TM-9-2815-259-24 Diesel Engine Assembly Model L70AE-DEGFR Manual



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Tm-9-2815-259-24

Chapter 1 Introduction
Section Ii. Equipment Description And Data
C. Intake And Exhaust Valves
Figure 1-1. Engine Components
Table 1-1. Table Of Specifications
Table 1-2. Engine Options Codes - 4 Cylinder, 4.5 Liter
Engine Base Code: 2116f
Section Iii. Preparation For Use
Chapter 2 Operating Instructions
Section Iii. Special Instructions.
Section Ii. Repair Parts; Tools; Special Tools; Test, Measurement And Diagnostic (Tmde); And Support Equipment
Table 3-1. Preventive Maintenance Checks And Services
Section Iv. Troubleshooting
Table 3-2. Unit Troubleshooting (Sheet 1 Of 11) Engine Fails To Crank
Unit Troubleshooting (Sheet 2 Of 11) Engine Cranks But Fails To Start
Unit Troubleshooting (Sheet 3 Of 11) Engine Misfires Or Runs Erratically Or Stalls Frequently
Unit Troubleshooting (Sheet 4 Of 11) Engine Does Not Develop Full Power
Unit Troubleshooting (Sheet 5 Of 11) Engine Overheating
Unit Troubleshooting (Sheet 6 Of 11) Excessive Oil Consumption
Unit Troubleshooting (Sheet 7 Of 11) Low Oil Pressure
Unit Troubleshooting (Sheet 8 Of 11) Excessive Fuel Consumption
Unit Troubleshooting (Sheet 9 Of 11) Black Or Gray Exhaust Smoke
Unit Troubleshooting (Sheet 10 Of 11) Engine Knocks
Unit Troubleshooting (Sheet 11 Of 11) Engine Makes A Hissing Or Vapor Leaking Noise
Section V. Maintenance Procedures
3.7.1. Test Engine Compression Pressure
3.7.3 Intake Manifold Pressure Check
3.8. Cooling System Maintenance
Figure 3-1. Thermostat And Water Manifold/Thermostat Cover.
C. Replacement
Figure 3-2. Thermostat Installation.
B. Inspection
3.9. Electrical System Maintenance.
Figure 3-4. Battery Charging Alternator Mounting
3.9.2. Starter
B. Removal
Figure 3-6. Starter Assembly
3.10. Intake And Exhaust System Maintenance
Figure 3-8. Exhaust Manifold.
Figure 3-9. Oil Filter Assembly
3.11.3. Oil Cooler
Figure 3-10. Oil Cooler Assembly
Figure 3-11. Oil Fill Tube Assembly
Figure 3-12. Oil Dipstick Tube Assembly
Figure 3-13. Oil Dipstick Tube Installation.
Figure 3-14. Oil Pan.
3.12.1. Bleeding Fuel System
Figure 3-15. Fuel Filter Assembly
Figure 3-16. Fuel Supply Pump.
D. Bleed At Fuel Injection Nozzles
Figure 3-17. Fuel Injection Assembly
3.12.2. Fuel Filter
3.12.3. Fuel Transfer Supply Pump.
B. Removal
C. Inspection
E. Replacement.
3.12.4. Fuel Lines.
B. Inspection.
3.12.5. Fuel Injection Pump
Chapter 4 Direct Support Maintenance Instructions
Table 4-1. Direct Support Troubleshooting (Sheet 1 Of 12) Engine Fails To Crank
Direct Support Troubleshooting (Sheet 2 Of 12) Starter Operates But Engine Does Not Turn Over.
