Pages 196–232 (37 pages)

Engine Assembly from Subassemblies

From the 6.2L and 6.5L Diesel Engine Direct and General Support Maintenance Manual (TM 9-2815-237-34)

Reassembly in order: crankshaft and main bearings, flywheel, pistons and connecting rods, oil pump, camshaft, timing chain and gear cover, oil pan, filter adapter, fuel pump, injection pump, water pump, lifters, cylinder heads, glow plugs, nozzles, rocker arms and covers, fuel lines, water crossover and manifolds, plus the turbocharger, exhaust pipe and wastegate on turbocharged engines.

Read this section free, starting at page 196

What this section covers

  • Crankshaft, main bearings and flywheel
  • Pistons, connecting rods and oil pump
  • Camshaft, timing chain and timing cover
  • Fuel injection pump and nozzles
  • Cylinder heads and rocker arms
  • Manifolds and water crossover
  • Turbocharger and wastegate
Make
U.S. Military
Vehicle
Military, Military Equipment
Type
Technical Manual
Models
DDA 6.2L and 6.5L V8 diesel engines
Publication
TM 9-2815-237-34
Pages
267

What’s inside

Front matter

  1. Warnings, Change Pages and ContentsTitle page with the engine models and NSNs covered, exhaust and safety warning summary, list of effective pages, Change 1 instructions and the table of contents.pp. 1–9

Chapter 1: Introduction

  1. Introduction and Equipment Descriptionpp. 10–14

Chapter 2: Engine maintenance

  1. Tools, Troubleshooting and General Maintenancepp. 15–20
  2. Shipping Container and Repair Standpp. 21–25
  3. Engine Disassembly into Subassembliespp. 26–57
  4. Cylinder Block Repairpp. 58–69
  5. Crankshaft, Pistons, Camshaft and Timing Gear Coverpp. 70–79
  6. Cylinder Heads, Valve Train, Damper and Flywheelpp. 80–94
  7. Oil Pan, Oil Pump and Oil Filter Adapterpp. 95–100
  8. Manifolds and Fuel PumpCleaning and inspection of the exhaust manifolds, intake manifold and fuel pump.pp. 101–103
  9. Fuel Injection Pump Repairpp. 104–143
  10. Fuel Injection Pump Calibrationpp. 144–183
  11. Glow Plugs and Fuel Injection NozzlesGlow plug cleaning, inspection and testing, and fuel injection nozzle testing, including the leakage test.pp. 184–186
  12. Water Pump, Water Crossover and Fan Drivepp. 187–195
  13. Engine Assembly from Subassembliespp. 196–232
  14. Final Inspection and Engine Run-InOut-of-chassis engine run-in on a dynamometer after major repair, with references for in-chassis run-in.pp. 233–234
  15. Repair and Replacement Standardspp. 235–238

Appendices and index

  1. Appendices A–E: References, Supplies, Parts and Toolspp. 239–253
  2. Appendix F: Torque LimitsGeneral torque limits, with Table F-1 of torque limits for dry fasteners.pp. 254–256
  3. IndexAlphabetical index by paragraph and page, followed by the back pages.pp. 257–267

Other manuals for this vehicle