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TM 5-2420-222-34
Table 2-1. Troubleshooting (Con’t).
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Step 4.
Start engine assembly and operate at idle speed (see TM 5-2420-222-10). Listen for noise at
cylinder block just below cylinder head and in line with cylinder bore.
If no noise is heard, increase engine speed. If noise gets louder as engine rpm increases,
replace valve springs (see paragraph 3-12).
Step 5.
Remove cylinder head (see paragraph 3-6). Check for foreign material in cylinders.
Remove foreign material. Remove pistons and rings and check for damage (see paragraph 3-11).
Check cylinder sleeves for ridge. If ridge is present, replace cylinder sleeves (see paragraph 3-5).
Step 6.
Remove timing gear cover (see paragraph 3-18).
Check for proper end clearance of idler gear and repair as required (see paragraph 3-15).
7.
ENGINE OVERHEATS.
Step 1.
Inspect cylinder head for cracks. If cracks in cylinder head are not seen, start engine assembly and
operate at 800 rpm for five minutes (see TM 5-2420-222-10). With engine operating at idle speed,
check for engine coolant leakage at exhaust manifold.
If cracks in cylinder head are seen, replace cylinder head (see paragraph 3-6).
Step 2.
Remove cylinder head (see paragraph 3-6). Check for a cracked cylinder sleeve. Crank engine
until piston in cylinder being checked is at bottom of cylinder. Visually check cylinder sleeve.
Repeat for all four cylinders.
Replace cylinder sleeve if cracked (see paragraph 3-5).
If cylinder sleeves are not damaged, replace cylinder head (see paragraph 3-6).
Step 3.
Check valve timing (see paragraph 3-12).
Adjust valve timing (see paragraph 3-12).
Step 4.
Check fuel metering pump drive gear-to-idler gear backlash (see paragraph 3-19).
Adjust fuel metering pump drive gear-to-idler gear backlash (see paragraph 3-19).
Step 5.
Remove engine oil pan (see paragraph 3-20). Check for signs of engine coolant leakage at bottom
of cylinder sleeves.
If engine coolant leakage is evident, replace cylinder sleeve(s) packing (see paragraph 3-5).
If engine coolant leakage is not evident, check cylinder sleeves and pistons for scoring (see
paragraphs 3-5 and 3-11).
8.
ENGINE PERFORMS POORLY.
Step 1.
Perform engine assembly compression test (see paragraph 3-1).
Repair as required.
2-5
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