Direct Support Troubleshooting (Sheet 3 Of 12) Engine Cranks But Fails To Start
Direct Support Troubleshooting (Sheet 4 Of 12) Engine Misfires Or Runs Erratically Or Stalls Frequently
Direct Support Troubleshooting (Sheet 5 Of 12) Engine Does Not Develop Full Power
Direct Support Troubleshooting (Sheet 6 Of 12) Engine Overheating
Direct Support Troubleshooting (Sheet 7 Of 12) Low Oil Pressure
Direct Support Troubleshooting (Sheet 8 Of 12) Excessive Fuel Consumption
Direct Support Troubleshooting (Sheet 9 Of 12) Black Or Gray Exhaust Smoke
Direct Support Troubleshooting (Sheet 10 Of 12) Blue Or White Exhaust Smoke
Direct Support Troubleshooting (Sheet 11 Of 12) Engine Knocks
Direct Support Troubleshooting (Sheet 12 Of 12) Abnormal Engine Noise
Section Ii. Maintenance Procedures
B. Repair
Figure 4-2. Battery Charging Alternator Assembly
Figure 4-3. Stator And Rear Housing Separation.
Figure 4-5. Testing Exciting Diodes
Figure 4-7. Testing Stator Windings
Figure 4-8. Testing Rotor
4.3.2. Starter
Figure 4-9. Starter Bench Test Setup
Figure 4-10. Starter Assembly
Figure 4-11. Disconnecting Lead Wire (Typical)
Figure 4-13. Removing Starter End Frame And Yoke Assembly (Typical)
Figure 4-15. Removing Armature
Figure 4-17. Removing Overrunning Clutch (Typical)
Figure 4-19. Removing Pinion, Retainer, And Rollers (Typical)
Figure 4-21. Checking Commutator Run-Out
Figure 4-23. Measuring Segment Mica Depth
Figure 4-25. Measuring Brush Length
Figure 4-27. Growler Test
Figure 4-29. Checking For Open Circuit Windings
Figure 4-31. Checking Field Coils
Figure 4-33. Installing Brushes
Figure 4-34. Installing Cover On Yoke
4.4. Intake And Exhaust System Maintenance
B. Inspection
Figure 4-36. Turbocharger
Figure 4-37. Turbocharger Inspection Points
C. Replacement
E. Install.
Figure 4-38. Inspecting Turbocharger Bearings
4.4.2. Intake Manifold
4.4.3. Exhaust Manifold
4.5. Lubrication System Maintenance
Figure 4-39. Oil Pressure Regulating Valve Assembly
4.5.3. Oil Pan
4.5.4 Pick-Up Tube Assembly
4.6. Fuel System Maintenance
Fuel Injection Pump
Figure 4-41. Separating Gear And Shaft
Figure 4-42. Check Timing Marks
D. Installation.
Figure 4-43. Fuel Injection Pump Pressure Outlet Ports
4.6.2. Fuel Injection Nozzle Assembly.
B. Test.
Diesel Or Jp Fuel
Figure 4-44. Fuel Injection Nozzle Assembly
(8) Perform Spray Pattern Test
D. Installation
4.6.3. Fuel Filter Base
4.7. Cylinder Head Assembly Maintenance
4.7.2. Intake And Exhaust Valve Checks And Adjustments
Figure 4-45. Rocker Arm Cover.
Figure 4-46. Engine Timing Hole Location
Figure 4-47. Rocker Arm Location
Table 4-2. Valve Clearance Specification (Rocker Arm-To-Valve Tip)
Table 4-3. Valve Lift Specification At 0.00 In. (Mm) Valve Clearance
Figure 4-48. Rocker Arm Assembly.
