TM 54115-593-12TO 35C2-3-463-1(1) Drain cooling system by opening drain plugand shut-off cock. Use suitable container tostore coolant for reuse.(2) Disconnect water connection tube (1) byloosening clamps (2), then separate hose(3) from outlet (4).(3) Disconnect water transfer tube assembly (5)by loosening clamps (2) and separatingtransfer tubing (7) from hose (3). Removebolt (8) and washers (9 and 10) to loosentee (6). Remove bolt (11) and washer (12)to separate fitting (13) from intercooler (29).Remove assembly in one piece, or loosenclamps (2) to disassemble tubing intoindividual sections. Remove and discardgaskets (14 and 15).(4) Remove air balance tube assembly (16) byremoving bolts (17) and washers (18 and19). Remove and discard gaskets (20).Remove assembly as one piece, or loosenclamps (2) to disassemble tubing intoindividual sections.(5) Loosen clamp (23) securing air intakeconnection (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 blockusing 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) byreplacing gaskets (20) and mounting tubingusing bolts (17) andwashers (18 and 19).(10) Install water transfer tube assembly (5) byreplacing gaskets (14 and 15), then mounttee (6) using bolt (8) and washers (9 and10). Secure fitting (13) to intercooler (29)using bolt (11) and washer (12). Securetubing (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. Refillcooling system.(13) Check all connections for security. Observeclosely during first use after replacement forsigns of leakage.4-85. EXHAUST MANIFOLD. The exhaust manifold(figure 4-57) provides for the routing of the engineexhaust gases. Also, the exhaust gases serve as aninput to the turbocharger.a.Inspection. Inspect the exhaust manifold forrust, loose mounting, cracks, and breaks.b.Replacement.(1) Refer to paragraph 4-78 and remove theturbocharger.(2) Disconnect and plug fuel and oil lines asneeded to facilitate removal.(3) Remove fuel injection lines.(4) Rem6ve bolts (1, figure 4-57), washers (2)and spacers (3) attaching exhaust manifoldto engine.(5) Remove gaskets (4) and lift exhaustmanifold from engine.(6) Reinstall exhaust manifold with bolts (1),washers (2), and spacers (3). Use newgaskets (4). Replace injection lines and4-122
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