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Isuzu C-240PW-28 Technical Manual Download Page 7

CHANGE

No. 1

ARMY TM 9-2815-254-24

AIR FORCE TO 38G1-94-2

C1

HEADQUARTERS

DEPARTMENTS OF THE ARMY, AND AIR FORCE

WASHINGTON, DC., 15 DECEMBER 1993

TECHNICAL MANUAL

UNIT, DIRECT SUPPORT AND GENERAL SUPPORT

MAINTENANCE INSTRUCTIONS

DIESEL ENGINE

MODEL C-240PW-28

4 CYLINDER 2.4 LITER

NSN: 2815-01-350-2207

DISTRIBUTION STATEMENT A; 

Approved for public release; distribution is unlimited.

TM 9-2815-254-24/TO 39G1-94-2, 1 SEPTEMBER 1993 is changed as follows:

1.

Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar

in the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages

lnsert pages

iii and iv

iii and iiv

3-3 and 3-4

3-3 and 3-4

3-9 through 3-12

3-9 through 3-12

B-5 and B-6

B-5 and B-6

- - - - - -

Appendix E

2.

Retain this sheet in front of manual for reference purposes.

Summary of Contents for C-240PW-28

Page 1: ...8G1 94 2 TECHNICAL MANUAL UNIT DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS DIESEL ENGINE MODEL C 240PW 28 4 CYLINDER 2 4 LITER NSN 2815 01 350 2207 HEADQUARTERS DEPARTMENTS OF THE ARMY...

Page 2: ......

Page 3: ...radiator cap or drain cock slowly to relieve any excess pressure Diesel fuel is flammable and toxic to eyes skin and respiratory tract Skin eye protection required Avoid repeated prolonged contact Go...

Page 4: ......

Page 5: ...tember 1993 is changed as follows 1 Remove and insert pages as indicated below New or changed text material is indicated by a vertical bar in the margin An illustration change is indicated by a miniat...

Page 6: ...eneral United States Army Chief of Staff Administrative Assistant to the Secretary of the Army 02954 RONALD R FOGELMAN General USAF Chief of Staff HENRY VICCELLIO Jr General USAF Commander Air Force M...

Page 7: ...ENT A Approved for public release distribution is unlimited TM 9 2815 254 24 TO 39G1 94 2 1 SEPTEMBER 1993 is changed as follows 1 Remove and insert pages as indicated below New or changed text materi...

Page 8: ...Assistant to the Secretary of the Army 05829 GORDON R SULLIVAN General United States Army Chief of Staff MERRILL A McPEAK General USAF Chief of staff Official RONALD W YATES General USAF Commander Air...

Page 9: ...may also submit your recommended changes by E mail directly to mpmt avma28 st louis emh7 army mil Instructions for sending an electronic 2028 may be found at the back of this publication immediately p...

Page 10: ...sassembly and Assembly Sequence for Overhaul 3 12 Section IV COOLING SYSTEM MAINTENANCE 3 16 3 5 General 3 16 3 6 Thermostat 3 16 3 7 Water Pump 3 18 Section V FUEL SYSTEM MAINTENANCE 3 21 3 8 General...

Page 11: ...3 9 9 Rocker Cover and Arms 3 102 Cylinder Head Assembly 3 110 Pistons Connecting Rods and Crankshaft 3 127 Crankcase 3 148 Camshaft and ldler Gear Assemblies 3 150 Flywheel and Housing 3 158 Cylinder...

Page 12: ...37 Removing coupling Typical 3 37 Removing Tappet Holder Typical 3 38 Removing Tapped Typical 3 39 Removing Delivery Valve 3 40 Removing Plunger Barrel 3 41 Plunger Helix 3 43 Checking Plunger and Ba...

Page 13: ...nce 3 112 3 62 Hot Plug Removal 3 113 3 63 Cylinder Head Inspection 3 114 3 64 Cylinder Head Height Reference 3 115 3 65 Hot Plug Depression 3 116 3 66 Valve Stem and Guide Clearance 3 117 3 67 Valve...

Page 14: ...ation 3 144 Crankshaft Bearing Cap Bolt Tightening Sequence 3 145 Crankshaft Rear Oil Seal and Spacer 3 146 Piston Ring Gap Setting 3 147 Crankcase 3 149 Crankcase Fastener Tightening Sequence 3 150 M...

Page 15: ...FORCE TO 38G1 94 2 LIST OF TABLES 1 1 Table of Specifications 1 5 3 1 Preventive Maintenance Checks and Services PMCS 3 1 3 2 Troubleshooting 3 4 3 3 Fuel Pump Test Specifications 3 56 3 4 Capacity T...

Page 16: ......

Page 17: ...the Army Maintenance Management Sys tem TAMMS Air Force personnel will use AFR 66 1 Air Force Maintenance Management Policy for mainte nance reporting and TO 00 35D54 for unsatisfactory equipment repo...

Page 18: ...efer to TB 740 97 2 for procedures to place the equipment into storage WARRANTY The engine is warranted for a specific period of time Refer to Warranty Technical Bulletin for the end item The warranty...

Page 19: ...on System The lubrication system consists of the oil pan a gerotor type oil pump spin on type oil filter and internal passages within the engine There are two external oil lines one for rocker arm lub...

Page 20: ...Pipes Fuel Injector Pipes Injector Nozzle and Glow Plug Oil Filter Fuel Filter Housing PCV Valve Crankshaft Pulley Battery Charging Alternator Starter Intake Manifold Exhaust Manifold Valve cover Ther...

Page 21: ...800 rpm Compression Ratio 20 1 Length 28 9 in 736 mm Width 21 0 in 535 mm Height Weight 32 1 in 815 mm 491 Ibs 223 kg Firing Order Injection Pump 1 3 4 2 Kiki PES4A Governor Barber Colman Model 10502...

Page 22: ...packing materials have been removed b Check engine identification plate for positive identification c Inspect engine exterior for shipping damage d Check fan belt drive for proper tension Refer to en...

