ENGINE ACCESSORIES INSTALLATION

TM 9-2815-225-34&P · Work Package 0045 00

AIR AFTERCOOLER, FUEL PUMP AND FUEL LINES,

VIBRATION DAMPER AND CRANKSHAFT PULLEY

INITIAL SETUP

Tools and Special Tools                             Equipment Condition
 General mechanic’s tool kit: automotive             Engine mounted on maintenance stand
    (Item 1, WP 0061 00)                               (WP 0009 00)
 Maintenance and repair shop equipment:
    automotive (Item 2, WP 0061 00)                 References
 Automotive maintenance and repair                   TM 9-2320-273-20
    supplemental set no. 2 (Item 3, WP 0061 00)      TM 9-2320-283-20
 Air compressor wrench (Item 18, WP 0061 00)

Material/Parts
 Lubricating oil (Item 19, WP 0060 00)
 High pressure lubricant (Item 15, WP 0060 00)
 Three gaskets (Item 1, Table 28, WP 0062 00)
 Three lockwashers
   (Item 2, Table 28, WP 0062 00)
 Gasket (Item 3, Table 28, WP 0062 00)
 Lockwasher (Item 4, Table 28, WP 0062 00)
 Three lockwashers
   (Item 5, Table 28, WP 0062 00)
 Two lockwasher
   (Item 6, Table 28, WP 0062 00)
 Lockwasher (Item 7, Table 28, WP 0062 00)
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AIR AFTERCOOLER

1. Apply a small amount of high pressure lubricant to three new gaskets (9) on cylinder heads (1).

NOTE Perform steps 2 and 3 for Big Cam III only. Tighten screws from the center outward.

2. Install air aftercooler (2) on cylinder heads (1) with six washers (6) and screws (7). Tighten screws (7) 20–25 lb-ft (27–34 N•m).

3. Install screw (8), two screws (5), three new lockwashers (4) and washers (3) on bottom of each cylinder head (1). Thread in screws (8) and (5) three to five times. Tighten screws (8) and (5) 20–25 lb-ft (27–34 N•m).

NOTE Two middle holes in air aftercooler are used for mounting ether starting kit. Refer to TM 9-2320-273-20 or TM 9-2320-283-20 to install ether starting kit. Tighten but do not torque screws after installation. Perform steps 4 and 5 for Big Cam I.

4. Install air aftercooler (2) on cylinder heads (1) with six washers (6) and bolts (7).

5. Install three washers (3), new lockwashers (4) and bolts (5) on three outside holes of air aftercooler (2). Thread in bolts (5) three to five times.

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Figure 1. Air Aftercooler Installation.
Figure 1. Air Aftercooler Installation.
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FUEL PUMP AND FUEL LINES

1. Install new gasket (2) and fuel pump (12) with compressor spider coupling (3) on air compressor (1).

NOTE Perform steps 2 and 3 for Big Cam III.

2. Position support bracket (9) on fuel pump (12) and air compressor (1) with three washers (10) and bolts (11).

3. Using air compressor wrench, install washer (14) and bolt (13) on fuel pump (12) and into air compressor (1). Tighten bolt (13) finger-tight only.

NOTE Perform step 4 only for Big Cam I.

4. Using air compressor wrench, install support bracket (9) on fuel pump (12) and into air compressor (1) with four washers (4) and bolt (5).

5. Install new lockwasher (7) and bolt (6) on support bracket (9) and cylinder head (8).

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Figure 2. Fuel Pump Installation.
Figure 2. Fuel Pump Installation.
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FUEL PUMP AND FUEL LINES (Contd)

6. Install fuel pump adapter (14) on fuel pump (29).

7. Install two cylinder head adapters (8), fuel supply line (9), and fuel return line (10) on cylinder head (7).

8. Install fuel pump adapter (16) and fuel supply line (9) on fuel pump (29).

9. Install fuel pump adapter (28) and fuel return lines (10) and (15) on fuel pump (29).

10. Install fuel supply line (9) and fuel return line (10) on air aftercooler (6) with two washers (11), new lockwashers (12), and screws (13).

11. Install valve (27) and air supply line (26) on fuel pump (29).

12. Install adapter (17) on air aftercooler (6).

13. Install bracket (25) and air supply line (26) with screw (18), washer (24), new lockwasher (23), and nut (22) on air aftercooler (6).

NOTE Perform steps 14–16 for Big Cam I equipped with air signal attenuator (ASA) air tank.

14. Install ASA air tank (1) with washer (19), new lockwasher (20), and screw (21) on air aftercooler (6).

15. Install ASA hose fittings (2) on ASA air tank (1).

16. Install air aftercooler elbow (5) on air aftercooler (6).

17. Install two air supply hoses (4) and four hose clamps (3) on ASA air tank (1).

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Figure 3. Fuel Lines Installation.
Figure 3. Fuel Lines Installation.
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Figure 4. Vibration Damper and Crankshaft Pulley Installation.

VIBRATION DAMPER AND CRANKSHAFT PULLEY

CAUTION To avoid engine damage, ensure mounting surfaces of vibration damper and crankshaft pulley are clean and dry. Do not get any lubricating oil on these surfaces.

1. Install two vibration damper guide pins (5) on two opposite holes in face of crankshaft (6).

2. Install crankshaft pulley (4) and vibration damper (3) on two guide pins (5) and push into crankshaft (6) until seated.

3. Apply a coat of clean lubricating oil to threads of six screws (1) and washers (2).

4. Install four screws (1) and washers (2) on vibration damper (3), crankshaft pulley (4), and crankshaft (6).

5. Install remaining two screws (1) and washers (2) on vibration damper (3), crankshaft pulley (4), and crankshaft (6). Tighten screws 190 lb-ft (258 N•m).

NOTE Total indicator reading must not exceed 0.004 in. (0.102 mm) per 1.0 in. (25.4 mm) of vibration damper diameter. Remove and discard vibration damper if not within limits.

6. Using dial indicator gauge, measure movement on vibration damper (3) circumference by rotating crankshaft (6).

NOTE Crankshaft must be kept at front or rear limit of thrust clearance while measuring movement of vibration damper face. Total indicator reading must not exceed 0.007 in. (0.178 mm) per 1.0 in. (25.4 mm) of the vibration damper radius. Remove and discard vibration damper if not within limits.

7. Using dial indicator gauge, measure movement of vibration damper (3) face by rotating crankshaft (6).

END OF WORK PACKAGE

TM page 0046 00-1