NMWR_9-2815-274_6.5L_Engine_2012.pdf

*NMWR 9-2815-274

NATIONAL MAINTENANCE WORK REQUIREMENTS

CONTAINING

NATIONAL MAINTENANCE OVERHAUL STANDARDS

FOR

6.5 LITER ENGINES WITH CONTAINER

HMMWV FOV

Detuned 6.5 Liter 6.5 Liter Naturally Aspirated 6.5 Liter Turbo

NSN 2815-01-439-6664 NSN 2815-01-461-7078 NSN 2815-01-439-8164

NSN 2815-01-406-6675 NSN 2815-01-410-9710 NSN 2815-01-420-4180

NSN 2815-01-453-7404 NSN 2815-01-439-6665 NSN 2815-01-453-7402

NSN 2815-01-472-6312 NSN 2815-01-453-7403 NSN 2815-01-547-1716

AVAILABILITY STATEMENT: This publication is not available through the AG publication centers. This publication is available through T ACOM Life Cycle Management Command, Wa rren, MI 48397-5000

DISTRIBUTION STATEMENT A: Approved for pub lic release; distribution is unlimited.

*NMWR 9-2815-274 supersedes NMWR 9-2815-274 dated 30 Sept 2007

U. S. ARMY TACOM LIFE CYCLE MANAGEMENT COMMAND

30 APRIL 2012

WARNING SUMMARY

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 4-25.11 (WP 0035)

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.

a

WARNING SUMMARY - Continued

This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment.

Failure to observe these precautions could result in serious injury or death to personnel.

Refer to FM 4-25.11 (WP 0035) for first aid instructions.

Always wear eye-shields when using compressed air.

Compressed air used for cleaning purposes must 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.

Improper cleaning methods and use of unauthorized cleaning solutions will injure personnel and damage equipment.

Store, handle, and dispose solvents in accordance with local procedures, plans, and regulations.

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from flames and other sources ignition.

When not using MIL-PRF-680 solvents, ensure MIL-PRF-680 solvent container is sealed. Store, handle, and dispose unused and spent solvents in accordance with local procedures, plans, and regulations.

When steam cleaning, protective clothing must be used.

JP8 fuel is highly flammable. Do not perform these procedures near fire, flame, or sparks.

Cylinder block must be supported during removal and installation from engine stand.

Crankshaft must be supported during removal and installation.

Cylinder Heads must be supported during removal and installation.

Do not place hands or arms near injection nozzle during testing.

Direct personnel to stand clean during hoisting operation.

b

NMWR 9-2815-274

A/B blank

LIST OF EFFECTIVE PAGES / WORK PACKAGES

NOTE: This manual supersedes NMWR 9-2815-274 dated 30 September 2007.

No.” column indicates an original page or work package

Date of issue for the original NMWR is:

Original 30 April 2012

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 30 AND TOTAL NUMBER OF

WORK PACKAGES IS 40, CONSISTING OF THE FOLLOWING:

Page / WP No. Change No.

Page / WP No. Change No.

