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 26 of 267
TM 9-2815-237-34
2-10
Change 1
2 - 1 5 .
ENGINE DISASSEMBLY INTO SUBASSEMBLIES
This task covers:
a.
Fan Drive and Water Pump Pulley
b.
Crankshaft Pulley
c.
Torsional Damper
c.1. Wastegate Actuator
c.2. Wastegate Housing
c.3. Manifold-to-Turbocharger Exhaust Pipe
c.4. Turbocharger
d.
Exhaust Manifolds
e.
Intake Manifold
f.
Water Crossover
g.
Fuel Injection Lines
h.
Fuel Supply and Return Lines
i.
Modulator Link
j.
Rocker Arm Covers
k.
Rocker Arm Shafts and Pushrods
l.
Fuel Injection Nozzles
m.
Glow Plugs
n.
Cylinder Heads
o.
Valve Lifters
p.
Water Pump and Adapter Plate
q.
Fuel Injection Pump
r.
Timing Gear Cover
s.
Timing Chain and Drive Sprockets
t.
Oil Filter, Adapter, and Oil Pressure Sending Unit
u.
Oil Pan
v.
Oil Pump
w.
Fuel Pump
x.
Oil Pump Drive
y.
Camshaft
z.
Pistons and Connecting Rods
aa.
Flywheel
bb.
Crankshaft and Main Bearings
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.
a. Fan Drive and Water Pump Pulley
NOT E
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.
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)
NOT E
• 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.
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