TM 9-6115-604-34
NAVFAC P-8-633-34
SECTION VI. MAINTENANCE OF CYLINDER BLOCK, VIBRATION DAMPER, FRONT AND REAR CRANKSHAFT
AND ACCESSORY DRIVE SEALS, FLYWHEEL ASSEMBLY, FLYWHEEL AND REAR GEAR HOUSINGS, FRONT
ENGINE SUPPORT, !NSPECTION COVERS, OIL PAN ASSEMBLY, AND PISTON COOLING NOZZLES
9-29. GENERAL. This section covers maintenance of the cylinder block, housings, and related engine parts. Basic
inspection procedures are on engine inspections where possible. Complete inspection procedures are given in the
replacement and repair procedures. During repair operations, the cylinder block and all parts should be inspected by the
applicable magnetic or dye penetrant procedures. Adhere to the specifications and tolerances given in Table 1 -4. Keep
all parts dean during assembly; dirt and foreign material are a major cause of crankshaft and other internal part failures.
9-30. CYLINDER BLOCK INSPECTION.
a.
Visually inspect the cylinder block for cracks and evidence of coolant or oil leakage at gasket surfaces,
expansion plugs, and front and rear crankshaft seals.
b.
Repair cracks in the cylinder block in accordance with paragraph 9-31.
c.
Replace leaking expansion plugs in accordance with paragraph 2-10.
d.
Replace leaking front or rear crankshaft seals in accordance with paragraph 9-33.
e.
Leakage from gaskets may be caused by faulty gaskets or mating surfaces. Replace leaking gaskets and check
the mating surfaces in accordance with the following paragraphs: (1) Cylinder head, 9-8 and 9-10.
(2)
Cylinder block, 9-31.
(3)
Oil pan, 9-38.
(4)
Flywheel housing, 9-35.
(5)
Timing cover and housing, 9-18.
9-31. CYLINDER BLOCK MAINTENANCE
a.
Remove and Disassemble. (See Figure 9-24.)
(1)
Remove the engine from the generator set in accordance with Chapter 2, and install the engine in rebuild
stand 3375955.
(2)
Remove the fuel system components in accordance with Chapter 6 and the Operator and Organizational
Maintenance Manual.
(3)
Remove the cooling system components in accordance with Chapter 7 and the Operator and
Organizational Maintenance Manual.
(4)
Remove the lubrication system components in accordance with Chapter 8 and the Operator and
Organizational Maintenance Manual.
(5)
Remove the camshafts in accordance with paragraph 9-15.
(6)
Remove the timing gears and housing in accordance with paragraph 9-18.
(7)
Remove the camshaft bushings in accordance with paragraph 9-16.
(8)
Remove the flywheel in accordance with paragraph 9-34.
(9)
Remove the flywheel housing and rear gear housing in accordance with paragraph 9-35.
(10)
Remove the connecting rod and piston assemblies in accordance with paragraph 9-20.
(11)
Remove the crankshaft in accordance with paragraph 9-27.
(12)
Remove the capscrews (35, Figure 9-24) and thrust bearing retainer (36) from the cylinder block (58).
(13)
Remove 12 capscrews (37), and remove the 12 piston cooling nozzles (38). Remove and discard the
packings (39) from the piston cooling nozzles.
(14)
Remove the capscrews (40), washers (41), and lifting brackets (42).
(15)
Remove the dowels (43) from the head surface, and from the front and rear of the cylinder block (58) only
if damaged or loose.
9-98