Front Cover 0

WP 0019 (2 pgs) 0 Blank 0

WP 0020 (2 pgs) 0

Warning Summary (2 pgs) 0

WP 0021 (2 pgs) 0 i-xii 0

WP 0022 (6 pgs) 0

Chp 1 title page 0

WP 0023 (4 pgs) 0

WP 0024 (4 pgs) 0

WP 0001 (6 pgs) 0

WP 0025 (60 pgs) 0 WP 0002 (4 pgs) 0

WP 0026 (8 pgs) 0

WP 0003 (8 pgs) 0

WP 0027 (4 pgs) 0 Chp 2 title page 0

Chp 3 title page 0

WP 0004 (6 pgs) 0

WP 0028 (8 pgs) 0

WP 0005 (4 pgs) 0

WP 0029 (2 pgs) 0 WP 0006 (40 pgs) 0

WP 0030 (10 pgs) 0

WP 0007 (8 pgs) 0

WP 0031 (8 pgs) 0 WP 0008 (4 pgs) 0

WP 0032 (82 pgs) 0

WP 0009 (8 pgs) 0

WP 0033 (6 pgs) 0 WP 0010 (4 pgs) 0

WP 0034 (6 pgs) 0

WP 0011 (2 pgs) 0

WP 0035 (2 pgs) 0 WP 0012 (14 pgs) 0

WP 0036 (4 pgs) 0

WP 0013 (4 pgs) 0

WP 0037 (2 pgs) 0 WP 0014 (2 pgs) 0

WP 0038 (6 pgs) 0

WP 0015 (2 pgs) 0

WP 0039 (2 pgs) 0 WP 0016 (2 pgs) 0

WP 0040 (2 pgs) 0

WP 0017 (2 pgs) 0

Inside back cover 0 WP 0018 (2 pgs) 0

Back cover 0

Zero in the “Change

U.S. ARMY TACOM LIFE CYCLE

MANAGEMENT COMMAND

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING

NATIONAL MAINTENANCE OVERHAUL STANDARDS

6.5 LITER ENGINES WITH CONTAINER

NSN 2815-01-406-6675 NSN 2815-01-410-9710 NSN 2815-01-420-4180

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and to better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S.

Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/ TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil.

The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you.

i/ii blank

WARREN, MI 30 APRIL 2012

AVAILABILITY STATEMENT: This publication is not available through the AG publication centers. This publication is available through T ACOM Life Cycle Management Command, Wa rren, MI 48397-5000

DISTRIBUTION STATEMENT A: Approved for pub lic release; distribution is unlimited.

*NMWR 9-2815-274 supersedes NMWR 9-2815-274 dated 30 Sept 2007 iii

TABLE OF CONTENTS

WP or page No.

