MARINE 38V1-6-2 Service Manual

ARMY TM 9-2815-237-34

AIR FORCE TO 38V1-6-2

MARINE CORPS TM 2815-34/3 A

(SUPERSEDES TM 9-2815-237-34, 25 June 1985)

TECHNICAL MANUAL

DIRECT SUPPORT AND GENERAL SUPPORT

MAINTENANCE

ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED,

FUEL-INJECTED, WATER COOLED,

DDA MODEL 6.2 LITER (PRE-1990) (NSN 2815-01-231-3672), (POST-1990) (NSN 2815-01-314-7940);

DDA MODEL 6.5 LITER (NSN 2815-01-410-9710) (1995,1996), (NSN 2815-01-439-6665) (1997),

(NSN 2815-01-453-7403) (1998);

ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED, DETUNED,

FUEL-INJECTED, WATER COOLED,

DDA MODEL 6.5 LITER (NSN 2815-01-406-6675) (1996), (NSN 2815-01-439-6664) (1997),

(NSN 2815-01-453-7404) (1998);

ENGINE, DIESEL: 8 CYLINDER, TURBOCHARGED,

FUEL-INJECTED, WATER COOLED, (NSN 2815-01-420-4180) (1996), (NSN 2815-01-439-8164) (1997), (NSN 2815-01-453-7402) (1998).

Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENTS OF THE ARMY, THE AIR FORCE, AND MARINE CORPS

JANUARY 1996

TM 9-2815-237-34

WARNING

EXHAUST GASES CAN KILL

Brain damage or death can result from heavy exposure. Precautions must be followed to ensure personnel safety when the engine is operated for any purpose.

1.DO NOT operate your vehicle engine in enclosed area.

2.BE ALERT at all times for exhaust odors.

3.BE ALERT for exhaust poisoning symptoms. They are:

•Headache

•Dizziness

•Sleepiness

•Loss of muscular control

4.If YOU SEE another person with exhaust poisoning symptoms:

•Remove person from area

•Expose to open air

•Keep person warm

•Do not permit person to move

•Administer artificial respiration, if necessary*

•Notify a medic

*For artificial respiration, refer to FM 21-11

5.BE AWARE, the field protective mask for nuclear-biological-chemical (NBC) protection will not protect you from exhaust poisoning.

THE BEST DEFENSE AGAINST EXHAUST POISONING IS ADEQUATE VENTILATION.

Change 1

Warning a

TM 9-2815-237-34

WARNING SUMMARY

•Always wear eyeshields when using compressed air. Failure to wear eyeshields may result in eye injury.

•Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).

•Do not use compressed air to dry bearings. Spinning a dry bearing with compressed air may cause injury to personnel or damage to equipment.

•Improper cleaning methods and use of unauthorized cleaning solutions will injure personnel and damage equipment. See TM 9-247 for correct information.

•Drycleaning solvent is flammable and will not be used near an open flame. A fire extinguisher will be kept nearby when the solvent is used. Use only in well-ventilated places. Failure to do this may result in injury to personnel and/or damage to equipment.

•When steam cleaning, protective clothing must be used. Failure to use protective clothing may result in serous injury.

•Diesel fuel is highly flammable. Do not perform this procedure near fire, flame, or sparks. Severe injury or death may result.

•Cylinder block must be supported during removal and installation from engine stand. Failure to support cylinder block may cause injury to personnel or damage to equipment.

•Crankshaft must be supported during removal and installation. Failure to support crankshaft may cause injury to personnel or damage to equipment.

•Do not place hands or arms near nozzle during testing. Penetrating force of oil may cause serious injury or death.

•Direct personnel to stand clear during hoisting operation. Failure to do this may cause injury to personnel.

•Gaskets installed on some 6.2L engines assembled prior to 1991 may contain asbestos. Gaskets should be removed with a scraper or putty knife and then disposed of IAW current directives. Inhalation of asbestos fibers can cause respiratory ailments.

Warning b

Change 1

	ARMY TM 9-2815-237-34
	AIR FORCE TO 38V1-6-2
	MARINE CORPS TM 2815-34/3 A
CHANGE	HEADQUARTERS,
	DEPARTMENTS OF THE ARMY,
NO. 2	THE AIR FORCE, AND MARINE CORPS
	Washington, D.C., 15 July 2004

TECHNICAL MANUAL

DIRECT SUPPORT AND GENERAL SUPPORT

MAINTENANCE

ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED,

FUEL-INJECTED, WATER COOLED,

DDA MODEL 6.2 LITER (PRE-1990) (NSN 2815-01-231-3672), (POST-1990) (NSN 2815-01-314-7940);

DDA MODEL 6.5 LITER (NSN 2815-01-410-9710) (1995,1996), (NSN 2815-01-439-6665) (1997), (NSN 2815-01-453-7403) (1998);

ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED, DETUNED,

FUEL-INJECTED, WATER COOLED,

DDA MODEL 6.5 LITER (NSN 2815-01-406-6675) (1996), (NSN 2815-01-439-6664) (1997), (NSN 2815-01-453-7404) (1998);

ENGINE, DIESEL: 8 CYLINDER, TURBOCHARGED,

FUEL-INJECTED, WATER COOLED, (NSN 2815-01-420-4180) (1996), (NSN 2815-01-439-8164) (1997), (NSN 2815-01-453-7402) (1998)

TM 9-2815-237-34, 31 January 1996, is changed as follows:

1.Remove old pages and insert new pages as indicated below.

2.New or changed material is indicated by a vertical bar in the margin of the page.

Remove pages	Insert pages
A/(B blank)	A/(B blank)
i and ii	i and ii
1-1 and 1-2	1-1 and 1-2
1-5/(1-6 blank)	1-5/(1-6 blank)
2-23 and 2-24	2-23 and 2-24
2-85 through 2-90	2-85 through 2-90
2-101 and 2-102	2-101 and 2-102
2-113 and 2-114	2-113 and 2-114
2-117 through 2-120	2-117 through 2-120
2-125 and 2-126	2-125 and 2-126
2-155 and 2-156	2-155 and 2-156
2-173 and 2-174	2-173 and 2-174
A-1 and A-2	A-1 and A-2
Index 1 through Index 4	Index 1 through Index 4
DA Form 2028	DA Form 2028
Cover	Cover

3. File this change sheet in front of the publication for reference purposes.

Approved for public release; distribution is limited.