Page 23: ...coolant temperature and to warn if temperature exceeds a predetermined value 2 3 LUBRICATION SYSTEM The lubrication system consists of an oil pan dipstick pump and filter The oil sump is a reservoir...

Page 24: ...f external mounted batteries starter battery charging alternator and related re lays and switches for control of the system Battery power supplied to the starter during the start cycle energizes the s...

Page 25: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 SECTION II OPERATING INSTRUCTIONS NOTE Refer to end item operator s manual 2 3 2 4 blank...

Page 26: ......

Page 27: ...nd Services PMCS Item Interval Procedures Check Equipment is No Item for and have Not Ready M Q S A B H to be repaired or adjusted Available Inspected as necessary If 1 300 Oil Filter Change oil filte...

Page 28: ...y If 5 3000 Engine Fuel Remove clean and Injectors test injectors Refer to paragraph 3 10 6 1500 Engine Compression Check engine com pression Refer to paragraph 3 27 7 Engine compression is low 7 1500...

Page 29: ...table be sure you have performed your PMCS Prior to performing troubleshooting procedures within this manual per form your operator s troubleshooting and the end item maintenance manual troubleshootin...

Page 30: ...ied to fuel injection pump a Test feed pump capacity Refer to paragraph NO TAG If feed pump not defec tive do step 2 b Repair or replace fuel feed pump Refer to paragraph 3 11 Check for dogged fuel fi...

Page 31: ...Check for air in fuel system lines Bleed fuel system at fuel fitter Refer to paragraph 3 12 If no air do step 3 Check for tow coolant temperature a If coolant temperature not low do step 4 b Replace d...

Page 32: ...aks Check for defective thermostat a If thermostat is suspected of being defective replace thermostat Refer to paragraph 3 6 b If engine continues to overheat do step 3 Check for defective water pump...

Page 33: ...ive oil pump a Remove and inspect oil pump for defective parts Refer to paragraphs 3 18 1 and 3 18 2 If not defective do step 6 b Replace oil pump Refer to paragraph 3 18 Check for worn rocker arm bus...

Page 34: ...found do step 2 Check for defective fuel injectors a Test fuel injectors Refer to paragraph 3 10 If not defective do step 3 b Replace fuel injectors Refer to paragraph 3 10 Check for improper fuel in...

Page 35: ...5 ENGINE MAKES ABNORMAL NOISE Step 1 Check for worn or damage water pump bearing a Check for excessive water pump shaft play at cooling fan If not excessive do step 2 b Replace defective water pump Re...

Page 36: ...to paragraph 3 13 lf timing is correct proceed to Step 2 Defect fuel injector nozzles a Test fuel injection nozzles Refer to paragraph 3 10 lf fuel injection nozzles is not defective proceed to Step 2...

Page 37: ...eries not defective do step 2 b Replace batteries Refer to and item maintenance manual Step 2 Test for defective battery charging alternator fective do step 3 a Inspect and test battery charging alter...

Page 38: ...ces of old gasket and compound Take extreme care to exclude dirt from all gasket surfaces and gasket com pound from all tapped holes unless otherwise specified It is recommended that all oil seals are...

Page 39: ...to end item maintenance manual Check engine oil for metal contami nates Remove fan belt and alternator refer to paragraph 3 24 1 Remove starter assembly refer to paragraph 3 23 1 Remove glow plugs ref...

Page 40: ...ssembly refer to paragraph 3 30 1 u Remove pistons connecting rods and crankshaft refer to paragraph 3 28 1 v Remove camshaft assembly refer to paragraph 3 30 1 w Disassemble cylinder block assembly r...

Page 41: ...aph 3 13 q Install fuel injectors and piping refer to paragraph 3 10 7 r Install glow plugs refer to paragraph 3 22 4 s Install fuel filter refer to paragraph 3 9 4 t Install oil filter and piping ref...

Page 42: ...EMOSTAT AND HOUSING If the engine has been operating and coolant is hot allow engine to cool before you slowly loosen filler cap and relieve pressure from cooling system Failure to observe this warnin...

Page 43: ...ing 8 3 6 2 Inspection N O T E If thermostat is suspected of being defective replace thermostat a Inspect thermostat for excessive wear or damage b Inspect housing for cracks corrosion or other damage...

Page 44: ...Do not drain coolant until coolant temperature is below operating tem perature prior to removal Severe personal injury can occur a Drain coolant system if not already drained refer to end item mainte...

Page 45: ...tation 3 7 4 Installation Ensure longer bolts 5 FIGURE 3 2 are installed in the location noted during removal Failure to observe this caution will result in pump not being secured properly a Apply sea...

Page 46: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 2 Water Pump 3 20...

Page 47: ...suspected of leaking 3 9 1 Removal a b C d Diesel fuel is flammable and toxic to eyes skin and respiratory tract Skin eye protection required Avoid repeated prolonged contact Good general ventilation...

Page 48: ...Disassembly a Remove drain plug 1 FIGURE 3 3 and preformed packing 20 from thru bolt 21 Discard preformed pack ing 20 b Remove thru bolt 21 and remove preformed packing 22 filter bowl 23 and preformed...

Page 49: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 3 Fuel Filter Assembly 3 23...

Page 50: ...age bolt 7 Remove caps and connect fuel line to fitting 25 on side of filter body 15 If removed from fuel injection pump remove caps and attach one end of fuel tube 4 to pump with two new seals 6 and...

Page 51: ...y of foreign material e At each fuel injector remove fluid passage bolt 8 and two seals 7 securing fuel tube 10 At fuel filter re move fluid passage bolt 8 and two seals 9 remove fuel tube 10 Discard...

Page 52: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 4 Fuel lnjectors and Piping 3 26...

Page 53: ...needle in nozzle body and check for smooth movement of needle inside the body If needle does not move smoothly after cleaning replace nozzle Check nozzle body and nozzle needle for damage or deformat...

Page 54: ...ccur Do not use a metal brush since scars could cause leakage b Remove nozzle needle valve from nozzle body Holding the needle valve by stem only clean shaft section and seat surface of needle valve w...