How to use this NMWR ix

Table 1. NMWR Contents ix

Chapter 1 - General Information

General Information WP 0001

Table 1. Common Abbreviation 0001 00-5

Equipment Description and Data WP 0002

Figure 1 0002 00-2

Table 1. Data Abbreviatons 0002 00-3

Table 2. Tabulated Data 0002 00-4

General Maintenance Instructions WP 0003

Chapter 2 - Maintenance Instructions

Engine Removal and Installation in Shipping/Storage Container WP 0004

Figure 1. Engine and Container 0004 00-3

Figure 2. Engine and Container 0004 00-5

Mounting Engine on Repair Stand WP 0005

Figure 1. Engine and Repair Stand 0005 00-3

Figure 2. Engine and Repair Stand 0005 00-4

Engine Disassembly into Sub-Assemblies WP 0006

Figure 1. Fan Drive and Water Pump Pulley 0006 00-2

Figure 2. Crankshaft Pulley 0006 00-3

Figure 3. Torsional Damper 0006 00-4

Figure 4. Manifold to Turbocharger Exhaust Pipe 0006 00-5

Figure 5. Intake Crossover 0006 00-6

Figure 6. Turbocharger 0006 00-6

Figure 7. Non-Turbo Exhaust Manifolds 0006 00-7

Figure 8. Turbo Exhaust Manifolds 0006 00-8

Figure 9. Intake Manifolds 0006 00-9

Figure 10. Water Crossover 0006 00-10

Figure 11. Fan Cut-Off Switch (N.A.) 0006 00-11

Figure 12. Fuel Injection Lines 0006 00-13

Figure 13. Fuel Supply and Return Lines 0006 00-14

Figure 14. Modulator Link 0006 00-15

Figure 15. Rocker Arm Cover 0006 00-16

Figure 16. Rocker Arm Shaft and Pushrod 0006 00-17

Figure 17. Fuel Injection Nozzles 0006 00-18

Figure 18. Glow Plugs 0006 00-19

Figure 19. Cylinder Head 0006 00-20

Figure 20. Valve Lifters 0006 00-21

Figure 21. Water Pump and Adapter Plate 0006 00-22

Figure 22. Fuel Injection Pump 0006 00-23

Figure 23. TPS / Fan Cut-Off Switch 0006 00-24

Figure 24. Timing Gear Cover 0006 00-25

Figure 25. Timing Chain and Drive Sprockets 0006 00-26

Figure 26. Oil Filter and Adapter 0006 00-27

Figure 27. Pressure Relief Valves 0006 00-28

Figure 28. Oil Pressure Sending Unit and Cooler Line Fittings 0006 00-28

Figure 29. Oil Pan 0006 00-29 iv

TABLE OF CONTENTS – Continued

Figure 30. Oil Pump 0006 00-30

Figure 31. Fuel Pump 0006 00-31

Figure 32. Oil Pump Drive 0006 00-32

Figure 33. Camshaft 0006 00-33

Figure 34. Pistons and Connecting Rods 0006 00-35

Figure 35. Bearing Cap Location Numbers 0006 00-36

Figure 36. Crankshaft and Main Bearings 0006 00-37

Figure 37. Camshaft Bearings 0006 00-39

Figure 38. Cylinder Block Dust Caps and Plugs 0006 00-40

Cylinder Block Repair WP 0007

Figure 1. Engine Block 0007 00-3

Figure 2. Engine Block 0007 00-5

Figure 3. Cylinder Bore and Piston Head 0007 00-7

Crankshaft Repair WP 0008

Figure 1. Crankshaft 0008 00-2

Figure 2. Crankshaft 0008 00-3

Figure 3. Crankshaft 0008 00-4

Connecting Rod and Piston Repair WP 0009

Figure 1. Piston and Connecting Rod 0009 00-2

Figure 2. Piston and Connecting Rod 0009 00-3

Figure 3. Piston and Connecting Rod 0009 00-4

Figure 4. Connecting Rod, Piston, and Rings 0009 00-7

Camshaft and Drive Gears Repair WP 0010

Figure 1. Camshaft 0010 00-2

Figure 2. Gears 0010 00-3

Timing Gear Cover Repair WP 0011

Figure 1. Timing Gear Cover and Oil Filler Tube 0011 00-2

Cylinder Head and Valve Repair WP 0012

Figure 1. Intake and Exhaust Valves 0012 00-3

Figure 2. Cylinder Head 0012 00-4

Figure 3. Expansion Plug 0012 00-4

Figure 4. Cylinder Head and Valve 0012 00-5

Figure 5. Valve Cover Bolt Holes 0012 00-5

Figure 6. Cylinder Head and Valve 0012 00-7

Figure 7. Valve and Valve Guide 0012 00-8

Figure 8. Cylinder Head 0012 00-9

Figure 9. Valve Face 0012 00-10

Figure 10. Valve Tip 0012 00-10

Figure 11. Valve Seat 0012 00-11

Figure 12. Expansion Plugs 0012 00-12

Figure 13. Cylinder Head Assembly 0012 00-13

Figure 14. Cylinder Head Assembly 0012 00-14

Valve Train Repair WP 0013

Figure 1. Rocker Arm and Shaft Assembly 0013 00-1

Figure 2. Rocker Arm Assembly and Lifter 0013 00-2

Figure 3. Rocker Arm and Shaft Assembly 0013 00-3 v

Torsional Damper Repair WP 0014

Figure 1. Torsional Damper 0014 00-1

Figure 2. Torsional Damper 0014 00-2

Flywheel Repair WP 0015

Figure 1. Flywheel 0015 00-1

Figure 2. Flywheel 0015 00-2

Rocker Arm Cover Repair WP 0016

Figure 1. Rocker Arm Cover 0016 00-1

