Air Intake Manifold Replacement

TM 9-2320-363-34-1 · Chapter 3 — Power Package Maintenance

This task covers:    a. Removal b. Cleaning   c. Inspection d. Installation

Applicable Configuration:                        Equipment Description:

M915A2 and M916A1                                Reference               Condition Description
                                                 TM 9-2320-363-20        Air Intake Manifold to
Tools and Special Equipment:                                             Intercooler Tube Removed
Shop Equipment, SC 4910-95-CL-A31                TM 9-2320-363-20        Ether Atomizer and
Tool Kit. SC 5180-90-CL-N05                                              Bushing Removed
Guide, Stud (2), J36107
Caulking Gun, 805774                             TM 9-2320-363-20        Batteries Disconnected

Materials/Parts:
                                                 General Safety Instructions:
Ring, Seal           P/N 5182977

                     Appendix 6, Item 18
                                                                    WARNING
Eliminator, Gasket
                                                   Make sure all air lines and fittings are clear of
Oil, Lubricating     Appendix B, Item 37           debris. Make sure excess pipe sealing
                                                   compound does not enter air lines or fittings.
Compound, Pipe       Appendix B, Item 15           Failure to do so could result in equipment
Sealing                                            failure and/or injury to personnel.

References:
TM 9-2320-363-20

1.      LOOSEN HOSE CLAMP (1) AND DISCONNECT AIR COMPRESSOR INLET HOSE (2) FROM AIR
        SUPPLY CONNECTOR (3).

2.      REMOVE AIR SUPPLY CONNECTOR (3) AND REDUCER (4) FROM AIR INTAKE MANIFOLD (5).

TM page 3-62

Illustration from TM 9-2320-363-34-1 (PDF page 128)

3. DISCONNECT AIR LINE CONNECTOR (6) FROM NIPPLE (7).

4. DISCONNECT AIR LINE CONNECTOR (8) FROM NIPPLE (9).

5. REMOVE TWO NIPPLES (7 AND 9), CHECK VALVE (10), TEE (11), AND NIPPLE (12) FROM AIR INTAKE MANIFOLD (5).

6. DISCONNECT ENGINE WIRING HARNESS (13) FROM TURBO BOOST SENSOR (14).

7. REMOVE TWO RETAINING BOLTS (15) AND TURBO BOOST SENSOR (14).

8. REMOVE AND DISCARD SEAL RING (16).

9. REMOVE FIVE LONG BOLTS (17) AND TWO SHORT BOLTS (18) FROM AIR INTAKE MANIFOLD (5).

TM page 3-63

Illustration from TM 9-2320-363-34-1 (PDF page 129)

10. IF NECESSARY, USE BRASS DRIFT AND TAP AIR INTAKE MANIFOLD (5) LIGHTLY TO LOOSEN FROM CYLINDER HEAD (19). REMOVE AIR INTAKE MANIFOLD (5).

11. REMOVE GASKET ELIMINATOR FROM MATING SURFACES (20) OF AIR INTAKE MANIFOLD (5) AND CYLINDER HEAD.

Use general cleaning methods to clean all parts (page 2-30).

1. INSPECT EXHAUST MANIFOLD FOR CRACKS, PARTICULARLY IN MOUNTING BOLT BOSS AREAS. IF CRACKED, DISCARD EXHAUST MANIFOLD SECTION.

2. INSPECT ALL PARTS FOR WEAR OR DAMAGE.

WARNING Make sure all air lines and fittings are clear of debris. Make sure excess pipe sealing compound does not enter air lines or fittings. Failure to do so could result in equipment failure and/or injury to personnel.

1. USING CAULKING GUN, APPLY 1/16 IN. CONTINUOUS BEAD OF GASKET ELIMINATOR TO MATING SURFACE OF AIR INTAKE MANIFOLD (1).

TM page 3-64

Illustration from TM 9-2320-363-34-1 (PDF page 130)

2. INSTALL TWO GUIDE STUDS IN UPPER CENTER BOLT HOLES OF CYLINDER HEAD (2).

NOTE Make sure all wires are clear of intake manifold connection points before installing manifold.

