engine components.
13. Remove air intake manifold.
PLASTIGAGE is a trademark of DANA Corp.
RG,RG34710,1050
1923OCT971/1