Figure 2. Rocker Arm Cover 0016 00-2

Oil Pan Repair WP 0017

Figure 1. Oil Pan 0017 00-2

Oil Filter Adapter and Oil Pressure Sending Unit Repair WP 0018

Figure 1. Oil Filter Adapter and Oil Pressure Sending Unit 0018 00-2

Exhaust Manifold Repair WP 0019

Figure 1. Exhaust Manifold 0019 00-2

Intake Manifold Repair WP 0020

Figure 1. Intake Manifold 0020 00-1

Figure 2. Intake Manifold 0020 00-2

Fuel Pump Adapter Plate and Pushrod Repair WP 0021

Figure 1. Adapter Plate and Fuel Pump Push Rod 0021 00-2

Fuel Injection Nozzle Repair WP 0022

Figure 1. Fuel Injection Nozzle 0022 00-2

Figure 2. Fuel Injection Nozzle 0022 00-3

Figure 3. Fuel Injection Nozzle 0022 00-5

Water Pump Repair WP 0023

Figure 1. Water Pump 0023 00-2

Figure 2. Water Pump 0023 00-3

Figure 3. Water Pump 0023 00-4

Water Crossover Repair WP 0024

Figure 1. Water Crossover 0024 00-2

Figure 2. Water Crossover 0024 00-3

Figure 3. Water Crossover 0024 00-4

Engine Assembly From Sub-Assemblies WP 0025

Figure 1. Camshaft Bearings 0025 00-5

Figure 2. Camshaft Bearings 0025 00-6

Figure 3. Engine Block Caps and Plugs 0025 00-7

Figure 4. Crankshaft and Main Bearings 0025 00-9

Figure 5. Crankshaft 0025 00-11

Figure 6. Crankshaft and Bearing Caps 0025 00-13

Figure 7. Crankshaft End Play 0025 00-14

Figure 8. Crankshaft and Rear Main Seal 0025 00-14

Figure 9. Bearing Caps 0025 00-15

Figure 10. Bearing Caps 0025 00-16

Figure 11. Bearing Caps 0025 00-17

Figure 12. Bearing Caps 0025 00-17

Figure 13. Crankshaft and Rear Main Seal 0025 00-18

Figure 14. Drain Tube 0025 00-19 vi

Figure 15. Pistons and Connecting Rods 0025 00-21

Figure 16. Rod Bearing Clearance 0025 00-23

Figure 17. Oil Pump 0025 00-24

Figure 18. Camshaft 0025 00-25

Figure 19. Timing Chain and Drive Sprockets 0025 00-26

Figure 20. Timing Gear Cover 0025 00-27

Figure 21. Oil Pan 0025 00-28

Figure 22. Oil Pressure Relief Valves 0025 00-29

Figure 23. Oil Filter and Adapter 0025 00-30

Figure 24. Fuel Pump 0025 00-31

Figure 25. Oil Pump Drive 0025 00-32

Figure 26. TPS / Fan Cut-Off Switch 0025 00-33

Figure 27. Fuel Injection Pump 0025 00-35

Figure 28. Water Pump and Adapter Plate 0025 00-36

Figure 29. Torsional Damper 0025 00-37

Figure 30. Timing Tab 0025 00-38

Figure 31. Valve Lifters 0025 00-39

Figure 32. Cylinder Heads 0025 00-41

Figure 33. Glow Plugs 0025 00-42

Figure 34. Fuel Injection Nozzles 0025 00-43

Figure 35. Rocker Arm Assemblies and Pushrods 0025 00-44

Figure 36. Rocker Arm Covers 0025 00-45

Figure 37. Modulator Link 0025 00-46

Figure 38. Fuel Supply and Return Lines 0025 00-47

Figure 39. Fuel Injection Lines 0025 00-48

Figure 40. Fan Cut-Off Switch (N.A.) 0025 00-49

Figure 41. Water Crossover 0025 00-50

Figure 42. Turbocharger 0025 00-51

Figure 43. Intake Manifold 0025 00-53

Figure 44. Intake Manifold 0025 00-54

Figure 45. Intake Manifold 0025 00-55

Figure 46. Exhaust Manifold 0025 00-56

Figure 47. Manifold to Turbocharger Exhaust Pipe 0025 00-57

Figure 48. Crankshaft Pulley 0025 00-58

Figure 49. Fan Drive and Water Pump Pulley 0025 00-59

Engine Run-In WP 0026

Figure 1. Dynamic Timing Meter 0026 00-3

Figure 2. Dynamic Timing Meter 0026 00-4

Figure 3. Fuel Injection Pump 0026 00-5

Table 1. Detuned 6.5L Run-In Schedule 0026 00-6

Table 2. 6.5L N.A. Run-In Schedule 0026 00-7

Table 3. 6.5L Turbo Run-In Schedule 0026 00-7

Flywheel Removal and Installation WP 0027

Figure 1. Flywheel 0027 00-2

Figure 2. Flywheel 0027 00-3 vii

Chapter 3 - Supplemental Information

Preservation, Packaging, and Marking WP 0028

Figure 1. IUID tag and Serial Number 0028 00-3

Figure 2. IUID Tag Location 0028 00-7

Figure 3. Serial Number Location 0028 00-8

Quality Assurance Requirements WP 0029

Torque Limits WP 0030

Figure 1. Capscrew Diameter 0030 00-2

Figure 2. Capscrew Head Markings 0030 00-2

Figure 3. Threads per Inch 0030 00-2

Figure 4. Torque Wrench 0030 00-4

Table 1. Torque Limits for Dry Fasteners 0030 00-5

Table 2. Torque Limits for Wet Fasteners 0030 00-6

Table 3. Dry Torque Limits for Metric Fasteners 0030 00-7

Table 4. WP 0012. Cylinder Head and Valve Repair 0030 00-7

Table 5. WP 0024. Water Crossover Repair 0030 00-7