C. Repair.
D. Replacement
4.7.4. Cylinder Head
(13) Remove Rocker Arm Assembly
Figure 4-49. Cylinder Head Assembly
Figure 4-50. Fuel Transfer Pump Push Rod Location
Table 4-4. Valve Recess Specifications
Table 4-5. Cylinder Block Top Deck Specifications
Figure 4-52. Cylinder Head Capscrew Torque Sequence
(12) Install Push Rods And Rocker Arm Assembly
4.8. Flywheel And Housing Assembly Maintenance
Figure 4-53 Flywheel Flatness
Figure 4-55 Flywheel Housing Cutouts
Figure 4-57. Removal Of Rear Crankshaft Oil Seal
B. Inspection
Figure 4-58 Rear Crankshaft Oil Seal Installation
4.8.3. Flywheel Housing.
Figure 4-59. Flywheel And Housing Assembly
Figure 4-60. Gasket Application To Cylinder Block
4.9. Crankshaft Pulley And Timing Gear Cover Assembly Maintenance
4.9.2. Timing Gear Cover.
B. Inspection
Figure 4-63. Timing Gear Cover
D. Installation.
4.10. Vehicle Engine Stand
To Avoid Structural Or Personal Injury
Figure 4-64 Engine Lifting
B. Disconnect Turbocharger Oil Inlet Line
Chapter 5 General Support Maintenance Instructions
5.3. Fuel System Maintenance
Transfer Pump
Transfer Pump Pressure Gage
Table 5-2. Fuel Injection Pump Checks
Figure 5-1. Fuel Injection Pump (Typical) (Page 1 Of 3)
Figure 5-1. Fuel Injection Pump (Typical) (Page 2 Of 3)
Figure 5-1. Fuel Injection Pump (Typical) (Page 3 Of 3)
Figure 5-2. Clip Removal.
Figure 5-4. Control Rod Assembly And Governor Spring Removal.
Figure 5-5. Cam Advance Pin Removal
Figure 5-7. Linkage Hook Disconnection
Figure 5-9. Governor Arm And Linkage Hook Removal
Figure 5-10. Drive Shaft Bearing And Seal Removal (Shown Removed).
Figure 5-12. Cam Ring Removal.
Figure 5-14. Delivery Valve Removal
Figure 5-16. Fuel Injection Housing
Figure 5-17. Drive Shaft
Figure 5-18. Cam Ring
Figure 5-19. Hydraulic Head Assembly (Typical)
Figure 5-21. Shoes And Rollers
Figure 5-23. Transfer Pump Blades
Figure 5-24. Transfer Pump Liner
Figure 5-26. Transfer Pump Regulator Assembly
Figure 5-27. Metering Valve And Arm Assembly
Figure 5-29. Fuel Side Seal Installation
Figure 5-30. Oil Side Seal Installation
Figure 5-32. Seal Protection Tube
Figure 5-34. Spring Washer And Retaining Ring
Figure 5-36. Weight Retaining Assembly
Figure 5-38. Pumping Plunger Installation.
Figure 5-40. Measuring Roller To Roller Dimension
Figure 5-41. Transfer Pump Liner Installation (Typical)
Figure 5-43. Regulator Assembly Installation (Typical)
Figure 5-44. Governor Weight Installation (Typical).
Figure 5-46. Thrust Sleeve Installation (Typical)
Figure 5-48. Control Spring Installation
Figure 5-49. Control Rod Installation
Figure 5-51. Damper Barrel And Piston
Figure 5-53. Setting Governor Linkage Gap
Figure 5-54. Reed Valve Assembly
Figure 5-56. Piston Ring
Figure 5-58. Piston In Power Side Piston Hole
Figure 5-60. Aligning Pin Hole In Piston
5.4. Short Block Assembly
(7) Inspect Push Rods
Figure 5-61. Camshaft And Balancer Shafts
D. Test.
Cylinder Block Bore
Figure 5-62. Measuring Camshaft Lobe Height
F. Installation.
Camshaft Lobes
5.4.2. Idler Gears And Idler Gear Shafts
Table 5-4. Camshaft And Timing Gear Train Specifications – Cont
Figure 5-63. Idler Gears
Figure 5-64. Spring Pin Protrusion
5.4.3. Front Plate
B. Inspection.
Figure 5-66. Front Plate Sealant Application
5.4.4 Crankshaft And Main Bearings
Figure 5-67. Crankshaft And Main Bearings
B. Crankshaft End Play Test
Figure 5-68. Critical Areas Of Crankshaft Load Stress
Table 5-5. Crankshaft And Main Bearings Specifications
Figure 5-69. Measuring Main Thrust Journal And Thrust Bearing Width
Main Bearing Cap Line
D. Repair
D. Installation
When Installing Gear
5.4.5. Pistons And Connecting Rods.
Figure 5-70. Fastening Cylinder Liners
Use Plastigage
B. Repair.
Figure 5-72. Pistons, Connecting Rods, And Cylinder Liners
Figure 5-73. Piston Inspection (Defects Exaggerated)
Figure 5-75. Measuring Piston Ring Groove Clearance.