Page 55: ...5 d Install adjusting screw 16 N O T E New gasket 15 and cap nut 14 will be installed after adjustment paragraph 3 10 6 3 10 6 Test Adjustment N O T E Perform step a through c if cap nut 14 FIGURE 3 4...

Page 56: ...3 4 as necessary to obtain starting pressure and spray pattern in step f h Repeat step e and operate level to hold pressure at 290 psi 20 4 kg cm2 below opening pressure i No drops should fall from fu...

Page 57: ...le fuel tube rupture Carefully position and tighten each of the three clamp assemblies 5 Tighten fuel injector screw 22 to 54 ft lbs 73 2 Nm Remove caps and position fuel tube 10 on each fuel injector...

Page 58: ...g fuel tube from fuel fitter Remove and discard two seals 2 Cap openings e Remove fluid passage bolt 3 from side of fuel injection pump securing oil feed tube Remove and discard two preformed packings...

Page 59: ...ns and defects if any Lay out parts in order of disassembly This will aid in reassembling pump Clean outer surface of pump Remove all grease and dirt Drain lubricating oil from pump Procedure Mount fu...

Page 60: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 7 Fuel Feed Pump and Timer Assembly 3 34...

Page 61: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 8 Fuel Injection Pump Assembly 3 35...

Page 62: ...lockwashers 9 and preformed packing 11 i Remove two screws 11 FIGURE 3 8 securing cover 12 to side of pump remove cover Remove and dis card two gaskets 13 and gasket 14 j Rotate camshaft 18 until tap...

Page 63: ...uring housing 17 to end of pump By tapping housing 17 lightly with a mallet separate it from the pump Remove and discard gasket 18 o Remove adapter 19 from pump housing 3 p Lay pump on its side and re...

Page 64: ...ocation of rings 22 u If necessary remove bearings 20 shims 21 and rings 22 from each end of camshaft v Lay pump 19 on its side N O T E Steps w through ac apply to each of the pumping chambers w Inser...

Page 65: ...tom plug hole remove plunger 24 lower spring seat 25 and spacer ring 26 aa Remove spring 27 through bottom plug hole ab Remove upper spring seat 28 and then remove cylinder sleeve 29 sleeve pinion 30...

Page 66: ...and gasket 36 refer to FIGURE 3 15 FIGURE 3 15 Removing Delivery Valve Be sure to keep each plunger 24 FIGURE 3 8 with its corresponding plunger barrel 37 If plungers and barrels are not matched clea...

Page 67: ...damage to feed pump housing 10 FIG URE 3 7 a Clamp feed pump in a vise with priming pump 20 up b Unscrew and remove priming pump 20 and preformed packing 21 Discard preformed packing c Unscrew and rem...

Page 68: ...oes not meet the specifications contained in paragraph 3 11 3 3 The only disassem bly authorized is described below Mount base of inserter tool 157924 1620 in a vise If not already done install guide...

Page 69: ...o not reuse them 3 11 3 1 Injection Pump a Check that plunger helix FIGURE 3 17 is not damaged that color of plunger and plunger barrel 37 FIGURE 3 8 have not changed and that Plungers move smoothly i...

Page 70: ...ssembly d Holding delivery valve seat close port with finger tip Push valve into seat and check that it is returned by the air inside when released refer to FIGURE 3 19 If valve is not returned then f...

Page 71: ...of gear teeth on control rack 39 and sleeve pinion 30 If backlash is more than 0 012 in 0 3 mm replace both control rack 39 and sleeve pinion 300 h Check that flange on plunger 24 is not damaged refe...

Page 72: ...cam surfaces refer to FlGURE 3 23 Check thread damage and keyway groove on both ends If damaged replace camshaft FIGURE 3 23 Camshaft m Check bearings 20 FIGURE 3 8 for rollers deviating from inner r...

Page 73: ...3 2 Feed Pump a Inspect check valve 24 FIGURE 3 7 seats for wear or damage If defective replace check valve b Check piston 29 for damage or cracks If defective replace piston c Check tappet 31 roller...

Page 74: ...1 mm If clearance is not within tolerance change shim thickness 3 11 4 Assembly 3 11 4 1 a b c d e f Mount base of inserter tool 157924 1620 in a vise Install holder 7 FIGURE 3 7 on base Install wash...

Page 75: ...et 27 and plug 26 Apply sealing compound FORMAGASKET2 to threads and seating face of plug 26 Tighten plug 63 ft lbs 86 4 Nm FIGURE 3 27 Feed Pump Plug g Position pump housing so priming pump opening f...

Page 76: ...n pump housing Tighten as follows 1 Tighten to 21 7 ft lbs 29 4 Nm 2 Loosen to zero torque 3 Retighten to 21 7 ft lbs 29 4 Nm 4 Loosen to zero torque 5 Finally tighten to 25 3 ft lbs 34 3 Nm Install c...

Page 77: ...l rack is pushed or pulled refer to FIGURE 3 28 FIGURE 3 28 Checking Sleeve Pinion Movement l Install upper spring seat 28 and spring 27 on plunger barrel 37 through bottom plug holes m Dip plunger 24...

Page 78: ...tappet installer 157921 0120 through bottom plug hole push tappet 23 FIGURE 3 8 upwards align ing plunger flange with groove of cylinder sleeve 29 p When by pushing upward on tappet 23 plunger 24 is...

Page 79: ...y End play should be 0 001 to 0 002 in 0 03 to 0 05 mm If end play is not within limits remove camshaft and change thickness of shims 21 FIGURE 3 8 and recheck end play Check control rack 39 sliding r...

Page 80: ...rs 6 and nuts 5 ak Install timer assembly on camshaft and secure with new lockwasher 6 FIGURE 3 7 and nut 5 Attach spanner 157916 5320 to timer assembly to hold it while tightening nut 5 to 45 ft lbs...

Page 81: ...Remove control rack guide screw 38 and lock control lever rack at 0 472 in 12 mm using locking screw k Attach measuring device 105782 4020 to pump housing No 2 cylinder Measuring needle must rest on t...

Page 82: ...ARMY TM 9 2815 254 24 AlR FORCE TO 36G1 94 2 TABLE 3 1 Fuel Pump Test Specifications 3 56...