By Order of the Secretary of the Army:

Peter J. Schoomaker

General, United States Army

Chief of Staff

Official:

JOEL B. HUDSON

Administrative Assistant to the Secretary of the Army

0223410

By Order of the Secretary of the Air Force:

RONALD R. FOGLEMAN

General, United States Air Force

Chief of Staff

Official:

HENRY VICCELLIO, JR.

General, United States Air Force

Commander, Air Force Materiel Command

By Order of the Marine Corps:

R. P. SHOCKEY

Director, Program Support

Marine Corps Systems Command

Distribution:

To be distributed in accordance with the initial distribution number (IDN) 380623, requirements for TM 9-2815-237-34.

	ARMY TM 9-2815-237-34
	AIR FORCE TO 38V1-6-2
	MARINE CORPS TM 2815-34/3 A
CHANGE	HEADQUARTERS,
	DEPARTMENTS OF THE ARMY,
NO. 1	THE AIR FORCE, AND MARINE CORPS
	Washington, D.C., 31 May 1999

TECHNICAL MANUAL

DIRECT SUPPORT AND GENERAL SUPPORT

MAINTENANCE

ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED,

FUEL-INJECTED, WATER COOLED,

DDA MODEL 6.2 LITER (SERIAL NUMBER 1-99,999) (NSN 2815-01-231-3672), (SERIAL NUMBER 100,000 AND ABOVE) (NSN 2815-01-314-7940) (1990); DDA MODEL 6.5 LITER (NSN 2815-01-410-9710) (1995,1996),

(NSN 2815-01-439-6665) (1997), (NSN 2815-01-453-7403) (1998); ENGINE, DIESEL: 8 CYLINDER,NATURALLY ASPIRATED, DETUNED, FUEL-INJECTED, WATER COOLED,

DDA MODEL 6.5 LITER (NSN 2815-01-406-6675) (1996), (NSN 2815-01-439-6664) (1997), (NSN 2815-01-453-7404) (1998);

ENGINE, DIESEL: 8 CYLINDER, TURBOCHARGED,

FUEL-INJECTED, WATER COOLED, (NSN 2815-01-420-4180) (1996), (NSN 2815-01-439-8164) (1997), (NSN 2815-01-453-7402) (1998).

TM 9-2815-237-34, 31 January 1996, is changed as follows:

1.New engine models have been added to the front cover. The new cover, located at the end of the change package, replaces the front cover.

2.Remove old pages and insert new pages as indicated below.

3.New or changed material is indicated by a vertical bar in the margin of the page.

4.File this change sheet in front of the publication for reference purposes.

Remove pages	Insert pages	Remove pages	Insert pages
Warning a and b	Warning a and b	2-153 through 2-156	2-153 through 2-156
None	A (After Warning b)	2-169 and 2-170	2-169 and 2-170
i and ii	i and ii	2-183 through 2-186	2-183 through 2-186
1-3 and 1-4	1-3 and 1-4	2-189 and 2-190	2-189 and 2-190
None	2-6.1 and 2-6.2	None	2-193/(2-194 blank)
2-7 through 2-18	2-7 through 2-18	D-1 through D-3/(D-4 blank)	D-1 through D-3/(D-4 blank)
2-23 through 2-26	2-23 through 2-26	E-3/(E-4 blank)	E-3 and E-4
2-31 through 2-34	2-31 through 2-34	F-3/(F-4 blank)	F-3/(F-4 blank)
2-37 through 2-48	2-37 through 2-48	Index 1 through Index 4	Index 1 through Index 4
2-53 through 2-56	2-53 through 2-56	Cover	Cover
2-83 and 2-84	2-83 and 2-84
None	2-140.1 through
	2-140.25/(2-140.26 blank)

Approved for public release; distribution is limited.

By Order of the Secretary of the Army:

ERIC K. SHINSEKI

General, United States Army

Chief of Staff

Official:

JOEL B. HUDSON

Administrative Assistant to the Secretary of the Army

05694

By Order of the Secretary of the Air Force:

RONALD R. FOGLEMAN

General, United States Air Force

Chief of Staff

Official:

HENRY VICCELLIO, JR.

General, United States Air Force

Commander, Air Force Materiel Command

By Order of the Marine Corps:

D.R. BLOOMER

Colonel, USMC

Director, Program Support

Marine Corps Systems Command

Distribution:

To be distributed in accordance with the initial distribution number (IDN) 380623, requirements for TM 9-2815-237-34.

TM 9-2815-237-34

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page.

Dates of issue for original and changed pages are:

Original	. . . . . 0 . . . . . . .	31 January 1996
Change .	. . . . . 1 . . . . . . .	. . . 31 May 1999
Change .	. . . . . 2 . . . . . . .	. . . 1 5 J u l y 2004

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 232, CONSISTING OF THE FOLLOWING:

	Page No. . . . . . . . .*Change No.			Page No. . . . . . . . .*Change No.			Page No. . . . . . . . .*Change No.
Warning a and b . . . . . . . . . .		.1	2-40 - 2-41 . . . . . . . . . . . .		. . . .0	2-173 . . . . . . . . . . . . . . .		. . . . .2
A . . . . . . . . . . . . . . . . . . . . . .		2	2-42 - 2-47 . . . . . . . . . . . . .		. . .1	2-174 - 2-182 . . . . . . . . . .		. . . .0
B Blank . . . . . . . . . . . . . . . . .		.1	2-48 - 2-53 . . . . . . . . . . . . .		. . .0	2-183 - 2-184 . . . . . . . . . .		. . . .1
i - ii . . . . . . . . . . . . . . . . . . . . .		2	2-54 - 2-56 . . . . . . . . . . . . .		. . .1		2-184.1 - 2-184.2 Added	. . . . .1
iii . . . . . . . . . . . . . . . . . . . . . . .		0	2-57 - 2-82 . . . . . . . . . . . . .		. . .0	2-185 . . . . . . . . . . . . . . . .		. . . .0
iv Blank . . . . . . . . . . . . . . . . .		0	2-83 - 2-84 . . . . . . . . . . . . .		. . .1	2-186 . . . . . . . . . . . . . . . .		. . . .1
1-1 . . . . . . . . . . . . . . . . . . . . .		2	2-85 . . . . . . . . . . . . . . . . . .		. . .0	2-187 - 2-188 . . . . . . . . . .		. . . .0
1-2 - 1-3 . . . . . . . . . . . . . . . . . .		0	2-86 . . . . . . . . . . . . . . . . . .		. . .2	2-189 . . . . . . . . . . . . . . . .		. . . .1
1-4 . . . . . . . . . . . . . . . . . . . . . .		1	2-86.1 - 2-86.2 Added . . . .		. . .2	2-190 - 2-192 . . . . . . . . . .		. . . .0
1-5 . . . . . . . . . . . . . . . . . . . . . .		2	2-87 - 2-90 . . . . . . . . . . . . .		. . .2		2-193 Added . . . . . . . . . .	. . . .1
1-6 Blank . . . . . . . . . . . . . . . .		0	2-91 - 2-101 . . . . . . . . . . . .		. . .0		2-194 Blank . . . . . . . . . . .	. . . .1
2-1 - 2-6 . . . . . . . . . . . . . . . . . .		0	2-102 . . . . . . . . . . . . . . . . .		. . .2		A-1 . . . . . . . . . . . . . . . . .	. . . .0
2-6.1 - 2-6.2 Added . . . . . . . . .		1	2-103 - 2-112 . . . . . . . . . . .		. . .0		A-2 . . . . . . . . . . . . . . . . .	. . . .2
2-7 - 2-8 . . . . . . . . . . . . . . . . . .		1	2-113 . . . . . . . . . . . . . . . . .		. . .2		B-1 - B-3 . . . . . . . . . . . . .	. . . .0
2-9 . . . . . . . . . . . . . . . . . . . . . .		0	2-114 - 2-117 . . . . . . . . . . .		. . .0		B-4 Blank . . . . . . . . . . . .	. . . .0
2-10 - 2-11 . . . . . . . . . . . . . . . .		1	2-118 - 2-120 . . . . . . . . . . .		. . .2		C-1 - C-3 . . . . . . . . . . . . .	. . . .0
2-12 . . . . . . . . . . . . . . . . . . . . .		0	2-121 - 2-124 . . . . . . . . . . .		. . .0		C-4 Blank . . . . . . . . . . . .	. . . .0
2-12.1 - 2-12.2 Added . . . . . . .		1	2-125 . . . . . . . . . . . . . . . . .		. . .2		D-1 . . . . . . . . . . . . . . . . .	. . . .0
2-13 - 2-15 . . . . . . . . . . . . . . . .		1	2-126-2-140 . . . . . . . . . . . .		. . .0		D-2 - D-3 . . . . . . . . . . . . .	. . . .1
2-16 - 2-17 . . . . . . . . . . . . . . . .		0	2-140.1 - 2-140.25 Added		. . . .1		D-4 Blank . . . . . . . . . . . .	. . . .0
2-18 . . . . . . . . . . . . . . . . . . . . .		1	2-140.26 Blank . . . . . . . . .		. . .1		E-1 - E-2 . . . . . . . . . . . . .	. . . .0
2-19 - 2-22 . . . . . . . . . . . . . . . .		0	2-141 - 2-152 . . . . . . . . . . .		. . .0		E-3 . . . . . . . . . . . . . . . . .	. . . .1
2-23 . . . . . . . . . . . . . . . . . . . . .		2	2-153 . . . . . . . . . . . . . . . . .		. . .1		E4 Added . . . . . . . . . . . .	. . . .1
2-24 . . . . . . . . . . . . . . . . . . . . .		0	2-154 . . . . . . . . . . . . . . . . .		. . .0		F1 - F2 . . . . . . . . . . . . . .	. . . .0
2-25 - 2-26 . . . . . . . . . . . . . . . .		1	2-155 . . . . . . . . . . . . . . . . .		. . .1		F3 . . . . . . . . . . . . . . . . . .	. . . .1
2-27 - 2-31 . . . . . . . . . . . . . . . .		0	2-156 . . . . . . . . . . . . . . . . .		. . .2		F4 Blank . . . . . . . . . . . . .	. . . .0
2-32 - 2-33 . . . . . . . . . . . . . . . .		1	2-157 - 2-168 . . . . . . . . . . .		. . .0		Index 1 . . . . . . . . . . . . . .	. . . .1
2-34 - 2-37 . . . . . . . . . . . . . . . .		0	2-169 . . . . . . . . . . . . . . . . .		. . .1		Index 2 - Index 4 . . . . . . .	. . . .2
2-38 - 2-39 . . . . . . . . . . . . . . . .		1	2-170 - 2-172 . . . . . . . . . . .		. . .0

*Zero in this column indicates original page.

Change 2	A/(B blank)

	*ARMY TM 9-2815-237-34
	AIR FORCE TO 38V1-6-2
	MARINE CORPS TM 2815-34/3 A
TECHNICAL MANUAL	HEADQUARTERS,
NO. 9-2815-237-34	DEPARTMENTS OF THE ARMY,
NO. 2815-34/3 A	THE AIR FORCE, AND MARINE CORPS
TECHNICAL ORDER	Washington, D.C., 31 January 1996
NO. 38V1-6-2

TECHNICAL MANUAL

DIRECT SUPPORT AND GENERAL SUPPORT

MAINTENANCE

ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED,

FUEL-INJECTED, WATER COOLED,

DDA MODEL 6.2 LITER (PRE-1990) (NSN 2815-01-231-3672), (POST-1990) (NSN 2815-01-314-7940);

DDA MODEL 6.5 LITER (NSN 2815-01-410-9710) (1995,1996), (NSN 2815-01-439-6665) (1997), (NSN 2815-01-453-7403) (1998); ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED, DETUNED, FUEL-INJECTED, WATER COOLED,

DDA MODEL 6.5 LITER (NSN 2815-01-406-6675) (1996), (NSN 2815-01-439-6664) (1997), (NSN 2815-01-453-7404) (1998);

ENGINE, DIESEL: 8 CYLINDER, TURBOCHARGED,

FUEL-INJECTED, WATER COOLED, (NSN 2815-01-420-4180) (1996), (NSN 2815-01-439-8164) (1997), (NSN 2815-01-453-7402) (1998)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACCESS REQUEST FORM.” The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax or E-mail your letter or DA Form 2028 direct to: AMSTA-LC-CI Tech Pubs, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The E-mail address is [e-mail]. The fax number is DSN 793-0726 or Commercial [phone]. (Marine Corps) Submit NAVMC 10722 to Commander Code 835-2, Marine Corps Logistic Base, 814 Radford Boulevard, Albany, GA 31704-1128.

Approved for public release; distribution is unlimited.