3. INSTALL AIR INTAKE MANIFOLD (1) OVER TWO GUIDE STUDS AND AGAINST CYLINDER HEAD (2).

4. INSTALL TWO SHORT BOLTS (3) HAND-TIGHT IN AIR INTAKE MANIFOLD (1) (ONE ON EACH END).

5. REMOVE GUIDE STUDS.

6. INSTALL FIVE LONG BOLTS (4) HAND-TIGHT IN AIR INTAKE MANIFOLD (1).

7. TIGHTEN SEVEN BOLTS (3 AND 4) TO 43-54 LB-FT (58-73 N.m) IN SEQUENCE SHOWN.

TM page 3-65

Illustration from TM 9-2320-363-34-1 (PDF page 131)

8. COAT THREADS OF REDUCER (5) WITH SEALING COMPOUND AND INSTALL REDUCER (5) IN AIR INTAKE MANIFOLD (1).

9. COAT THREADS OF AIR SUPPLY CONNECTOR (6) WITH SEALING COMPOUND AND INSTALL AIR SUPPLY CONNECTOR (6) IN REDUCER (5).

10. COAT NEW SEAL RING (7) WITH LUBRICATING OIL AND INSTALL SEAL RING (7) IN AIR INTAKE MANIFOLD (1).

11. INSTALL TURBO BOOST SENSOR (8) AND TWO RETAINING BOLTS (9) IN AIR INTAKE MANIFOLD (1). TIGHTEN BOLTS TO 21-26 LB-FT (2.4-2.9 N.m).

12. CONNECT ENGINE WIRING HARNESS (10) TO TURBO BOOST SENSOR (8).

TM page 3-66

Illustration from TM 9-2320-363-34-1 (PDF page 132)

CAUTION Do not use lubricant on inside of air compressor inlet hose, on hose contact surfaces of intercooler ducting, or on air intake manifold. Lubricant can cause hose to blow off when turbocharger builds up pressure.

13. COAT THREADS OF NIPPLE (11) WITH SEALING COMPOUND AND INSTALL NIPPLE (11), TEE (12), CHECK VALVE (13), AND TWO NIPPLES (14 AND 15) IN AIR INTAKE MANIFOLD (1).

14. CONNECT AIR LINE CONNECTOR (16) TO NIPPLE (14).

15. CONNECT AIR LINE CONNECTOR (17) TO NIPPLE (15).

16. CONNECT AIR COMPRESSOR INLET HOSE (18) TO AIR SUPPLY CONNECTOR (6).

17. POSITION AND TIGHTEN HOSE CLAMP (19).

NOTE Follow-on Maintenance:

lnstall air intake manifold to intercooler tube (TM 9-2320-363-20). Install ether atomizer and bushing (TM 9-2320-363-20). Connect batteries (TM 9-2320-363-20).

TM page Change 1 3-66.1

Illustration from TM 9-2320-363-34-1 (PDF page 133)

This task covers:    a. Removal b. Cleaning   c. Inspection d. Installation

Applicable Configuration:                        Equipment Description:

All except M915A2 and M916A1                     Reference               Condition Description

Tools and Special Equipment:                     TM 9-2320-363-20        Air Intake Manifold to
                                                                         Intercooler Tube Removed
Shop Equipment, SC 4910-95CL-A31
Tool Kit, SC 5180-90-CL-N05                      TM 9-2320-363-20        Batteries Disconnected

Materials/Parts:                                 General Safety Instructions:

Ring, Seal           P/N 5182977
                                                                     WARNING
Gasket (2)           P/N 23514622                  Make sure all air lines and fittings are clear of
                                                   debris. Make sure excess pipe sealing
Oil, Lubricating     Appendix B, Item 37           compound does not enter air lines or fittings.
                                                   Failure to do so could result in equipment
Compound, Pipe       Appendix B, Item 15           failure and/or injury to personnel.
Sealing

References:

TM 9-2320-363-20

1.      LOOSEN HOSE CLAMP (1) AND DISCONNECT AIR COMPRESSOR INLET HOSE (2) FROM AIR
        SUPPLY CONNECTOR (3).

2.      REMOVE AIR SUPPLY CONNECTOR (3) AND REDUCER (4) FROM AIR INTAKE MANIFOLD (5).

TM page 3-66.2 Change 1

Illustration from TM 9-2320-363-34-1 (PDF page 134)

3. DISCONNECT ENGINE WIRING HARNESS (6) FROM TURBO BOOST SENSOR (7).

4. REMOVE TWO RETAINING BOLTS (8) AND TURBO BOOST SENSOR (7).

5. REMOVE AND DISCARD SEAL RING (9).

6. REMOVE FIVE LONG BOLTS (10) AND TWO SHORT BOLTS (11) FROM AIR INTAKE MANIFOLD (5).

7. IF NECESSARY, USE BRASS DRIFT AND TAP AIR INTAKE MANIFOLD (5) LIGHTLY TO LOOSEN FROM CYLINDER HEAD (12). REMOVE AIR INTAKE MANIFOLD AND THREE GASKETS (13). DISCARD GASKETS.