Table 5-6. Connecting Rod Journal And Bearing Specifications.
Table 5-7. Connecting Rod Bore (Without Bearing Inserts) Specifications
Table 5-8. Connecting Rod Piston Pin Bushing Specifications
Figure 5-77. Measuring Rod Center-To-Center Bores
Piston Rings
C. Installation
5.4.6. Cylinder Liners
C. Inspection
If Liner Pitting Has Occurred
Figure 5-78. Inspecting Cylinder Liner Pitting
Table 5-10. Cylinder Liner Thickness Specifications
Table 5-11. Piston And Cylinder Liner Specifications (Continued)
D. Repair
5.4.7. Balancer Shaft Assembly
C. Test.
E. Installation
5.4.8. Cylinder Block
(7) Remove Rocker Arm Cover
Figure 5-79. Inspecting Piston Cooling Orifice
Figure 5-80. Oil Gallery Plugs
Figure 5-81. Inspecting Cylinder Block
Figure 5-82. Measuring Main Bearing Bore
Figure 5-83. Measuring Cam Follower Bore Diameter
Figure 5-85. Measuring Cylinder Block Top Deck Flatness
(12) Install Camshaft Bushing And Timing Gears
5.4.9 Oil Pump Assembly.
Figure 5-86. Oil Pump Assembly
Figure 5-87. Oil Pump Axial Clearance
Figure 5-88. Oil Pump Radial Clearance Measurement.
5.4.10 Oil Bypass Valve Assembly
Figure 5-89. Oil Bypass Valve.
5.4.11. Cylinder Head
When Using Bench Grinder
Figure 5-90. Valve Face Angle
Cleaning Solvent
Figure 5-91. Measuring Cylinder Head Thickness
Valve Guides
If Valve Seat Width Is Too Narrow
Figure 5-92. Valve Seat Removal Chisel
Figure 5-94. Measure Valve Seat Bore In Cylinder Head
Table 5-12. Valve Seat Insert Bore Specifications
5.4.12. Oil Pressure Regulating Valve Assembly Valve Seat.
Appendix A References
A-5 Miscellaneous Publications -Cont
Maintenance Allocation Chart
B.3 Explanation Of Columns In The Mac
B.5 Explanation Of Columns In Remarks
Section Ii. Maintenance Allocation Chart For Diesel Engine Model 4045tf151
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont.
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont.
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont.
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont.
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont.
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont.
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont
Section Iii. Tool And Test Equipment Requirements For Diesel Engine Model 4045tf151
Tool And Test Equipment Requirements For Diesel Engine Model 4045tf151 – Cont.3.
Tool And Test Equipment Requirements For Diesel Engine Model 4045tf151 – Cont.
Tool And Test Equipment Requirements For Diesel Engine Model 4045tf151 – Cont.
Tool And Test Equipment Requirements For Diesel Engine Model 4045tf151 – Cont.
Section Iv. Remarks For Diesel Engine Model 4045tf151
Appendix C Components Of End Item (Coei) And Basic Issue Items (Bii) List
Section Iii. Basic Issue Items
Unit Direct Support And General Support Maintenance Manual Diesel Engine Model 4045tf151 4 Cylinder 4.5 Litre Nsn: 2851-01-462-2289
Appendix E Expendable And Durable Items List
Expendable Durable Items List – Cont
Appendix F Illustrated List Of Manufactured Items
Figure F-1, Fuel Injection Pump Holding Fixture
Figure F-2, Fuel Injection Pump Timing Mark Template
Table F-1. Metric Conversion
Appendix G Torque Limits
Torque Limits For Dry Fasteners (Continued)
Torque Limits For Dry Fasteners (Continued)
Appendix H Mandatory Replacement Parts
Table H-1. Mandatory Replacement Parts – Cont.