* This publication supersedes TM 9-2815-237-34 dated 25 June 1985 and all changes.

Change 2

i

TM 9-2815-237-34

												Page
		HOW TO USE THIS MANUAL						. . . . . . . . . . . . . . . . . . . . . . .				. . . . . . . . . iii
CHAPTER 1		INTRODUCTION		. . . . . . . . . . .				. . . . . . . . . . . . . . . . . . . . . . .				. . . . . . . . . 1-1
Section I.	General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .											. . . . . . . . . 1-1
II.	Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . .											. . . . . . . . . 1-2
CHAPTER 2.		ENGINE MAINTENANCE				. . . .		. . . . . . . . . . . . . . . . . . . . . . .				. . . . . . . . . 2-1
Section I.	Repair Parts, Special Tools, Test, Measurement, and Diagnostic
		Equipment(TMDE), and Support Equipment . . . . . . . . . . . . . . . .										. . . . . . . . . 2-1
II.	Service Upon receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .											. . . . . . . . . 2-1
III.	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .											. . . . . . . . . 2-2
IV.	General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . .											. . . . . . . . . 2-3
V.	Engine Disassembly, Repair, and Assembly . . . . . . . . . . . . . . . . . .											. . . . . . . . . 2-7
VI.	Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .											. . . . . . . . . 2-188
VII.	Repair and Replacement Standards . . . . . . . . . . . . . . . . . . . . . . . .											. . . . . . . . . 2-190
APPENDIX A		REFERENCES	. .	. . . . . .		. . . . .		. . . . . . . . . . . . . . . . . . . . . . .				. . . . . . . . . A-1
APPENDIX B		EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST										. . . . . . . . . B-1
APPENDIX C		ILLUSTRATED LIST OF MANUFACTURED ITEMS									. . . . . . .	. . . . . . . . . C-1
APPENDIX D		MANDATORY REPLACEMENT PARTS							. . . . . . . . .	.	. . . . . . .	. . . . . . . . . D-1
APPENDIX E		TOOL IDENTIFICATION LIST					.	. . . . .	. . . . . . . . . .	.	. . . . . . .	. . . . . . . . . E-1
APPENDIX F		TORQUE LIMITS			. . . . . .	. . . .	.	. . . . .	. . . . . . . . . .	.	. . . . . . .	. . . . . . . . . F-1
INDEX		. . . . . . . . . . . . . .	. .		. . . . . .	. . . .	.	. . . . .	. . . . . . . . . .	.	. . . . . . .	. . . . . . . . . Index 1

ii Change 2

TM 9-2815-237-34

CHAPTER 1

INTRODUCTION

Section I. GENERAL INFORMATION

1-1. SCOPE

This technical manual contains instructions for direct support and general support maintenance of

the 6.2 liter naturally aspirated, 6.5 liter naturally aspirated detuned, and 6.5 liter turbo V-8 diesel engines.

1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS

(Army) Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA Pam 738-750, The Army Maintenance Management System (TAMMS). (Marine Corps) Refer to MCO 4855-10.

1-3. DESTRUCTION OF ARMY EQUIPMENT TO PREVENT ENEMY USE

Procedures for destruction of Army tank-automotive equipment to prevent enemy use are found in TM 750-244-6.

1-4. PREPARATION FOR SHIPMENT

(Army) Refer to TM 746-10, Marking, Packaging, and Shipment of Supplies and Equipment: General Packaging Instructions for Field Use. (Marine Corps) Refer to MCO 4450-7.

1-5. EQUIPMENT REQUIRING CALIBRATION

Calibration requirements in this manual cover the fuel injection pump and can be found in paras. 2-33, 2-34, and 2-35 of this manual.

1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)

If your vehicle needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or performance. The preferred method for submitting QDRs is through the Army Electronic Product Support (AEPS) website under the Electronic Deficiency Reporting System (EDRS). The web address is: https://aeps.ria.army.mil. This is a secured site requiring a password that can be applied for on the front page of the website. If the above method is not available to you, put it on an SF 368, Product Quality Deficiency Report (PQDR), and mail it to us at: Department of the Army, U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA-TR-E/PQDR MS 267, 6501 E. 11 Mile Road, Warren, MI 48397-500. We’ll send you a reply. (Marine Corps) Submit QDR’s in accordance with MCO 4855-10.

1.7. EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE DIGEST (EIR MD)

The quarterly Equipment Improvement Report and Maintenance Digest, TB 43-0001-62 series, contains valuable field information on the equipment covered in this manual. The information in the TB 43-0001-62 series is compiled from some of the Equipment Improvement Reports that you prepared on the vehicles covered in this manual. Many of these articles result from comments, suggestions, and improvement recommendations that you submitted to the EIR program. The TB 43-0001-62 series contains information on equipment improvements, minor alterations, proposed Modification Work Orders (MWOs), warranties (if applicable), actions taken on some of your DA Form 2028s (Recommended Changes to Publications and Blank Forms), and advance information on proposed changes that may affect this manual. The information will help you in doing your job better and will help in keeping you advised of the latest changes to this manual. Also refer to DA Pam 25-30, Consolidated Index of Army Publications and Blank Forms, and appendix A, References, of this manual. (Marine Corps) Submit QDR’s in accordance with MCO 4855-10. For those with access to the World Wide Web (WWW), the EIR MD can be viewed through the Army Electronic Product Support. The site is http://aeps.ria.army.mil.

Change 2

1-1

TM 9-2815-237-34

1-8. METRIC SYSTEM

The engines described herein contain metric components and require metric common and special tools; therefore, metric units in addition to standard units will be used throughout this publication. In addition, a metric conversion table is located on the inside back cover of this publication.

1-9. MANDATORY REPLACEMENT PARTS

The maintenance instructions contained herein make reference to removing and discarding piece parts such as: gaskets, lockwashers, cotter pins, O-rings, seals, etc.; these items should be considered mandatory replacement items and replaced with new parts during assembly/installation.

Section II. EQUIPMENT DESCRIPTION AND DATA

1-10. DESCRIPTION

The engine used in the M998 series vehicles is an eight-cylinder, four-cycle, liquid-cooled, naturally aspirated diesel engine. The 6.2L engine has a compression ratio of 21.5:1 and develops approximately 150 horsepower (112 kW) at 3600 rpm. The 6.5L engine has a compression ratio of 21.5:1 and develops approximately 160 horsepower (119 kW) at 3400 rpm. For proper orientation, the left and right sides of the engine are as viewed from the rear.