8. REMOVE AIR TEMPERATURE SENSOR (14) FROM AIR INTAKE MANIFOLD (5).

Use general cleaning methods to clean all parts (page 2-30).

Inspect air intake manifold for cracks, particularly in mounting bolt boss areas. If cracked, discard air intake manifold.

TM page Change 1 3-66.3

Illustration from TM 9-2320-363-34-1 (PDF page 135)

1. COAT THREADS OF AIR TEMPERATURE SENSOR (1) WITH SEALING COMPOUND AND INSTALL AIR TEMPERATURE SENSOR IN AIR INTAKE MANIFOLD (2).

NOTE Make sure that gaskets are positioned so that arrows of each gasket are facing front of engine.

Make sure all wires are clear of intake manifold connection points before installing manifold.

2. POSITION THREE NEW GASKETS (3) TO AIR INTAKE MANIFOLD (2) AND POSITION AIR INTAKE MANIFOLD TO CYLINDER HEAD (4).

3. INSTALL TWO SHORT BOLTS (5) HANDTIGHT IN AIR INTAKE MANIFOLD (2), ONE AT EACH END.

4. INSTALL FIVE LONG BOLTS (6) IN AIR INTAKE MANIFOLD (2).

TM page 3-66.4 Change 1

Illustration from TM 9-2320-363-34-1 (PDF page 136)

5. TORQUE SEVEN BOLTS (5 AND 6) TO 43-54 LB-FT (58-73 N.m) IN SEQUENCE SHOWN.

6. COAT NEW SEAL RING (7) WITH LUBRICATING OIL AND INSTALL SEAL RING IN AIR INTAKE MANIFOLD (2).

7. INSTALL TURBO BOOST SENSOR (8) AND TWO RETAINING BOLTS (9) IN AIR INTAKE MANIFOLD (2). TORQUE BOLTS TO 21-26 LB-IN. (2.4 - 2.9 N.m).

8. CONNECT ENGINE WIRING HARNESS (10) TO TURBO BOOST SENSOR (8).

PDF page 137

9. COAT THREADS OF REDUCER (11) WITH SEALING COMPOUND AND INSTALL REDUCER IN AIR INTAKE MANIFOLD (2).

10. COAT THREADS OF AIR SUPPLY CONNECTOR (12) WITH SEALING COMPOUND AND INSTALL AIR SUPPLY CONNECTOR IN REDUCER (11).

11. CONNECT AIR COMPRESSOR INLET HOSE (13) TO AIR SUPPLY CONNECTOR (11).

12. POSITION AND TIGHTEN HOSE CLAMP (14).

NOTE Follow-on Maintenance:

Install air intake manifold to intercooler tube (TM 9-2320-363-20). Connect batteries (TM 9-2320-363-20).

Change 1 3-66.5/(3-66.6 Blank)

PDF page 138

TM page Change 1 3-67

Illustration from TM 9-2320-363-34-1 (PDF page 139)

EXHAUST        MANIFOLD        REPLACEMENT

This task covers:    a. Removal b. Cleaning   c. Inspection d. Installation

Applicable Configuration: Equipment Description:

Reference Condition Description M915A2 and M916A1 Page 3-101 Turbocharger Removed Tools and Special Equipment: Page 3-78 Breather Tube Removed Shop Equipment, SC 4910-95-CL-A31 Tool Kit, SC 5180-90-CL-N05 General Safety Instructions: Guide, Stud (4), J36107

Materials/Parts: WARNING Exhaust manifold weighs 60 lb (27 kg). Use Gasket (3) P/N 23511666 extreme caution during removal or installation to prevent possible injury to personnel.

1. REMOVE FOUR BOLTS (1) AND INSTALL FOUR GUIDE STUDS (2)

TM page 3-68 Change 1

Illustration from TM 9-2320-363-34-1 (PDF page 140)