Rocker Cover Replacement

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

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

Tools and Special Equipment:                           Equipment Condition (Cont):
Shop Equipment, SC 4910-95-CL-A31                      Reference                Condition Description
Tool Kit, SC 5180-90-CL-N05
                                                       TM 9-2320-363-20         Diagonal Radiator Support
Materials/Parts:                                                                Rod Removed
Gasket                     P/N 8929863                 General Safety Instructions:
Sealant, RTV               Appendix B, Item 52
Solvent, Drycleaning       Appendix B, item 54                          WARNING
                                                              Adhesives, solvents, and
References:                                                   sealing compounds can burn
TM 9-2320-363-20                                              easily, can give off harmful
                                                              vapors, and are harmful to skin
Equipment Condition:                                          and clothing. To avoid injury or
                                                              death, keep away from open
Reference                  Condition Description              fire and use in well-ventilated
                                                              area. If adhesive, solvent, or
TM 9-2320-363-20           Air Cleaner, Pre-Cleaner,          sealing compound gets on skin
                           and Duct Assembly                  or clothing, wash immediately
                           Removed                            with soap and water.
TM 9-2320-363-20           Thermostat to Radiator
                           Coolant Tube Removed
TM page 3-72
Illustration from TM 9-2320-363-34-1 (PDF page 148)
Illustration from TM 9-2320-363-34-1 (PDF page 148)

1. LOOSEN HOSE CLAMP (1) AND DISCONNECT CRANKCASE BREATHER TUBE(2) FROM ROCKER COVER NECK (3).

2. REMOVE TWO ROCKER COVER PLUGS (4), FOUR BOLTS (5), FOUR WASHERS (6), AND FOUR ISOLATORS(7).

CAUTION Handle rocker cover carefully, Dropping or bumping may cause unrepairable damage.

3. REMOVE ROCKER COVER (8) FROM CYLINDER HEAD (9).

TM page 3-73
Illustration from TM 9-2320-363-34-1 (PDF page 149)
Illustration from TM 9-2320-363-34-1 (PDF page 149)
CAUTION Do not pull rocker cover gasket to remove to prevent damage to equipment.

4. FREE GASKET SADDLE CORNERS (10) AND SADDLE ARCH AREAS (11). LIFT ROCKER COVER GASKET (12) STRAIGHT OUT OF ROCKER COVER (8) GROOVE TO PREVENT TEARING OR STRETCHING GASKET (12). DISCARD GASKET IF DAMAGED OR STRETCHED.

5. INVERT ROCKER COVER (8) ON BENCH. PRESS AND SLIDE STRAIGHT END OF BREATHER ELEMENT RETAINING CLIP (13) UNTIL CLIP (13) DISENGAGES FROM ROCKER COVER (8), LIFT CLIP (13) UPWARD TO DISENGAGE CURVED END.

6. REMOVE BREATHER ELEMENT (MESH) (14) FROM ROCKER COVER (8).

TM page 3-74
Illustration from TM 9-2320-363-34-1 (PDF page 150)
Illustration from TM 9-2320-363-34-1 (PDF page 150)

1. CLEAN ROCKER COVER GASKET (1), FOUR ISOLATORS (2), AND TWO ROCKER COVER PLUGS (3) WITH MILD SOAP AND WATER AND DRY WITH COMPRESSED AIR. DISCARD IF DAMAGED.

2. CLEAN ALL OLD RTV SEALANT FROM ROCKER COVER GROOVES. CLEAN ALL DIRT AND FOREIGN MATTER FROM ROCKER COVER (4) AND ROCKER COVER HOLDDOWN BOLT RECESSES (5).

WARNING Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

3. CLEAN BREATHER ELEMENT (MESH) (6) WITH SOLVENT AND DRY WITH COMPRESSED AIR.

4. REMOVE OLD RTV SEALANT FROM CORNERS OF CYLINDER HEAD LOCATED AT FRONT AND REAR CAM CAP AREA.

TM page 3-75
Illustration from TM 9-2320-363-34-1 (PDF page 151)
Illustration from TM 9-2320-363-34-1 (PDF page 151)

Inspect all park for wear or damage.

1. PRESS BREATHER ELEMENT (MESH) (1) INTO BREATHER POCKET (2).

2. INSERT CURVED END OF BREATHER ELEMENT RETAINING CLIP (3) INTO ONE BREATHER POCKET (2) HOLE. PRESS AND SLIDE STRAIGHT END OF CLIP (3) INTO OPPOSITE BREATHER POCKET (2) HOLE.

3. POSITION ROCKER COVER GASKET (4) IN ROCKER COVER (5).

4. INSTALL ROCKER COVER GASKET (4) BEGINNING AT CORNERS (6) OF SADDLE ARCH (7) ON EACH END OF ROCKER COVER (5). WORK BACK INTO SADDLE ARCH (7) EQUALLY FROM EACH CORNER (6) PUSHING GASKET (4) FIRMLY INTO ROCKER COVER GROOVE (8).

NOTE Make sure rocker cover gasket is firmly seated in rocker cover groove.

5. BEGINNING AT CENTER OF ROCKER COVER (5), INSTALL LONG RUNS OF ROCKER COVER GASKET (4) TOWARD CORNERS (6) OF SADDLE ARCHES (7) AND CONTINUE UNTIL GASKET (4) INSTALLATION IS COMPLETED.

TM page 3-76
Illustration from TM 9-2320-363-34-1 (PDF page 152)
WARNING Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

6. APPLY SMALL FILLET OF RTV SEALANT IN FRONT AND REAR CORNERS (9) OF CYLINDER HEAD (10) WHERE FRONT AND REAR CAM CAPS ARE LOCATED ON CYLINDER HEAD.

CAUTION Handle rocker cover carefully, Dropping or bumping may cause unrepairable damage.

7. POSITION ROCKER COVER (5) ON CYLINDER HEAD (10).

8. INSTALL FOUR ISOLATORS (11), FOUR WASHERS (12), AND FOUR BOLTS (13) THRU HOLES IN ROCKER COVER (5).

TM page 3-77
Illustration from TM 9-2320-363-34-1 (PDF page 153)

9. STARTING WITH CENTER BOLTS AND WORKING TO OUTER BOLTS, TIGHTEN FOUR BOLTS (13) TO 15-18 LB-FT (20-25 N.m).

10. PRESS TWO ROCKER COVER PLUGS (14) INTO ROCKER COVER (5) WITH HEEL OF HAND UNTIL PLUGS (14) ARE FULLY SEATED.

11. INSTALL CRANKCASE BREATHER TUBE (15) OVER ROCKER COVER NECK (16) AND SECURE WITH HOSE CLAMP (17).

NOTE Follow-on Maintenance:

Install air cleaner, pre-cleaner, and duct assembly (TM 9-2320-363-20). Install thermostat to radiator coolant tube (TM 9-2320-363-20). Install diagonal radiator support rod (TM 9-2320-363-20).

TM page 3-78