Index
Index (Continued)
Index (Continued)
Index (Continued)
Index (Continued)
Index (Continued)
Index (Continued)
Index (Continued)
Index (Continued)
Index (Continued)
Index (Continued)
Index (Continued)
Index (Continued)
Index (Continued)
Index (Continued)
Index (Continued)
Chapter 1 Introduction
Section Ii. Equipment Description And Data
C. Intake And Exhaust Valves
Figure 1-1. Engine Components
Table 1-1. Table Of Specifications
Table 1-2. Engine Options Codes - 4 Cylinder, 4.5 Liter
Engine Base Code: 2116f
Section Iii. Preparation For Use
Chapter 2 Operating Instructions
Section Iii. Special Instructions.
Section Ii. Repair Parts; Tools; Special Tools; Test, Measurement And Diagnostic (Tmde); And Support Equipment
Table 3-1. Preventive Maintenance Checks And Services
Section Iv. Troubleshooting
Table 3-2. Unit Troubleshooting (Sheet 1 Of 11) Engine Fails To Crank
Unit Troubleshooting (Sheet 2 Of 11) Engine Cranks But Fails To Start
Unit Troubleshooting (Sheet 3 Of 11) Engine Misfires Or Runs Erratically Or Stalls Frequently
Unit Troubleshooting (Sheet 4 Of 11) Engine Does Not Develop Full Power
Unit Troubleshooting (Sheet 5 Of 11) Engine Overheating
Unit Troubleshooting (Sheet 6 Of 11) Excessive Oil Consumption
Unit Troubleshooting (Sheet 7 Of 11) Low Oil Pressure
Unit Troubleshooting (Sheet 8 Of 11) Excessive Fuel Consumption
Unit Troubleshooting (Sheet 9 Of 11) Black Or Gray Exhaust Smoke
Unit Troubleshooting (Sheet 10 Of 11) Engine Knocks
Unit Troubleshooting (Sheet 11 Of 11) Engine Makes A Hissing Or Vapor Leaking Noise
Section V. Maintenance Procedures
3.7.1. Test Engine Compression Pressure
3.7.3 Intake Manifold Pressure Check
3.8. Cooling System Maintenance
Figure 3-1. Thermostat And Water Manifold/Thermostat Cover.
C. Replacement
Figure 3-2. Thermostat Installation.
B. Inspection
3.9. Electrical System Maintenance.
Figure 3-4. Battery Charging Alternator Mounting
3.9.2. Starter
B. Removal
Figure 3-6. Starter Assembly
3.10. Intake And Exhaust System Maintenance
Figure 3-8. Exhaust Manifold.
Figure 3-9. Oil Filter Assembly
3.11.3. Oil Cooler
Figure 3-10. Oil Cooler Assembly
Figure 3-11. Oil Fill Tube Assembly
Figure 3-12. Oil Dipstick Tube Assembly
Figure 3-13. Oil Dipstick Tube Installation.
Figure 3-14. Oil Pan.
3.12.1. Bleeding Fuel System
Figure 3-15. Fuel Filter Assembly
Figure 3-16. Fuel Supply Pump.
D. Bleed At Fuel Injection Nozzles
Figure 3-17. Fuel Injection Assembly
3.12.2. Fuel Filter
3.12.3. Fuel Transfer Supply Pump.
B. Removal
C. Inspection
E. Replacement.
3.12.4. Fuel Lines.
B. Inspection.
3.12.5. Fuel Injection Pump
Chapter 4 Direct Support Maintenance Instructions
Table 4-1. Direct Support Troubleshooting (Sheet 1 Of 12) Engine Fails To Crank
Direct Support Troubleshooting (Sheet 2 Of 12) Starter Operates But Engine Does Not Turn Over.
