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 TM 5-1940-277-20
TM 1940-20/2
REMOVE:
1.
Open and secure engine hatches (refer to paragraph 3-154).
2.
Using 9/32-in. box wrench loosen hose clamps (1, 2 and 3).
3.
Remove hoses from intercooler connections.
4.
Using 1/2-in. box wrench remove two bolts (5) and washers (6) from reservoir bracket (7).
5.
Using 1/2-in. box wrench remove four bolts (8) and washers (9) from both ends of intercooler
assembly.
6.
Remove thermostat fuel reservoir (24) (refer to paragraph 3-107).
7.
Remove front stub pipe (10) and gasket (11). Discard gasket.
8.
Clean mounting surface of front stub pipe (10) using putty knife.
9.
Remove rear stub pipe (12) and gasket (11). Discard gasket.
10.
Clean mounting surface of stub pipe (12) using putty knife.
11.
Using 1/2-in. box wrench remove eight bolts (13) and washers (14) from intercooler duct (15).
12.
Using 1/2-in. box wrench remove two bolts (16) and washers (14) from intercooler duct (15).
13.
Using 1/2-in. box wrench remove bolt (17) and washer (14) from intercooler duct (15).
14.
Using 11/16-in. box wrench loosen nut (18) and disconnect drain down tubing (19) on MK1.
15.
Using 5/8-in. box wrench remove two bolts (20) lockwashers (21) and flat washers (22) from
intercooler assembly (23).
16.
Remove intercooler assembly (23) from engine.
17.
Clean intercooler duct (15).
INSTALL:
1.
Install replacement intercooler assembly (23) on engine.
CAUTION
Support intercooler until steps 2 and 3 have been completed.
2.
Secure intercooler by installing two flat washers (22), lockwashers (21) and bolts (20).
3.
Tighten bolts (20) using 5/8-in. wrench.
4.
Reinstall washer (14) and bolt (17) through intercooler duct (15) into intercooler assembly (23).
5.
Reinstall four washers (14) and bolts (13) through intercooler duct (15) into intercooler
assembly (23). Finger tighten.
6.
Reinstall two washers (14) and bolts (16) through intercooler duct (15) into intercooler
assembly (23). Hand tighten.
7.
Install lockwashers (6) and bolts (5) through reservoir bracket (7) into intercooler assembly (23).
Hand tighten.
8.
Using 1/2-in. wrench evenly tighten bolts (17, 13, 16, and 5).
9.
Coat new gaskets (11) with sealant (Item 3, App. C) on both sides.
10.
Install new gaskets (11) on ends of intercooler assembly (23).
11.
Reinstall rear stub pipe (12), washers (9) and bolts (8). Tighten bolts using 1/2-in. wrench.
12.
Reinstall front stub pipe (10), washers (9), and bolts (8). Tighten bolts using 1/2-in. wrench.
13.
Install thermostat fuel reservoir (24) (refer to paragraph 3-107)
14.
Reconnect drain down tube (19) on MK1. Using 11/16-in. wrench, tighten nut.
15.
Reinstall hoses to intercooler connections.
16.
Position clamps (1, 2 and 3) and tighten using 9/32-in. box wrench.
17.
Close engine hatches.
3-180
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