TM 54115-593-12
TO 35C2-3-463-1
(1) Drain cooling system by opening drain plug
and shut-off cock. Use suitable container to
store coolant for reuse.
(2) Disconnect water connection tube (1) by
loosening clamps (2), then separate hose
(3) from outlet (4).
(3) Disconnect water transfer tube assembly (5)
by loosening clamps (2) and separating
transfer tubing (7) from hose (3). Remove
bolt (8) and washers (9 and 10) to loosen
tee (6). Remove bolt (11) and washer (12)
to separate fitting (13) from intercooler (29).
Remove assembly in one piece, or loosen
clamps (2) to disassemble tubing into
individual sections. Remove and discard
gaskets (14 and 15).
(4) Remove air balance tube assembly (16) by
removing bolts (17) and washers (18 and
19). Remove and discard gaskets (20).
Remove assembly as one piece, or loosen
clamps (2) to disassemble tubing into
individual sections.
(5) Loosen clamp (23) securing air intake
connection (24) to air hose (25).
(6) Remove bolts (26) and washers (27 and 28)
to free intercooler (29) from engine.
(7) Mount intercooler (29) onto engine block
using bolts (26) and washers (27 and 28).
(8) Secure air hose (25) to air intake connection
(24) with clamp (23).
(9) Install air balance tube assembly (16) by
replacing gaskets (20) and mounting tubing
using bolts (17) and
washers (18 and 19).
(10) Install water transfer tube assembly (5) by
replacing gaskets (14 and 15), then mount
tee (6) using bolt (8) and washers (9 and
10). Secure fitting (13) to intercooler (29)
using bolt (11) and washer (12). Secure
tubing (7) to hose (3) using clamp (2).
(11) Secure water connection tube (11) to outlet
(4) using clamps (2).
(12) Close draincock and drain plug. Refill
cooling system.
(13) Check all connections for security. Observe
closely during first use after replacement for
signs of leakage.
4-85. EXHAUST MANIFOLD. The exhaust manifold
(figure 4-57) provides for the routing of the engine
exhaust gases. Also, the exhaust gases serve as an
input to the turbocharger.
a.
Inspection. Inspect the exhaust manifold for
rust, loose mounting, cracks, and breaks.
b.
Replacement.
(1) Refer to paragraph 4-78 and remove the
turbocharger.
(2) Disconnect and plug fuel and oil lines as
needed to facilitate removal.
(3) Remove fuel injection lines.
(4) Rem6ve bolts (1, figure 4-57), washers (2)
and spacers (3) attaching exhaust manifold
to engine.
(5) Remove gaskets (4) and lift exhaust
manifold from engine.
(6) Reinstall exhaust manifold with bolts (1),
washers (2), and spacers (3). Use new
gaskets (4). Replace injection lines and
4-122