Direct Support Troubleshooting (Sheet 3 Of 12) Engine Cranks But Fails To Start
Direct Support Troubleshooting (Sheet 4 Of 12) Engine Misfires Or Runs Erratically Or Stalls Frequently
Direct Support Troubleshooting (Sheet 5 Of 12) Engine Does Not Develop Full Power
Direct Support Troubleshooting (Sheet 6 Of 12) Engine Overheating
Direct Support Troubleshooting (Sheet 7 Of 12) Low Oil Pressure
Direct Support Troubleshooting (Sheet 8 Of 12) Excessive Fuel Consumption
Direct Support Troubleshooting (Sheet 9 Of 12) Black Or Gray Exhaust Smoke
Direct Support Troubleshooting (Sheet 10 Of 12) Blue Or White Exhaust Smoke
Direct Support Troubleshooting (Sheet 11 Of 12) Engine Knocks
Direct Support Troubleshooting (Sheet 12 Of 12) Abnormal Engine Noise
Section Ii. Maintenance Procedures
B. Repair
Figure 4-2. Battery Charging Alternator Assembly
Figure 4-3. Stator And Rear Housing Separation.
Figure 4-5. Testing Exciting Diodes
Figure 4-7. Testing Stator Windings
Figure 4-8. Testing Rotor
4.3.2. Starter
Figure 4-9. Starter Bench Test Setup
Figure 4-10. Starter Assembly
Figure 4-11. Disconnecting Lead Wire (Typical)
Figure 4-13. Removing Starter End Frame And Yoke Assembly (Typical)
Figure 4-15. Removing Armature
Figure 4-17. Removing Overrunning Clutch (Typical)
Figure 4-19. Removing Pinion, Retainer, And Rollers (Typical)
Figure 4-21. Checking Commutator Run-Out
Figure 4-23. Measuring Segment Mica Depth
Figure 4-25. Measuring Brush Length
Figure 4-27. Growler Test
Figure 4-29. Checking For Open Circuit Windings
Figure 4-31. Checking Field Coils
Figure 4-33. Installing Brushes
Figure 4-34. Installing Cover On Yoke
4.4. Intake And Exhaust System Maintenance
B. Inspection
Figure 4-36. Turbocharger
Figure 4-37. Turbocharger Inspection Points
C. Replacement
E. Install.
Figure 4-38. Inspecting Turbocharger Bearings
4.4.2. Intake Manifold
4.4.3. Exhaust Manifold
4.5. Lubrication System Maintenance
Figure 4-39. Oil Pressure Regulating Valve Assembly
4.5.3. Oil Pan
4.5.4 Pick-Up Tube Assembly
4.6. Fuel System Maintenance
Fuel Injection Pump
Figure 4-41. Separating Gear And Shaft
Figure 4-42. Check Timing Marks
D. Installation.
Figure 4-43. Fuel Injection Pump Pressure Outlet Ports
4.6.2. Fuel Injection Nozzle Assembly.
B. Test.
Diesel Or Jp Fuel
Figure 4-44. Fuel Injection Nozzle Assembly
(8) Perform Spray Pattern Test
D. Installation
4.6.3. Fuel Filter Base
4.7. Cylinder Head Assembly Maintenance
4.7.2. Intake And Exhaust Valve Checks And Adjustments
Figure 4-45. Rocker Arm Cover.
Figure 4-46. Engine Timing Hole Location
Figure 4-47. Rocker Arm Location
Table 4-2. Valve Clearance Specification (Rocker Arm-To-Valve Tip)
Table 4-3. Valve Lift Specification At 0.00 In. (Mm) Valve Clearance
Figure 4-48. Rocker Arm Assembly.
