TM 5-6115-400-12
(1) Remove capscrews securing the fuel filter
wedge the header away from the front of
the manifold to break the gasket sealing
assembly to the intake manifold. With the
compound. Slide intercooler core out of
fuel filter assembly and hoses intact,
the intake manifold. Do not drive on rear
carefully let it hang to one side.
end of intercooler core.
(2) Remove ether primer.
Note.
(3) Remove air inlet pipe.
Pressure
test
intercooler
core
(4) Remove clamping plates securing fuel
assembly with 70 to 75 psi air
injection tubes to front and rear supporting
pressure. Immerse intercooler core
brackets.
in hot water for a sufficient length of
(5) Remove breather tube.
time
until
the
tube
bundle
(6) Open drain cocks on both end bonnets
temperature is up to approximately
and allow water to drain.
180F. Use an improvised seal, such
(7) Disconnect water inlet and outlet hoses
as a drilled metal plate and a thick
from front end bonnet by removing
rubber gasket. Drill and tap a hole in
attaching capscrews and lockwashers.
the plate and attach an air pressure
(8) Remove
collector
manifold
tube
hose to it; secure the plate to the
assembly.
front of the intercooler core with
(9) Remove intake manifold.
capscrews and nuts. Secure a metal
c. Disassembly of Manifold and Intercooler.
plate and a rubber gasket to
(1) Remove front and rear end bonnets and
the rear of the intercooler core with C
gaskets. Remove packing from rear end
clamps.
bonnet.
(3) Observe for air bubbles around the tubes.
(2) To loosen intercooler from intake manifold
If any leaks are found, the intercooler core
(fig. 3-46), carefully
must be replaced.
(4) Check collector manifold tube for damage
or clogged condition. Clean or replace as
necessary.
e. Intake Manifold with Intercooler installation.
(1) Install two temporary guide studs in the
front end of the intake manifold.
(2) Cement a new gasket (split type) to the
front end of the intake manifold using a
gasket sealant on both sides of the
gasket.
(3) Make certain the open end of the baffles
on the intercooler core are to the top and
slide the intercooler core into the intake
manifold.
(4) Install gasket and front end bonnet;
secure with capscrews and lockwashers.
(5) Remove temporary guide studs and install
capscrews and lockwashers.
(6) Install a new packing in the rear end
bonnet.
(7) Cement a new gasket (split type) to the
rear end of the intake manifold using a
gasket sealant on both sides of the
gasket.
Figure 3-45. Intake manifold, removal and
installation.
(8) Install rear end bonnet to intake manifold;
secure with capscrews and lockwashers.
3-51