1990 and above 6.2L and 1994 6.5L engines have the following new and revised parts:

*Cylinder Heads. The 1990 cylinder heads have been revised to meet 1990 emissions standards.

Precombustion Valves. The 1990 engine is equipped with reverse throat precombustion chambers.

Exhaust Valves. The 1990 exhaust valves are coated with chrome to prevent burning and to increase durability.

*Exhaust Valve Stem Seal. The 1990 engine is equipped with a new exhaust valve stem seal that is not available for previous model engines.

Cylinder Head Gaskets. The 1990 cylinder head gaskets have new circular combustion seals and are made of a non-asbestos material.

Fuel Injection Pump. The 1994 fuel injection pump has a TP sensor and a revised calibration procedure.

Fuel Injection Pump. The 1990 fuel injection pump has a new governor and a revised calibration procedure.

*Fuel Injection Nozzles. The 1990 fuel injection nozzles are shorter and are orientated ten degrees from the vertical.

*Fuel Injection Lines. The 1990 engine is equipped with high pressure fuel injection lines.

Fuel Injection Line Brackets. The 1990 fuel injection line brackets have been revised to provide clearance for the injection nozzles.

*RPM Sensors. The 1994 engine is equipped with two rpm sensors. One is for STE-ICE-R and one is for the engine.

*Fan Cut-Off Switch. The 1994 engine is equipped with a fan cut-off switch which replaced the kick-down switch.

*These 1990 parts are not interchangeable with parts for previous model engines. Differences in maintenance procedures are identified where applicable. Refer to engine decal number on left rocker arm cover before ordering replacement parts.

1-2

TM 9-2815-237-34

The 1990 6.2L engine is identified by a decal which is adhered to the left rocker arm cover. The 6.5L engine is identified by a serial number bar code decal.

1-11. COMPONENT LOCATION

The locations of components described below are common to all engines in the M998 series vehicles. Special differences are described in para. 1-10.

FAN CLUTCH

ROCKER ARM COVERS (2)

FUEL INJECTORS (8)

OIL FILTER

EXHAUST MANIFOLDS (2)

OIL PAN

TIMING GEAR COVER

CRANKSHAFT PULLEY

INTAKE MANIFOLD

FUEL INJECTION PUMP

WATER CROSSOVER

WATER PUMP

FUEL PUMP

GLOW PLUGS (8)

1-3

TM-9-2815-237-34

1-12. TABULATED DATA

Engine tabulated data is listed in tables 1-1 and 1-2. This information includes only those data applicable to direct support and general support maintenance. Information not covered can be found in TM 9-2320-280-20 and TM 9-2320-280-10.

TABULATED DATA ABBREVIATIONS

MEASUREMENT	ABBREVIATION
Quart . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . qt
Kilogram . . . . . . . . . . . . . . . . . . . .	. . . . . . . . kg
Inch . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . in.
Pound . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . lb
Pounds Per Square Inch . . . . . . . . .	. . . . . . . psi
Revolutions Per Minute . . . . . . . . . .	. . . . . . rpm
Pound-Feet . . . . . . . . . . . . . . . . . . .	. . . . . . lb-ft
Cubic Inch . . . . . . . . . . . . . . . . . . . .	. . . . . cu-in.
Fahrenheit . . . . . . . . . . . . . . . . . . .	. . . . . . . . F

MEASUREMENT	ABBREVIATION
Celsius . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . C
Liter . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . L
Centimeter . . . . . . . . . . . . . . . . . . .	. . . . . . . cm
Millimeter . . . . . . . . . . . . . . . . . . . .	. . . . . . mm
Kilopascal . . . . . . . . . . . . . . . . . . . .	. . . . . . kPa
Newton Meter . . . . . . . . . . . . . . . . .	. . . . . . N•m
Horsepower . . . . . . . . . . . . . . . . . . .	. . . . . . . hp
Kilowatt . . . . . . . . . . . . . . . . . . . . .	. . . . . . . kW

Table 1-1. Tabulated Data (6.2 L)

NOTE

Standard and metric measurements will be used in this table.

A list of their abbreviations is provided above.

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detroit Diesel Allison Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 L Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cycle, liquid-cooled, naturally aspirated

Dimensions:		STANDARD	METRIC
	Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . 35 in.	89 cm
	Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . 28 in.	71 cm
	Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . 28 in.	71 cm
	New weight, dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . 650 lbs	295 kg
Cylinders:
	Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . Eight
	Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . 90° V
	Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-8-7-2-6-5-4-3 (clockwise)
	Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . 3.98 in.	10.1 cm
	Stroke (nominal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . 3.82 in.	9.7 cm
	Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 392 cu-in.	6.2 L
	Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . 21.5:1
Maximum Torque (gross) . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . 260 lb-ft @ 2000 rpm	353 N•m @
			2000 rpm
Governed Speed:
	Full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 3600 rpm
	No load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 4000 rpm
	Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . 650±25 rpm
Lubrication System:
	Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . Pressure feed
	Operating pressure (normal) . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 40-50 psi	276-345 kPa
	Operating pressure (at idle) . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . 10 psi	69 kPa
	System capacity (including filter) . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . 8 qts	7.6 L
	Operating temperature (normal) . . . . . . . . . . . . . . . . .	. . . . . . . . . . . 180°-260°F	82°-126°C
	Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . Gear-driven
Cooling system:
	Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	Liquid with fan and radiator
	Operating temperature (normal) . . . . . . . . . . . . . . . . .	. . . . . . . . . . . 190°-230°F	88°-110°C
1-4	Change 1

TM 9-2815-237-34

Section III. TROUBLESHOOTING

2-6. GENERAL

Information in this section is for use of support maintenance personnel in conjunction with, and as a supplement to, troubleshooting procedures in TM 9-2320-280-20 and TM 9-2320-280-34.

2-7. ENGINE TROUBLESHOOTING

CAUTION

Operation of a deadlined engine without preliminary inspection will cause further damage.

Information to be used for troubleshooting the engine is contained in TM 9-2320-280-20 and TM 9-2320-280-34.

a.Excessive oil consumption is generally caused by leaky gaskets or loose line connections.

b.Always check the easiest and most obvious things first. This simple rule saves time and trouble.

c.Double check before disassembly. The source of most engine problems can be traced to more than one part in a system. For example:

(1)Excessive fuel consumption may not be caused by the fuel pump alone. Instead, the trouble could be a clogged air cleaner, or a restricted exhaust passage causing severe back pressure.