C. Repair.
D. Replacement
4.7.4. Cylinder Head
(13) Remove Rocker Arm Assembly
Figure 4-49. Cylinder Head Assembly
Figure 4-50. Fuel Transfer Pump Push Rod Location
Table 4-4. Valve Recess Specifications
Table 4-5. Cylinder Block Top Deck Specifications
Figure 4-52. Cylinder Head Capscrew Torque Sequence
(12) Install Push Rods And Rocker Arm Assembly
4.8. Flywheel And Housing Assembly Maintenance
Figure 4-53 Flywheel Flatness
Figure 4-55 Flywheel Housing Cutouts
Figure 4-57. Removal Of Rear Crankshaft Oil Seal
B. Inspection
Figure 4-58 Rear Crankshaft Oil Seal Installation
4.8.3. Flywheel Housing.
Figure 4-59. Flywheel And Housing Assembly
Figure 4-60. Gasket Application To Cylinder Block
4.9. Crankshaft Pulley And Timing Gear Cover Assembly Maintenance
4.9.2. Timing Gear Cover.
B. Inspection
Figure 4-63. Timing Gear Cover
D. Installation.
4.10. Vehicle Engine Stand
To Avoid Structural Or Personal Injury
Figure 4-64 Engine Lifting
B. Disconnect Turbocharger Oil Inlet Line
Chapter 5 General Support Maintenance Instructions
5.3. Fuel System Maintenance
Transfer Pump
Transfer Pump Pressure Gage
Table 5-2. Fuel Injection Pump Checks
Figure 5-1. Fuel Injection Pump (Typical) (Page 1 Of 3)
Figure 5-1. Fuel Injection Pump (Typical) (Page 2 Of 3)
Figure 5-1. Fuel Injection Pump (Typical) (Page 3 Of 3)
Figure 5-2. Clip Removal.
Figure 5-4. Control Rod Assembly And Governor Spring Removal.
Figure 5-5. Cam Advance Pin Removal
Figure 5-7. Linkage Hook Disconnection
Figure 5-9. Governor Arm And Linkage Hook Removal
Figure 5-10. Drive Shaft Bearing And Seal Removal (Shown Removed).
Figure 5-12. Cam Ring Removal.
Figure 5-14. Delivery Valve Removal
Figure 5-16. Fuel Injection Housing
Figure 5-17. Drive Shaft
Figure 5-18. Cam Ring
Figure 5-19. Hydraulic Head Assembly (Typical)
Figure 5-21. Shoes And Rollers
Figure 5-23. Transfer Pump Blades
Figure 5-24. Transfer Pump Liner
Figure 5-26. Transfer Pump Regulator Assembly
Figure 5-27. Metering Valve And Arm Assembly
Figure 5-29. Fuel Side Seal Installation
Figure 5-30. Oil Side Seal Installation
Figure 5-32. Seal Protection Tube
Figure 5-34. Spring Washer And Retaining Ring
Figure 5-36. Weight Retaining Assembly
Figure 5-38. Pumping Plunger Installation.
Figure 5-40. Measuring Roller To Roller Dimension
Figure 5-41. Transfer Pump Liner Installation (Typical)
Figure 5-43. Regulator Assembly Installation (Typical)
Figure 5-44. Governor Weight Installation (Typical).
Figure 5-46. Thrust Sleeve Installation (Typical)
Figure 5-48. Control Spring Installation
Figure 5-49. Control Rod Installation
Figure 5-51. Damper Barrel And Piston
Figure 5-53. Setting Governor Linkage Gap
Figure 5-54. Reed Valve Assembly
Figure 5-56. Piston Ring
Figure 5-58. Piston In Power Side Piston Hole
Figure 5-60. Aligning Pin Hole In Piston
5.4. Short Block Assembly
(7) Inspect Push Rods
Figure 5-61. Camshaft And Balancer Shafts
D. Test.
Cylinder Block Bore
Figure 5-62. Measuring Camshaft Lobe Height
F. Installation.
Camshaft Lobes
5.4.2. Idler Gears And Idler Gear Shafts
Table 5-4. Camshaft And Timing Gear Train Specifications – Cont
Figure 5-63. Idler Gears
Figure 5-64. Spring Pin Protrusion
5.4.3. Front Plate
B. Inspection.
Figure 5-66. Front Plate Sealant Application
5.4.4 Crankshaft And Main Bearings
Figure 5-67. Crankshaft And Main Bearings
B. Crankshaft End Play Test
Figure 5-68. Critical Areas Of Crankshaft Load Stress
Table 5-5. Crankshaft And Main Bearings Specifications
Figure 5-69. Measuring Main Thrust Journal And Thrust Bearing Width
Main Bearing Cap Line
D. Repair
D. Installation
When Installing Gear
5.4.5. Pistons And Connecting Rods.
Figure 5-70. Fastening Cylinder Liners
Use Plastigage
B. Repair.
Figure 5-72. Pistons, Connecting Rods, And Cylinder Liners
Figure 5-73. Piston Inspection (Defects Exaggerated)
Figure 5-75. Measuring Piston Ring Groove Clearance.