Page 83: ...rbitrary angle graduation with No 2 cam placed in beginning of injection position Ensure test oil stops flowing from measuring device pipe in this position Do not move flywheel pointer after it has be...

Page 84: ...uld measure 42 to 44 cc with 1 08 cc between cylinders ae If fuel injection quantity is not as specified adjust as follows N O T E Scribe a mark to identify starting point 1 Loosen sleeve pinion screw...

Page 85: ...e port of feed pump and insert other end into empty container N O T E Ensure a suction head of approximately 3 3 ft 1 m FIGURE 3 32 Feed Pump Test 4 Operate injection pump at 100 rpm 5 Fuel oil must b...

Page 86: ...scon nect discharge hose and insert in measuring container Crank engine for 15 seconds Supply rate should be at least 60 cc Replace feed pump if it fails to meet supply rate 1 Pump should be piped as...

Page 87: ...p suction as piped in step ah refer to FIGURE 3 35 2 Pump discharge connected to test stand pressure gage 3 Operate injection pump at 600 rpm 4 Ensure that feed pump maintains a feed pressure of 25 6...

Page 88: ...scharge port 3 Connect an air supply to suction port and apply a pressure of 28 5 psi 196 5 kPa 4 Immerse feed pump in a container of diesel fuel and check for air leakage There must be no air leakage...

Page 89: ...e a mechanical gover nor skip steps a thru g and proceed with step h Disconnect and remove spring 1 FIGURE 3 37 Remove stud 2 and washer 3 Position pump in a pan to collect any oil which may be contai...

Page 90: ...s 4 FlGURE 3 8 and fluid passage bolt 3 Tighten bolt to 132 in lbs 14 9 Nm l Remove caps and position fuel tube from fuel filter on top front of fuel injection pump and secure with two new seals 2 and...

Page 91: ...flame Failure to observe this warning could result in severe personal injury or death N O T E Drain fuel into suitable container d Operate priming pump 20 Figure 3 7 until no more bubbles are visible...

Page 92: ...y valve i When fuel stops flowing from No 1 delivery valve stop pumping and stop rotating crankshaft This is correct fuel injection timing j Observe and ensure that crankshaft pulley middle timing mar...

Page 93: ...particles in fuel injection pump while delivery valve is removed Otherwise damage to pump could oc cur e Hold fuel control lever to full fuel position N O T E Injection timing adjustment is done by p...

Page 94: ...no fuel flows as pumping is continued N O T E Remove fuel priming pump and PCV hoses as necessary to torque nuts k Tighten four nuts 5 securing pump to 168 in lbs 19 0 Nm l Remove delivery valve body...

Page 95: ...Using filter wrench turn cartridge an additional 1 to 1 1 4 turns h Service lubrication system refer to end item maintenance manual i Operate engine and check for leakage 3 14 2 Removal a Drain lubri...

Page 96: ...e engine and check for leakage 3 15 OIL PRESSURE RELIEF VALVE 3 15 1 Removal a Drain lubrication system refer to end item maintenance manual b Remove oil pressure relief valve 5 FIGURE 3 38 and o ring...

Page 97: ...tion a If removed install plug 7 with new seal 8 Torque plug between 18 1 to 25 3 ft lbs 24 5 to 34 3 Nm b Install oil pressure relief valve 5 and o ring 6 Torque relief valve between 18 1 to 25 3 ft...

Page 98: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 39 Oil Piping 3 72...

Page 99: ...3 and secure with two new gaskets 2 and fluid passage bolt 1 Tighten bolt to 84 in lbs 9 5 Nm c Service lubrication system refer to end item maintenance manual d Operate engine and check for leaks 3 1...

Page 100: ...ces of oil pan gasket or liquid gasket Apply an even coat of sealing compound FORMAGASKET2 to crankcase flange Affix new gasket 7 FIGURE 3 40 to crankcase flange Remove screw 3 and washer 4 securing t...

Page 101: ...ove crankcase refer to paragraph 3 29 1 c Disconnect oil pipe 1 FIGURE 3 41 at sleeve nut d Remove two screws 2 securing pump assembly and remove pump e Disconnect pipe 1 from pump f Unscrew strainer...

Page 102: ...in View C FIGURE 3 42 Standard clearance is 0 0079 to 0 0106 in 0 20 to 0 27 mm and limit is 0 016 in 0 40 mm If clearance exceeds limit replace pump rotor 8 FIGURE 341 d Inspect strainer 3 for blocka...

Page 103: ...VIEW A ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 VIEW C FIGURE 3 42 Oil Pump Inspections VIEW B 3 77...

Page 104: ...perature or high oil pressure readings will occur b At 850 rpm engine speed and 200 F 93 C operating temperature gage should show a minimum pressure of 14 psi 100 kPa c At rated speed 1800 to 2500 rpm...

Page 105: ...move two bolts 11 lockwashers 13 and washers 12 securing PCV valve 14 remove valve Discard lockwashers 13 Remove two screws 15 securing breather pipe 17 to tappet cover 28 Remove bracket 16 breather p...

Page 106: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 44 PCV Assembly 3 80 Change 2...

Page 107: ...hten screws evenly to 168 in lbs 19 0 Nm Position tube 25 on side of engine and secure with bolt 23 and new lockwasher 24 Attach hose 22 to tube 25 and oil pan and secure with two clamps 20 Attach hos...

Page 108: ...e manifold Remove intake manifold 7 exhaust manifold 8 and gasket 9 Discard lockwashers 5 and gasket 14 Remove two nuts 10 lockwashers 11 and washers 12 securing inlet pipe 13 to intake manifold 5 Rem...

Page 109: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 45 Intake and Exhaust Manifolds 3 83...

Page 110: ...n studs in cylinder head NOTE lntake manifold and exhaust manifold must be installed as an assembly e Position exhaust manifold 8 and intake manifold 7 on studs and secure hand tight at points A and B...

Page 111: ...s as a set Never replace just one glow plug 3 22 3 Testing a Disconnect connector 1 from glow plug b Set multimeter for ohms and connect one lead of multimeter to glow plug terminal and other lead to...

