a. Inspection. Inspect the idler pulley to assure
freedom of rotation and that there is no evidence of
cracking or signs of excessive wear.
b. Removal. To remove and disassemble the
idler pulley, proceed as follows:
(1) Refer to paragraph 3-183 and remove
engine drive belts from around idler pulley (1 O,
fig. 3-45).
(2) See figure 3-45 and remove bracket (15)
with pulley (1 O) still in place on the bracket (15).
(3) Remove pulley (10) and related hardware
from bracket (15).
c. Installation.
(1) Install pulley (10) and related hardware on
mounting bracket (15).
(2) Install bracket (15) onto engine.
(3) Torque nut (5) to 140 lb-ft (lubricated).
(4) Pack areas between bearing (9) and two seals
(4) and (7) 2/3 - full of BR grease.
NOTE
Do not repack bearing
(5) Refer to paragraph 3-183 and install engine
drive belts onto pulley (10). Position bracket (15)
for proper belt tension.
d. Repair. Repair of the idler pulley and mount-
ing-bracket is accomplished by replacement of defec -
tive components.
Section XLI. INTAKE MANIFOLD
3-214. General.
a. The air intake system consists of components
which convey filtered air to the engine cylinders.
The intake system includes the air cleaner, com-
pressor side of the turbocharger, and the intake
manifold.
b. The intake manifold is sealed to the cylinder
head with a one piece gasket and secured in place with
screws and washers.
3-215. Removal and Replacement.
See figure 3-46 and proceed as follows
a. Removal.
(1) Disconnect atomizer (1, fig. 3-46) and
tube (1A) from intake manifold (6).
(2) Remove screws (11, fig. 3-42) and washers
(12) securing turbocharger air outlet elbow (14) to
top of intake manifold (6, fig. 3-46). Loosen clamp
(13, fig. 3-42) and remove air outlet elbow (14) and
gasket (16).
(3) Remove screws (2, fig. 3-46) washers (3),
securing intake manifold (6) to cylinder head; remove
brackets (5), intake manifold (6), and gasket (7).
b . Inspection.
Proceed as follows:
(1) Wash and clean intake manifold with
cleaning solvent, Federal Specification P-D-680.
(2) Check manifold for foreign deposits. Clear
and remove obstructions found within the manifold.
(3) If manifold is cracked, it must be replaced.
(4) If the mounting surface of the intake
manifold is warped enough so that it will not seal,
the manifold must be replaced.
(5) Inspect and clean the mounting surface on
the cylinder head to make certain it is free of gasket
particles or foreign matter.
c. Installation. Proceed as follows
(1) Install the intake manifold (6, fig. 3-46)
to the engine in reverse order of removal.
(2) Always use a new gasket (7) when in-
stalling the intake manifold (6).
(3) Torque the intake manifold securing screws
(2) to 28-33 foot -pounds.
(3A) Install atomizer and tighten atomizer so
that locating dots on hex are located as shown in view
A of figure 3-46.
(4) After the engine is run and the water
temperature reaches approximately 170°F, again
torque screws (2) to 28-33 foot-pounds.
3-108 Change 8
