Pages 26–57 (32 pages)

Engine Disassembly into Subassemblies

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

Step-by-step teardown of the engine on the stand: glow plugs, fuel injection lines and nozzles, cylinder heads, valve lifters, water pump and adapter plate, fuel injection pump, torsional damper and crankshaft pulley, timing gear cover, timing chain and sprockets, oil filter adapter, oil pan and oil pump, fuel pump, camshaft, pistons and connecting rods, flywheel, and crankshaft and main bearings.

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What this section covers

  • Glow plugs and fuel injection lines
  • Cylinder heads and valve lifters
  • Water pump and fuel injection pump
  • Timing gear cover, chain and sprockets
  • Oil pan, oil pump and fuel pump
  • Camshaft, pistons and connecting rods
  • Flywheel, crankshaft and main bearings
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

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