Page 112: ...housing c Cover opening in flywheel 3 23 2 Disassembly a Benchmark gear case 23 FIGURE 3 47 field coil 24 and housing 11 to aid in aligning parts during assembly b Disconnect field coil connecting wir...

Page 113: ...ng spring against brush i Remove brusher holder 15 NOTE Note installation of shift fork 20 to aid in assembly j Remove nut 16 lockwasher 17 and stud 19 securing shift fork 20 in gear case 23 k Remove...

Page 114: ...RCE TO 38G1 94 2 FIGURE 3 47 Starter Assembly 3 23 3 Testing 3 23 3 1 Testing Starter Installed a Make sure batteries are fully charged and that all battery and starter cables are serviceable and prop...

Page 115: ...ead battery voltage the solenoid is defective If multimeter indicates battery voltage but starter does not operate starter is defective 3 23 5 2 Testing Starter Components a Test armature for grounds...

Page 116: ...B with a multimeter Refer to FIGURE 3 48 2 No continuity should be indicated when solenoid plunger is in normal out position 3 Push solenoid plunger in and note multimeter Multimeter should indicate c...

Page 117: ...r in a lathe to re move surface pits scoring and contamination Normal diameter is 1 89 in 48 0 mm minimum after turning is 1 77 in 45 0 mm Maximum runout should be 0 016 in 0 4 mm Total Indicator Read...

Page 118: ...sure they move smoothly NOTE Thrust washers 30 consist of two washers one 0 008 in 0 2 mm and the other 0 039 in 1 0 mm thick Thrust washer 31 is 0 009 in 0 25 mm thick Thrust on armature is normally...

Page 119: ...n starter on flywheel housing engaging clutch 27 FIGURE 3 47 gear teeth with flywheel ring gear Secure starter to flywheel housing with two nuts 1 new lockwashers 2 and washers 3 b Connect electrical...

Page 120: ...to wires connecting stator to rectifier 26 b Remove three thru screws 8 and 9 Remove front cover 10 with rotor 11 from stator 25 and rear cover 24 c Clamp rotor 11 in a soft jawed vise d Remove nut l...

Page 121: ...ear Normal length is 0 630 in 16 mm wear limit is 0 276 in 7 mm If below wear limit replace brush assembly d Check brush spring tension Ensure they hold brush tight against slip ring If weak replace b...

Page 122: ...ARMY TM 9 2815 264 24 AIR FORCE TO 38G1 94 2 FIGURE 3 49 Alternator Assembly 3 96 Change 2...

Page 123: ...k negative side diodes by connecting multimeter positive test probe to each stator terminal and neg ative test probe to terminal E There should be continuity Reverse test probes There should be no con...

Page 124: ...n rear cover to hold brush depressed in brush holder to allow slip ring to pass through Position rotor 11 with front cover 10 attached into stator and rear cover Align benchmarks remove two steel rods...

Page 125: ...TDC e Remove bolt 4 FIGURE 3 50 securing crankshaft pulley 5 to crankshaft and remove pulley f Remove two screws 7 g Support front gear cover 9 and remove thirteen screws 8 attaching cover to engine...

Page 126: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 50 Front Gear Cover 3 100...

Page 127: ...ial pointer 6 Insert new preformed packing 10 firmly into groove on front gear cover Position front gear cover 9 on engine block and secure with thirteen screws 8 Tighten each bolt to 168 ftlbs 19 9 N...

Page 128: ...as viewed from front b Remove two bolts 1 FIGURE 3 52 washers 2 and gaskets 3 securing rocker cover 5 remove rocker cover 5 and preformed packing 6 Discard two gaskets 3 and preformed packing 6 c Loo...

Page 129: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 52 Rocker Covet and Arms 3 103...

Page 130: ...equence c Remove nut 19 and adjusting screw 20 from each rocker arm d Remove dust cap 11 from each end of shaft 18 3 26 3 Inspect and Measure a Check rocker arm shaft 18 FIGURE 3 52 run out as follows...

Page 131: ...t of 0 744 in 18 90 mm If measured value is less than limit replace rocker arm shaft 18 FIGURE 3 52 FIGURE 3 55 Rocker Arm Shaft Outside Diameter c Use either a vernier caliper or a dial indicator and...

Page 132: ...air if necessary to clean oil ports FIGURE 3 56 Rocker Arm Oil Ports Location of f Inspect rocker arm valve stem contact surface for step wear and storing If contact services have light step wear or s...

Page 133: ...2184 NOTE Rocker arm shaft 18 positioning is done by a cutaway machined on shaft end Install retaining plates 13 and shaft 18 so that cutaway faces mating bolt stem NOTE Rocker arms 12 14 16 and 17 ea...

Page 134: ...following the sequence shown in FIGURES 3 52 and 3 53 Start with rocker arm 12 and finish with rocker arm 17 front of engine Retaining plates are marked with an F and this side must face the front of...

Page 135: ...h 3 26 1 b Ensure all eight retaining plate bolts 7 are tight If not tighten in accordance with paragraph 3 26 5 c Rotate crankshaft until crankshaft pulley TDC line is aligned with timing pointer Thi...

Page 136: ...E 3 52 refer to paragraph 3 26 5 3 27 CYLINDER HEAD ASSEMBLY 3 27 1 Removal Do not drain coolant until coolant temperature is below operating tem perature Scalding can occur from failure to observe th...

Page 137: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 60 Cylinder Head Assembly 3 111...

Page 138: ...at a time in the sequence shown in FIGURE 3 61 i After all nineteen bolts 2 FIGURE 3 60 have been loosened remove them and lift cylinder head assembly 3 from engine block Remove and discard head gask...

Page 139: ...ng seven valves N O T E If valves are to be reused tag them with cylinder number from which they were removed If they are to be replaced valve guides must also be replaced e Remove eight valves 10 and...

Page 140: ...9 239 weld four spots evenly spaced to inside circumference of valve seat insert These will be used to pry insert free 2 Allow it to cool for a few minutes which will cause contraction and make remov...