Table 5-6. Connecting Rod Journal And Bearing Specifications.
Table 5-7. Connecting Rod Bore (Without Bearing Inserts) Specifications
Table 5-8. Connecting Rod Piston Pin Bushing Specifications
Figure 5-77. Measuring Rod Center-To-Center Bores
Piston Rings
C. Installation
5.4.6. Cylinder Liners
C. Inspection
If Liner Pitting Has Occurred
Figure 5-78. Inspecting Cylinder Liner Pitting
Table 5-10. Cylinder Liner Thickness Specifications
Table 5-11. Piston And Cylinder Liner Specifications (Continued)
D. Repair
5.4.7. Balancer Shaft Assembly
C. Test.
E. Installation
5.4.8. Cylinder Block
(7) Remove Rocker Arm Cover
Figure 5-79. Inspecting Piston Cooling Orifice
Figure 5-80. Oil Gallery Plugs
Figure 5-81. Inspecting Cylinder Block
Figure 5-82. Measuring Main Bearing Bore
Figure 5-83. Measuring Cam Follower Bore Diameter
Figure 5-85. Measuring Cylinder Block Top Deck Flatness
(12) Install Camshaft Bushing And Timing Gears
5.4.9 Oil Pump Assembly.
Figure 5-86. Oil Pump Assembly
Figure 5-87. Oil Pump Axial Clearance
Figure 5-88. Oil Pump Radial Clearance Measurement.
5.4.10 Oil Bypass Valve Assembly
Figure 5-89. Oil Bypass Valve.
5.4.11. Cylinder Head
When Using Bench Grinder
Figure 5-90. Valve Face Angle
Cleaning Solvent
Figure 5-91. Measuring Cylinder Head Thickness
Valve Guides
If Valve Seat Width Is Too Narrow
Figure 5-92. Valve Seat Removal Chisel
Figure 5-94. Measure Valve Seat Bore In Cylinder Head
Table 5-12. Valve Seat Insert Bore Specifications
5.4.12. Oil Pressure Regulating Valve Assembly Valve Seat.
Appendix A References
A-5 Miscellaneous Publications -Cont
Maintenance Allocation Chart
B.3 Explanation Of Columns In The Mac
B.5 Explanation Of Columns In Remarks
Section Ii. Maintenance Allocation Chart For Diesel Engine Model 4045tf151
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont.
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont.
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont.
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont.
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont.
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont.
Maintenance Allocation Chart For Diesel Engine Model 4045tf151 – Cont
Section Iii. Tool And Test Equipment Requirements For Diesel Engine Model 4045tf151
Tool And Test Equipment Requirements For Diesel Engine Model 4045tf151 – Cont.3.
Tool And Test Equipment Requirements For Diesel Engine Model 4045tf151 – Cont.
Tool And Test Equipment Requirements For Diesel Engine Model 4045tf151 – Cont.
Tool And Test Equipment Requirements For Diesel Engine Model 4045tf151 – Cont.
Section Iv. Remarks For Diesel Engine Model 4045tf151
Appendix C Components Of End Item (Coei) And Basic Issue Items (Bii) List
Section Iii. Basic Issue Items
Unit Direct Support And General Support Maintenance Manual Diesel Engine Model 4045tf151 4 Cylinder 4.5 Litre Nsn: 2851-01-462-2289
Appendix E Expendable And Durable Items List
Expendable Durable Items List – Cont
Appendix F Illustrated List Of Manufactured Items
Figure F-1, Fuel Injection Pump Holding Fixture
Figure F-2, Fuel Injection Pump Timing Mark Template
Table F-1. Metric Conversion
Appendix G Torque Limits
Torque Limits For Dry Fasteners (Continued)
Torque Limits For Dry Fasteners (Continued)
Appendix H Mandatory Replacement Parts
Table H-1. Mandatory Replacement Parts – Cont.
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