(2)Engines very often are disassembled in search of a complaint and the real evidence of the problem is destroyed. Check again to be sure an easier solution to the problem has not been overlooked.

d.Before correcting a problem, diagnose the cause of the problem. Do not allow the same failure to

occur again.

2-2

TM 9-2815-237-34

f. Oil Passages. Particular attention must be given to all oil passages in castings and machined parts. Oil passages must be clean and free of any obstructions.

(1)Clean passages with wire probes to breakup any sludge or gum deposits.

(2)Wash passages by flushing with solvents. See TM 9-247,

(3)Dry passages with compressed air.

CAUTION

Do not allow drycleaning solvents to come in contact with seals, cables, or flexible hoses. These cleaners cause leather, rubber, and synthetic materials to dry out, rot, and lose pliability making them unserviceable.

g.Nonmetallic Parts. Clean hoses and other nonmetallic parts with soap and water.

h.Bearings.

WARNING

Do not use compressed air to dry bearings. Spinning a dry bearing with compressed air may cause injury to personnel or damage to equipment.

(1) Bearings require special cleaning. After removing surface oil and gum deposits, place bearings in hot oil, 140°F (60•C), to loosen congealed oil and grease. Wipe bearings dry with a Iint-free cloth; do not use compressed air.

(2)See TM 9-214 for information and care of bearings.

i.Electrical Components.

(1)Clean electrical components with clean cloth dampened with drycleaning solvent. Care must be taken not to damage protective insulation.

WARNING

Compressed air used for cleaning purposes will not exceed 30 psi

(207 kPa). Use only with effective chip guarding and personaI protective equipment (goggles/shield, gloves, etc.).

(2) Use compressed air oa dry electrical components.

2-10. INSPECTION

a.General Instructions. Procedures for inspections will be the same for many parts and components which make up the engine subassemblies. General procedures are detailed in “b” through “k”, Dimensional standards for parts have been fixed at extremely close tolerances, so use specification tables. Use specified inspection equipment for inspection where cracks and other damage cannot be spotted visually. Exercise extreme care in all phases of inspection. Repair or replace all unserviceable components; refer to para. 2-11.

b.Castings.

(1)Inspect all ferrous and nonferrous castings for cracks. See MIL-I-6866, Inspection, Penetrant Methods, and MIL-I-6868, Inspection Process, Magnetic Particles. Particularly check areas around studs,

pipe plugs, threaded inserts, and sharp comers. Replace cracked castings.

(2)Inspect machined surfaces for nicks, burrs, and raised metal. Mark damaged areas for repair or replacement.

(3)Inspect all pipe plugs, pipe plug openings, capscrews, and capscrew openings for damaged and stripped threads. Replace if damaged or threads are stripped.

(4)Check all gasket mating surfaces, flanges on housings, and supports for warpage with a straight edge or surface plate. Inspect mating flanges for discolorations which may indicate leakage. Replace if warped.

(5)Check all castings for conformance to applicable repair standards.

2-4

		TM 9-2815-237-34
c. Bearings.
CAUTION
All engine connecting rod and	main bearings	will be replaced if one
o r m o r e b e a r i n g s f a i l .
Check all bearings for conformance	to applicable	repair standards .

d.Bushings and Bushing-Type Bearings.

(1)Check all bushings and bushing-type bearings for secure fit, evidence of heating, wear, burrs, nicks, and out-of-round conditions.

(2)Check for dirt in lubrication holes or grooves. Holes and grooves must be clean and free from damage.

e.Machined Parts.

(1)Check machined parts for cracks, distortion, and damage.

(2)Check all surfaces for nicks, burrs, and raised metal.

f.Studs, Bolts, and Capscrews. Replace if bent, loose, stretched, or threads are damaged.

g.Gears.

NOTE

When gear teeth wear limits are not established, good judgment is required to determine if gear replacement is necessary.

(1)Inspect all gears for cracks and missing teeth. Replace if cracked or teeth are missing.

(2)Inspect gear teeth for wear, sharp fins, burrs, and galled or pitted surfaces.

(3)Inspect splines for wear, burrs, and galled or pitted surfaces.

(4)Check keyway slots for wear and/or damage.

h.Oil Seals. Oil seals are mandatory replacement items.

i.Casting Plugs. Inspect for leakage. Replace plugs when leakage is present.

j.Springs. Inspect for damaged, distorted, and collapsed coils.

k.Snaprings, Retaining Rings, and Washers. Many of these parts are mandatory replacement items. Inspect all others for obvious damage.

2-11. REPAIR

a. General Instructions. Repair of most parts and components is limited to general procedures outlined in applicable maintenance instructions and the following detailed procedures “b” through “h”.

CAUTION

Repaired items must be thoroughly cleaned to remove metal chips and abrasives to prevent them from entering working parts of the engine.

b.Castings.

(1)All cracked castings will be replaced.

(2)Only minor repairs to machined surfaces, flanges, and gasket mating surfaces are permitted. Remove minor nicks, burrs, and/or scratches with:

(a)Fine mill file.

(b)Abrasive crocus cloth dipped in cleaning solvent.

(c)Lapping across a surface plate.

(d)Remachining of machined surfaces to repair damage, warpage, or uneven surfaces is not permitted. Replace castings.

(3)Repair damaged threaded pipe plug and/or capscrew holes with a thread tap or repair oversize holes with threaded inserts.

2-5

TM 9-2815-237-34

c.Bearings. See TM 9-214.

d.Studs. Replace all bent and stretched studs. Repair minor thread damage with a thread restorer file. Replace studs having stripped or damaged threads as outlined below:

(1)Remove, using a stud remover. Back studs out slowly to avoid heat buildup and seizure which can cause stud to break off.

(2)If studs break off too short to use with a stud remover, use extractor to remove.

(3)Replacement studs have a special coating and must have a small amount of antiseize compound (Appendix B, Item 3) applied on threads before stud is installed. Install replacement stud slowly to prevent heat buildup and snapping off.

e.Gears.

(1)Remove gears using pullers, as required.

(2)Use the same methods described in paragraph 2-11.b.(2) for castings tO remove minor nicks, burrs, or scratches on gear teeth.

(3)If keyways are worn or enlarged, replace gear.

f.Bushings and BushingType Bearings. When bushings and bushing-type bearings seize to a shaft and spin in the bore, the associated part must also be inspected and replaced, as required.

g.Oil Seals.