Page 141: ...l injector side of head is 3 620 to 3 624 in 91 95 to 92 05 mm with a limit of 3 612 in 91 75 mm refer to FIGURE 3 64 FIGURE 3 64 Cylinder Head Height Reference 6 If cylinder head lower face is regrou...

Page 142: ...replaced Be absolutely certain there are no scratches or protrusions on combus tion chamber surfaces which will be in contact with hot plug after it is installed These flaws will prevent hot plug fro...

Page 143: ...valve stem clearance standard is 0 0015 to 0 0027 in 0 039 to 0 069 mm with a limit of 0 008 in 0 20 mm Exhaust valve stem clearance standard is 0 0025 to 0 0037 in 0 084 to 0 093 mm with a limit of 0...

Page 144: ...tem standard OD is 0 3118 to 0 3124 in 7 921 to 7 936 mm with a limit of 0 3090 in 7 85 mm g Check valve thickness refer to FIGURE 3 68 Standard measurement is 0 05 in 1 3 mm with a limit of 0 04 in 1...

Page 145: ...rotate valve to pickup chalk on valve 3 Measure valve contact width Refer to FIGURE 3 70 Standard width is 0 05 to 0 06 in 1 2 to 1 5 mm with a limit of 0 08 in 2 0 mm 4 If measured value exceeds lim...

Page 146: ...1 46 in 37 0 mm or outer spring to 1 54 in 39 0 mm 2 Standard pressure to compress inner spring is 12 21 to 13 78 Ibs 5 55 to 6 25 kg with a limit of 11 03 lbs 5 0 kg Standard pressure to compress ou...

Page 147: ...gage 3 If measured value exceeds 0 012 in 0 3 mm replace pushrod 4 Inspect both ends of pushrod for excessive wear or damage If excessive wear or damage is found re place pushrod FIGURE 3 73 Push Rod...

Page 148: ...as of valve seat surface NOTE Use an adjustable valve cutter pilot Do not allow it to wobble inside valve guide 4 Apply lapping compound SSL1682 to valve seat insert surface 5 Insert valve into valve...

Page 149: ...seat insert on valve seat insert 2 NOTE Smooth side of attachment must contact insert Do not apply an excessive amount of pressure with press Damage to valve seat insert will result 2 Use an arbor pre...

Page 150: ...guide has been removed valve and valve guide must be re placed as a set c Install heat shields 14 FIGURE 3 60 as follows NOTE Always install a new heat shield 14 Never reuse an old heat shield 14 1 P...

Page 151: ...fter grinding ensure hot plug surfaces are completely free of protrusions Ensure there are no hot plug depressions 8 Tap each hot plug heed lightly to ensure they are firmly seated f Apply a coat of e...

Page 152: ...3 7 Nm Used bolts 47 0 ft lbs 63 7 Nm 2 Step 2 New bolts 58 ft lbs 78 Nm Used bolts 65 0 ft lbs 88 3 Nm e Lubricate ends of pushrods 1 FIGURE 3 60 with engine lubricating oil MIL L 2104 and install ei...

Page 153: ...of 327 psi 2254 kPa f Repeat steps b through e for each cylinder g If compression is less then limit troubleshoot the engine 3 28 PISTONS CONNECTING RODS AND CRANKSHAFT 3 28 1 Removal a Remove oil fil...

Page 154: ...rod side to drive it out of cylinder q Repeat steps n through p for remaining pistons and connecting rode r Remove camshaft refer to paragraph 3 30 1 s Remove flywheel and flywheel housing refere to...

Page 155: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 77 Pistons Connecting Rods and Crankshaft 3 129...

Page 156: ...End Play w Loosen ten crankshaft baring cap bolts a little at a time in sequence shown in FIGURE 3 79 FIGURE 3 79 Crankshaft Bearing Cap Bolt Loosening Sequence X Remove ten bolts five sets of bearin...

Page 157: ...hammer and a brass bar tap piston pin 13 from piston 5 e Remove deflector 15 from crankshaft f Using gear puller remove crankshaft gear 16 from crankshaft Remove key 17 3 28 3 Inspect and Measure 3 28...

Page 158: ...8G1 94 2 FlGURE 3 80 Piston Ring and Groove Clearance b Check piston ring gap as follows 1 Insert a piston ring horizontally in position as installed on piston into cylinder liner bore refer to FIGURE...

Page 159: ...tion is found replace piston FIGURE 3 82 Measuring Piston Ring Gap c Using a micrometer measure piston pin OD at several points Standard OD is 1 063 in 27 0 mm with a limit d 1 062 in 26 97 mm If OD i...

Page 160: ...replace connecting rod 3 28 3 2 Crankshaft and Bearings a The following is a summation of basic dimension measurements refer to FIGURE 3 84 1 Measure A and B dimensions and subtract B from A to obtai...

Page 161: ...and rear oil seal fitting surfaces of crankshaft for excessive wear and damage 3 Replace or repair crankshaft if any excessive wear or damage is found Compressed air used for cleaning can create airbo...

Page 162: ...is 0 012 in 0 03 mm or less with a limit of 0 0024 in 0 06 mm If measured run out exceeds knit replace crankshaft FIGURE 2 85 Crankshaft Run out d Use a vernier caliper to measure spead refer to FIGUR...

Page 163: ...eter for crankshaft journal is 2 7548 to 2 7533 in 69 920 to 69 632 mm with a limit of 2 7560 in 69 95 mm Standard diameter for crankpin is 2 0849 to 2 0854 in 52 918 to 52 930 mm with a limit of 2 08...

Page 164: ...h a limit of 0 0047 in 0 12 mm 4 If clearance exceeds limit replace bearing and or crankshaft g Check connecting rod bearing and crankpin clearance as follows 1 Install bearings on connecting rod FIGU...

Page 165: ...der block journal bearing surfaces bearing caps and bearings 2 Install bearings in cylinder block 3 Carefully place crankshaft on bearings 4 Rotate crankshaft approximately 30 degrees to seat bearings...

