TM-9-2815-237-34
ENGINE, DIESEL: 8 CYLINDER, 6.2 AND 6.5, NORMALLY-ASPIRATED, DETUNED AND TURBOCHARGED
TECHNICAL MANUAL; DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
JULY 2004
CHANGE 2
TM-9-2815-237-34 - Page 200 of 267
TM 9-2815-237-34
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Change 2
2-41. ENGINE ASSEMBLY FROM SUBASSEMBLIES (Cont’d)
WARNING
Crankshaft must be supported during removal and installation.
Failure to support crankshaft may cause injury to personnel or
damage to equipment.
CAUTION
Bearing caps are numbered one through five and must be
installed in correct order, starting with number one at front of
cylinder block. Arrow on bearing cap must point forward or engine
damage will result.
12.
After all main bearing clearances have been set, remove crankshaft (7) and gauging plastic and
apply OE/HDO to all main bearings. Install crankshaft (7), all bearing caps (1), (2), and (3), long
cap-
screws (4) and short capscrews (5). Tighten long capscrews (4) and short capscrews (5) to 12 lb-ft
(16 N
•
m).
13.
Tap crankshaft (7) rearward, then frontward; this will align main bearing thrust surfaces (6).
Tighten long capscrews (4) and short capscrews (5) to 40 lb-ft (54 N
•
m).
14.
Tighten all long capscrews (4) to 110 lb-ft (149 N
•
m). Tighten all short capscrews (5) to 100 lb-ft
(136 N
•
m).
15.
Rotate crankshaft (7) to ensure crankshaft (7) rotates freely.
16.
Force the crankshaft (7) to the extreme front position and hold in place. Measure end play at the
front end of the number three bearing with a feeler gauge. End play should be 0.004-0.010 in.
(0.101-0.250 mm).
NOTE
• Perform steps 17 through 24 for 6.2L engines ONLY when
using a 2-piece nylon rope type rear main seal.
• Perform steps 17 and 21 through 24 when using a 2-piece
rubber rear main seal.
17.
Remove long capscrews (4), short capscrews (5), bearing caps (1), (2), and (3), and crankshaft (7)
from cylinder block (8).
18.
Apply adhesive to seal groove in rear main bearing cap (1) and cylinder block (8).
19.
Install rear main oil seal (9) into cylinder block (8) and rear main bearing cap (1) using seal installer.
20.
Cut excess oil seal (9) off flush with bearing cap (1) and cylinder block (8) mounting surface.
21.
Repeat steps 4 through 10 to ensure rear oil seal (9) did not affect rear main bearing clearance.
If bearing clearance changed, remove bearing cap (1) and inspect rear oil seal (9).
22.
Remove gauging plastic.
23.
Install number three bearing cap (3), two long capscrews (4), and short capscrews (5). Tighten
capscrews (4) and (5) to 12 lb-ft (16 N
•
m).
24.
Tap crankshaft (7) rearward, then frontward; this will align main bearing thrust surfaces (6).
Tighten capscrews (4) and (5) on number three bearing cap (3) to 40 lb-ft (54 N
•
m).
NOTE
Immediately install rear main bearing cap after application of
sealant.
25.
Apply thin film of sealer to rear main bearing cap (1) mating surface. Keep sealer off bearing and
oil seal (9) (installed on 6.2L engines).
26.
Install rear main bearing cap (1) on cylinder block (8) with long capscrews (4), and short cap-
screws (5). Tighten capscrews (4) and (5) to 40 lb-ft (54 N
•
m).
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