(1)Remove oil seals, being careful not to damage casting or adapter bore.

(2)Always install new seal in bore using proper seal replacing tool.

h.Cylinder Block or Cylinder Head. Repair of cylinder block and cylinder head is limited to procedures outlined in paragraphs 2-16 and 2-21. Cylinder block or cylinder head must be replaced if measurements are outside tolerance limits listed in table 2-2 or table 2-3.

2-12. ASSEMBLY

a.Cleanliness is essential in all component assembly operations. Dirt and dust, even in minute quantities, are abrasive. Parts must be cleaned as specified, and kept clean. Wrap or cover parts and components when assembly procedures are not immediately completed.

b.Coat all bearings and contact surfaces with engine oil (MIL-L-2104) to ensure lubrication of parts during initial operation after repair.

c.Use new gaskets and preformed packings during assembly of all components.

2-6

TM 9-2815-237-34

Section V. ENGINE DISASSEMBLY, REPAIR, AND ASSEMBLY

2-13. ENGINE DISASSEMBLY, REPAIR, AND ASSEMBLY TASK SUMMARY

	TASK	PROCEDURES	PAGE
	PARA.		NO.
	2-13.1.	Engine Replacement in Shipping/Storage Container	2-6.2
	2-14.	Mounting Engine on Repair Stand	2-8
	2-15.	Engine Disassembly into Subassemblies	2-10
	2-16.	Cylinder Block Repair	2-40
	2-17.	Crankshaft Repair	2-52
	2-18.	Connecting Rod and Piston Repair	2-54
	2-19.	Camshaft, Timing Chain, and Drive Gears Repair	2-58
	2-20.	Timing Gear Cover Repair	2-60
	2-21.	Cylinder Head and Valve Repair	2-62
	2-22.	Valve Train Repair	2-72
	2-23.	Torsional Damper Repair	2-74
	2-24.	Flywheel Repair	2-75
	2-25.	Rocker Arm Cover Repair	2-76
	2-26.	Oil Pan Repair	2-77
	2-27.	Oil Pump Repair	2-78
	2-28.	Oil Filter Adapter and Oil Pressure Sending Unit Repair	2-82
	2-29.	Exhaust Manifold Repair	2-83
	2-30.	Intake Manifold Repair	2-84
	2-31.	Fuel Pump Repair	2-85
	2-32.	Fuel Injection Pump Repair (All Models)	2-86
	2-33.	Pre-1990 (6.2L) Fuel Injection Pump (DB2829-4523) Calibration	2-126
	2-34.	1990 (6.2L) Fuel Injection Pump (DB2829-4879) Calibration	2-131
	2-35.	(6.5L) Fuel Injection Pump (DB2831-5149) Calibration	2-136
	2-35.1.	(6.5L) Fuel Injection Pump (DB2831-5209) Calibration	2-140.1
	2-35.2.	(6.5L) Fuel Injection Pumps (DB2831-5485 or DB2831-5079)
		Calibration	2-140.6
	2-35.3.	(6.2L or 6.5L) Fuel Injection Pumps (DB2829-4523, DB2829-4879,
		or DB2831-5149) Calibration Using Fuel Injection Pump Test
		Stand (FTIS) Model A8022	2-140.12
	2-36.	Glow Plug Repair	2-141
	2-37.	Fuel Injection Nozzle Repair	2-142
	2-38.	Water Pump Repair	2-144
	2-39.	Water Crossover Repair	2-146
	2-40.	Fan Drive Repair	2-148
	2-41.	Engine Assembly from Subassemblies	2-153

Change 1

2-6.1

TM 9-2815-237-34

2-13.1. ENGINE REPLACEMENT IN SHIPPING/STORAGE CONTAINER

This task covers:

a. Removal

INITIAL SETUP:

Tools

General mechanic’s tool kit: automotive (Appendix E, Item 1)

Special Tools

Engine lifting sling (Appendix E, Item 3)

Materials/Parts

Eight lockwashers (Appendix D, Item 26.1)

b.Installation

Manual References

TM 9-2815-237-34P

Personnel Required

One mechanic

One assistant

General Safety Instructions

Direct personnel to stand clear during hoisting operation.

a.Removal

1.If engine container (5) is closed and sealed, press air-release button (1) located at center of breather valve (2) before opening engine container (5).

2.Remove twenty-six nuts (19), washers (18), capscrews (16), and upper container (4) from lower container (13).

3.Position engine lifting sling on engine assembly (6) and install sling on right cylinder head (25) with two capscrews (24).

4.Install sling bracket (21) to engine lifting sling with pin (22) and on left cylinder head (20) with two capscrews (23). Tighten capscrews (23).

5.Remove four capscrews (14), lockwashers (8), and washers (7) from two engine mounts (12). Discard lockwashers (8).

6.Remove four capscrews (9), lockwashers (8), and washers (7) from two rear engine mounts (10). Discard lockwashers (8).

WARNING

Direct personnel to stand clear during hoisting operation. Failure to do this may cause injury to personnel.

7.Attach hoist to engine lifting sling and remove engine assembly (6) from lower container (13).

8.Position engine on repair stand (para. 2-14).

b.Installation

1.Install engine assembly (6) in lower container (13).

2.Install engine assembly (6) on two rear engine mounts (10) with four washers (7), lockwashers (8), and capscrews (9).

3.Install engine assembly (6) on two engine mounts (12) with four washers (7), lockwashers (8), and capscrews (14).

4.Remove pin (22) from sling bracket (21).

5.Remove two capscrews (24) and lifting sling from right cylinder head (25).

6.Remove two capscrews (23) and sling bracket (21) from left cylinder head (20).

7.Visually check humidity indicator (17) for discolorization. If indicator (17) is dark purple, replace desiccant (3).

2-6.2

Change 1

TM 9-2815-237-34

2-13.1. ENGINE REPLACEMENT IN SHIPPING/STORAGE CONTAINER (Cont’d)

NOTE

Ensure gasket is seated properly.

8.Using alignment pins (15), position upper container (4) on gasket (11) and lower container (13).

9.Install upper container (4) on lower container (13) with twenty-six capscrews (16), washers (18), and nuts (19).