Page 166: ...step f FlGURE 3 91 Comparing Bearing Gage i Check crankpin and bearing clearance using bearing gage PLASTIGAGEPR1 as follows 1 Clean crankshaft connecting rods bearing cap and bearings 2 Install beari...

Page 167: ...a limit of 0 0047 in 0 12 mm 9 If measured clearance exceeds limit perform clearance check in accordance with step g 3 28 4 Assembly N O T E Crankshaft gear timing mark X X must face out a Install ke...

Page 168: ...on connecting rod ensuring piston head front mark notch on top of piston and con necting rod ISUZU forging mark are facing same direction h Using your hands and fingers push piston pin 13 into piston...

Page 169: ...3 Second Compression Ring 4 Third Compression Ring FIGURE 3 93 Piston Ring Installation 3 28 5 Installation a Carefully wipe any foreign material from upper bearings b If crankshaft bearings are bein...

Page 170: ...il MIL L 2104 to thrust hearings 9 and install them to crankshaft center journal with grooves facing crankshaft web Install lower halves of hearings 10 in main bearing cap and rod cap 3 Perform follow...

Page 171: ...lubricating oil MIL L 2104 to ten bearing cap bolts and install them in bearing caps hand tight n Tighten bearing cap bolts to 123 0 ft lbs 166 6 Nm a little at a time in sequence shown in FIGURE 3 9...

Page 172: ...5 t Apply a coat of engine lubricating oil MIL L 2104 to circumference of each piston ring 11 and piston 5 N O T E Position the piston ring 1800 from each other at the top The piston ring gap must be...

Page 173: ...ylinder bore until connecting rod makes contact with crankpin At same time rotate crankshaft until crankpin is at BDC y Position piston head front mark so it faces front of engine z Align bearing cap...

Page 174: ...l starter refer to paragraph 3 23 6 an Install fuel filter assembly refer to paragraph 3 9 4 ao Install oil filter refer to paragraph 3 14 3 3 29 CRANKCASE 3 29 1 Removal a Remove oil pan refer to par...

Page 175: ...ng cap arch gaskets b Position crankcase 6 FIGURE 3 98 on engine block aligning dowel pin in block with hole in crankcase Secure crankcase to engine block with fourteen screws 5 two bolts 2 two bolts...

Page 176: ...efer to paragraph 3 9 1 c Remove starter refer to paragraph 3 23 1 d Remove attemator refer to paragraph 3 24 1 e Remove water pump refer to paragraph 3 7 1 f Remove PCV system refer to paragraph 3 20...

Page 177: ...0 Measuring Timing Gear Backlash j Measure idler gear end play as follows 1 Insert feeler gage between idler gear 3 FIGURE 3 101 and thrust collar 2 and measure gap 2 Standard end play gap is 0 003 in...

Page 178: ...ARMY TM 9 2815 254 24 AlR FORCE TO 38G1 1 94 2 FIGURE 3 101 Camshaft and Idler Gear Assemblies 3 152...

Page 179: ...ock Remove it slowly and use both hands otherwise equipment damage could occur r Withdraw camshaft 6 from engine block using care not to damage camshaft journal cam and camshaft 3 30 2 Disassembly of...

Page 180: ...with a limit of 1 7756 in 45 10 mm c Standard clearance between idler gear shaft OD and idler gear ID is 0 0010 to 0 0033 in 0 025 to 0 085 mm If clearance exceeds limit of 0 608 in 02 mm replace idl...

Page 181: ...height refer to FIGURE 3 105 If cam height is less than limit of 1 58 in 40 2 mm replace camshaft FIGURE 3 105 Cam Height d Check camshaft run out as follows 1 Place camshaft on V blocks 2 Measure ru...

Page 182: ...ft journal OD measured in step b and camshaft bearing ID is 0 002 in 0 05 mm lf clearance exceeds limit of 0 005 in 0 12 mm replace bearings Refer to para graph 3 311 1 f Before disassembling camshaft...

Page 183: ...mshaft 6 use extreme care to avoid contact be tween camshaft and engine block Install it slowly and use both hands Otherwise equipment damage could occur Slide camshaft 6 into engine block using care...

Page 184: ...CV system refer to paragraph 3 20 3 r Install water pump refer to paragraph 3 7 4 s Install thermostat housing refer to paragraph 3 6 4 t Install alternator refer to paragraph 3 24 5 u Install flywhee...

Page 185: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 107 Flywheel and Housing 3 159...

Page 186: ...ary remove two starter mounting studs 14 plug 15 and gasket 16 Discard gasket 16 FIGURE 3 108 Flywheel Bolt Loosening Sequence 3 31 2 Inspection Repair a Inspect ring gear 17 FIGURE 3 107 for broken m...

Page 187: ...n flywheel housing and install two starter mounting studs 14 b Apply sealing compound FORMAGASKET2 to shaded areas at flywheel housing 10 shown in FIGURE 3 109 FIGURE 3 109 Flywheel Housing Installati...

Page 188: ...quence shown in FIGURE 3 110 N O T E Use a block of hard wood to prevent flywheel from turning while tighten bolts h Position flywheel assembly 3 on basic flywheel 6 and secure with four bolts 1 and w...

Page 189: ...Remove camshaft bearings 11 using bearing remover installer 320905 g Remove two screws 12 securing cover 13 to engine block remove cover 13 and packing 14 Discard packing N O T E If cylinder liner is...

Page 190: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 FIGURE 3 111 Cylinder Block Assembly 3 164 Change 2...

Page 191: ...3 grade cylinder liner will be supplied Either one may be used to replace whatever grade liner was used in production a Check cylinder block upper face warpage as follows 1 2 3 4 If not removed remove...

Page 192: ...URE 3 113 FIGURE 3 113 Cylinder Block Height Measurement 6 Install cylinder liner refer to paragraph 3 32 3 7 Install cylinder bled dowel pin b Measure cylinder liner bore as follows 1 Using a cylinde...

Page 193: ...ecked 2 Using a feeler gage measure each cylinder liner projection 3 Standard projection is 0 0 to 0 004 in 0 0 to 0 10 mm 4 The difference in projection height between any two adjacent cylinders must...