Change 1

2-7

TM 9-2815-237-34

2-14. MOUNTING ENGINE ON REPAIR STAND

This task covers:

a. Installation

b. Removal

INITIAL SETUP:

Tools

General mechanic’s tool kit: automotive (Appendix E, Item 1)

Special Tools

Engine repair stand (Appendix E, Item 2) Engine lifting sling (Appendix E, Item 3)

General Safety Instructions

Direct personnel to stand clear during hoisting operation.

a. Installation

NOTE

Do not perform step 1 if engine lifting sling has been previously installed.

1.Position engine lifting sling on engine (4) and secure to right cylinder head (10) with two bolts (11). Finger tighten bolts (11).

2.Install sling bracket (2) to engine lifting sling with pin (3) and on left cylinder head (1) with two bolts (9). Tighten bolts (9) and (11).

WARNING

Direct personnel to stand clear during hoisting operation. Failure to do this may cause injury to personnel.

3.Attach hoist to engine lifting sling and hoist engine (4) into position over engine repair stand.

4.Loosen four capscrews (5) securing repair stand arms (6) on engine repair stand and align arms (6) with holes in rear of engine (4).

5.Install repair stand arms (6) to engine (4) with four washers (8) and capscrews (7).

6.Tighten capscrews (5) and (7).

7.Disconnect hoist and remove two bolts (11) and (9), engine lifting sling, and bracket (2) from engine (4).

b.Removal

1.Position engine lifting sling on engine (4) and secure to right cylinder head (10) with two bolts (11). Finger tighten bolts (11).

2.Install sling bracket (2) to engine lifting sling with pin (3) and on left cylinder head (1) with two bolts (9). Tighten bolts (9) and (11).

3.Attach hoist to engine lifting sling and hoist engine (4) to relieve pressure on engine repair stand.

4.Remove four capscrews (7) and washers (8) from repair stand arms (6) and hoist engine away from engine repair stand.

2-8

Change 1

TM 9-2815-237-34

2-14. MOUNTING ENGINE ON REPAIR STAND (Cont’d)

2-9

TM 9-2815-237-34

2-15. ENGINE DISASSEMBLY INTO SUBASSEMBLIES

This task covers:
a. Fan Drive and Water Pump Pulley		m.	Glow Plugs
b.	Crankshaft Pulley	n.	Cylinder Heads
c.	Torsional Damper	o.	Valve Lifters
c.1. Wastegate Actuator		p. Water Pump and Adapter Plate
c.2. Wastegate Housing		q.	Fuel Injection Pump
c.3. Manifold-to-Turbocharger Exhaust Pipe		r.	Timing Gear Cover
c.4. Turbocharger		s.	Timing Chain and Drive Sprockets
d.	Exhaust Manifolds	t.	Oil Filter, Adapter, and Oil Pressure Sending Unit
e.	Intake Manifold	u.	Oil Pan
f.	Water Crossover	v.	Oil Pump
g.	Fuel Injection Lines	w.	Fuel Pump
h.	Fuel Supply and Return Lines	x.	Oil Pump Drive
i.	Modulator Link	y.	Camshaft
j.	Rocker Arm Covers	z.	Pistons and Connecting Rods
k. Rocker Arm Shafts and Pushrods		aa.	Flywheel
l.	Fuel Injection Nozzles	bb.	Crankshaft and Main Bearings

INITIAL SETUP:

Tools

General mechanic’s tool kit: automotive (Appendix E, Item 1) Puller (Appendix E, Item 19)

Cylinder ridge reamer (Appendix E, Item 11) Dial indicator (Appendix E, Item 10)

Special Tools

Hydraulic valve lifter remover (Appendix E, Item 4)

Injection nozzle socket (Appendix E, Item 5) Glow plug socket (Appendix E, Item 6) Hex-head driver, 6 mm (Appendix E, Item 7) Hex-head driver, 8 mm (Appendix E, Item 8) Hex-head driver, 5/16-in.

(Appendix E, Item 9)

Personnel Required

One mechanic

One assistant

Equipment Condition

Engine mounted on repair stand (para. 2-14).

General Safety Instructions

•Do not perform this procedure near fire, flame, or sparks.

•Gaskets installed on some 6.2L engines assembled prior to 1991 may contain asbestos. Gaskets should be disposed of IAW current directives.

NOTE

•Work area should be clean, well-ventilated, and free from blowing dirt and dust.

•In some cases, flanged head fasteners may be present instead of standard fasteners and washers. In all cases, washers should be used when replacing a flanged head fastener with a standard fastener.

•Disassembly procedures for pre-1990, 1990 and above 6.2L and 6.5L engines are basically the same. Any differences in procedures are noted. Refer to para.

1-10 to determine engine model before ordering replacement parts.

a.Fan Drive and Water Pump Pulley

NOTE

It may be necessary to apply compressed air to fan drive fitting. This disengages fan drive and allows access to socket head capscrews.

1.Position pry bar between water pump pulley (3) and crankshaft pulley (6) and apply pressure.

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2-15. ENGINE DISASSEMBLY INTO SUBASSEMBLIES (Cont’d)

2.Using a 5/16-in. hex-head driver, remove four socket-head screws (1) and fan drive (2) from water pump pulley (3).

3.Using a 6-mm hex-head driver, remove four socket-head screws (5) and water pump pulley (3) from water pump (4).

b. Crankshaft Pulley

Remove four capscrews (9), crankshaft pulley (6), and spacer (8) (if installed) from torsional damper (7).

Change 1

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2-15. ENGINE DISASSEMBLY INTO SUBASSEMBLIES (Cont’d)

c.Torsional Damper

1.Hold flywheel stationary with pry bar.

2.Remove capscrew (1) and washer (2) from torsional damper (3) and crankshaft (5).

3.Reinstall capscrew (1) and remove torsional damper (3) with puller.

4.Remove capscrew (1) and woodruff key (4) from crankshaft (5). Discard woodruff key (4).

2-12

TM 9-2815-237-34

2-15. ENGINE DISASSEMBLY INTO SUBASSEMBLIES (Cont’d)

NOTE

Perform tasks c.1 through c.4 for 6.5L turbo engines only.

c.1. Wastegate Actuator

1.Remove clip (11) and actuator rod (6) from wastegate bellcrank (12).

2.Remove two capscrews (8) from wastegate actuator (7) and wastegate housing (10).

3.Remove capscrew (13) and wastegate actuator (7) from cylinder head (9).

c.2. Wastegate Housing

Remove four capscrews (14) and wastegate housing (10) from turbocharger (15).

Change 1

2-12.1