Page 194: ...clearance after installa tion to be sure that is correct e Measure new cylinder liner bore as follows 1 Measure cylinder liner bore at two points A and B in four different directions W W X X Y Y and Z...

Page 195: ...s etc a Use compressed air to thoroughly clean cylinder block interior and exterior oil holes and water jackets before assembly b Install dowel pins and fittings if removed c Install new cylinder line...

Page 196: ...to FIGURE 3 116 5 Position cylinder block so installer center is directly beneath arbor press shaft center N O T E Check that cylinder liner is set perpendicular to arbor press and that there is no wo...

Page 197: ...talled in correct locations as tagged during disassembly Apply adhesive 242 to lip of coolant duct 9 and install it in engine block Apply adhesive 242 to all freeze plugs removed and tap them into hol...

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Page 199: ...ed Changes to Publications and Blank Forms DA Form 2028 Report of Discrepancy ROD SF 384 Reporting of Item and Packaging Discrepancies AR 735 11 2 Reporting of Transportation Discrepancies in Shipment...

Page 200: ...CE TO 38G1 94 2 APPENDIX A REFERENCES CONTINUED A 5 MlSCELLANEOUS PUBLICATIONS Continued Suggestion Program AFR 900 4 The Army Maintenance Management System TAMMS DA PAM 738 750 USAF Materiel Deficien...

Page 201: ...d explanatory notes for particular maintenance functions B 2 Maintenance Functions Maintenance functions will be limited to and defined as follows a b c d e Inspect To determine the serviceability of...

Page 202: ...rrecting specific damage fault malfunction or failure in a part subassembly module compo nent or assembly end item or system Overhaul That maintenance effort service action prescribed to restore an it...

Page 203: ...assembly time troubleshooting fault location time and quality as surance quality control time in addition to the time required to perform the specific tasks identified for the main tenance functions...

Page 204: ...ent e Column 5 Tool Number The manufacturer s part number of the tool or test equipment B 5 Explanation of Columns in Remarks Section IV a Column 1 Reference Code The code recorded in column 6 II b Co...

Page 205: ...00 COOLING SYSTEM SERVICE REPAIR 0101 THERMOSTAT lNSPECT REPLACE 0102 WATER PUMP INSPECT R I REPLACE 0200 FUEL SYSTEM INSPECT SERVICE REPAIR 0201 FUEL FILTER INSPECT 0202 FUEL INJECTOR INSPECT ADJUST...

Page 206: ...TERNATOR ASSEMBLY ENGINE BLOCK ASSEMBLY INSPECT FRONT GEAR COVER SEAL CRANKSHAFT WONT ROCKER ARM ASSEMBLY CYLINDER HEAD ASSY VALVE SPRINGS INSPECT SERVICE REPLACE R I REPAIR INSPECT R I REPLACE INSPEC...

Page 207: ...ECT 2 TEST 1 0 R I 3 5 3 5 REPLACE 1 5 3 5 1 5 C REPAIR 4 5 1 5 0606 CAMSHAFT ASSEMBLY INSPECT 5 TEST 1 0 3 5 R I 4 0 5 REPLACE 4 0 5 0 5 C REPAIR 1 4 5 0609 FLYWHEEL ASSEMBLY INSPECT 2 R I 1 0 REPLAC...

Page 208: ...CATEGORY F H NOMENCLATURE SHOP EQUIPMENT AUTOMOTIVE MAINTE NANCE AND REPAIR ORGANlZATlONAL MAlN TENANCE COMMON NO 1 LESS POWER SHOP EQUIPMENT FUEL AND ELECTRICAL SYSTEM ENGINE FIELD MAlNTENANCE BASIC...

Page 209: ...Refer to end item operator s manual B Refer to end item maintenance manual C Replace function is identical to removal install function D Fuel filter does not include a filter element for this applica...

Page 210: ......

Page 211: ...of maintenance that requires the listed item Column 3 National Stock Number This is the National Stock Number assigned to the item use it to request or requisition the item Column 4 Description Indic...

Page 212: ...LEVEL NUMBER 1 DS GS 8040 01 250 3969 2 DS GS 8040 00 390 7959 3 DS GS 8040 01 055 6407 Adhesive Silicon 584R46001101 4 DS GS 6850 00 311 6172 Bearing Dye Blue HISPOTBLUE 107 5 Units 7920 01 338 3329...

Page 213: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 APPENDIX D FABRICATION OF TOOLS FIGURE D 1 Fuel Injection Pump Tappet Holder D 1 D 2 blank...

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Page 215: ...shall be used when a Commercial Off The Shelf COTS manual is used by the Military services This appendix is divided into three sections Section I gives a brief description of the sections within this...

Page 216: ...ARMY TM 9 2815 254 24 AIR FORCE TO 38G1 94 2 Section 111 MAINTENANCE LEVELTD PARAGRAPHS...

Page 217: ...nder Head Assembly Maintenance of 3 110 Cylinder Head Bolt Loosening Sequence 3 112 Cylinder Head Bolt Tightening Sequence 3 126 D DetailedDescription 1 3 E Electrical System Maintenance of 3 8 5 Engi...

Page 218: ...Fitter Maintenance of 3 69 Oil Pan Maintenance of 3 73 Oil Piping Maintenance of 3 71 Oil Pump Maintenance of 3 75 P PCV Assembly Maintenance of 3 79 Pistons Connecting Rods and Crankshaft Maintenance...

Page 219: ...Continued Description Page No T Table of Contents i Teble of Specification 1 5 Thermostat And Housing Maintenance of 3 16 Troubleshooting Procedures 3 3 V Valve Clearance Adjustment Sequence 3 109 W W...

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Page 223: ...8 st louis emh7 army mil Subject DA Form 2028 1 From Joe Smith 2 Unit home 3 Address 4300 Park 4 City Hometown 5 St MO 6 Zip 77777 7 Date Sent 19 OCT 93 8 Pub no 55 2840 229 23 9 Pub Title TM 10 Publi...

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Page 234: ...PIN 071752 002...

Page 235: ...it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government...

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