Table 6. WP 0025. Engine Assembly From Sub-Assemblies 0030 00-8

Table 7. WP 0026. Engine Run-In 0030 00-9

Table 8. WP 0027. Flywheel Removal and Installation 0030 00-9

Repair Parts Introduction WP 0031

Repair Parts WP 0032

Figure 1. Engine and Container Assembly 0032 00-2

Figure 2. Engine Block Assembly and Cylinder Head 0032 00-8

Figure 3. Crankshaft, Damper, Bearings, and Pulley 0032 00-14

Figure 4. Flywheel 0032 00-16

Figure 5. Piston Assembly, Rod Assembly, and Ring Set 0032 00-18

Figure 6. Valves, Guides, and Rocker Arm Assemblies 0032 00-20

Figure 7. Camshaft, Timing Chain, and Related Parts 0032 00-22

Figure 8. Crankcase Cover Assembly and Rocker Cover 0032 00-24

Figure 9. Engine Oil Pan, Pump, and Filler Tube 0032 00-26

Figure 10. Oil Filter, Adapter, and Oil Line Fittings 0032 00-28

Figure 11. Air Intake Manifold (Detuned and N.A) 0032 00-30

Figure 12. Air Intake Manifolds (Turbo) 0032 00-32

Figure 13. Exhaust Manifolds (Detuned and N.A.) 0032 00-34

Figure 14. Exhaust Manifolds (Turbo) 0032 00-36

Figure 15. Fuel Injector Nozzle and Gasket 0032 00-38

Figure 16. Fuel Pump and Mounting Hardware 0032 00-40

Figure 17. Fuel Injection Pump and Fuel Filter Lines (Detuned and N.A.) 0032 00-42

Figure 18. Fuel Injection Pump and Fuel Filter Lines (Turbo) 0032 00-46

Figure 19. Fuel Injection Supply and Return Lines 0032 00-48

Figure 20. Turbocharger Assembly 0032 00-52

Figure 21. Glow Plug 0032 00-54

Figure 22. Accelerator Cable Bracket and Idle Spring 0032 00-56

Figure 23. Thermostat, Water Crossover, and Attaching Hardware 0032 00-58

Figure 24. Water Pump and Attaching Hardware 0032 00-60

Figure 25. Fan Drive and Pulley 0032 00-62 viii

Figure 26. Sending Units (Detuned and N.A.) 0032 00-64

Figure 27. Sending Units (Turbo) 0032 00-68

Figure 28. Fan Cut-Off Switch, Throttle Position Sensor and Engine Speed Sensor 0032 00-70

Figure 29. Modulator Rod Assembly and Bracket (Detuned) 0032 00-72

Figure 30. Power Steering Pump Support Bracket (Detuned) 0032 00-74

Figure 31. Engine Shipping Container 0032 00-76

Fig. KITS 0032 00-79

Fig. BULK 0032 00-81

NSN Index WP 0033

Part Number Index WP 0034

References WP 0035

Expendable and Durable Items List WP 0036

Table 1. Expendable and Durable Items List 0036 00-2

Tool Identification List WP 0037

Table 1. Tool Identification List 0037 00-2

Mandatory Replacement Parts List WP 0038

Table 1. WP 0004. Engine Removal and Installation in Shipping/Storage Container 0038 00-2

Table 2. WP 0009. Connecting Rod and Piston Repair 0038 00-2

Table 3. WP 0012. Cylinder Head and Valve Repair 0038 00-2

Table 4. WP 0013. Valve Train Repair 0038 00-2

Table 5. WP 0023. Water Pump Repair 0038 00-2

Table 6. WP 0024. Water Crossover Repair 0038 00-3

Table 7. WP 0025. Assembly From Sub-Assemblies 0038 00-3

Table 8. Kits 0038 00-5

Repair and Replacement Specifications WP 0039

Table 1. 6.5L Engine Specifications 0039 00-1

After Repair Performance Test Report WP 0040

Table 1. 6.5L Detuned Engine After Repair Performance Test Report 0040 00-1

Table 2. 6.5L Naturally Aspirated Engine After Repair Performance Test Report 0040 00-2

Table 3. 6.5L Turbo Engine After Repair Performance Test Report 0040 00-2 ix

HOW TO USE THIS NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

INTRODUCTION

This section explains the basic organization, content, format, and special features of this NMWR.

After reading this section, spend some time reviewing the NMWR to familiarize yourself with the contents and layout. This will enable you to locate information easily and reduce the time needed to complete required procedures.

ORGANIZATION AND CONTENTS

This NMWR is divided into three main chapters. Chapter 1 presents general information and data. Chapter 2 contains maintenance instructions. Chapter 3 provides supplemental information.

Table 1. NMWR Contents.

Chapter 1 General Information; Equipment Description and Data; and General Maintenance Instructions.

Chapter 2

Engine Removal and Installation in Container; Mounting Engine on Repair Stand; Disassembly into Subassemblies; Cylinder Block Repair; Crankshaft Repair; Connecting Rod and Piston Repair; Camshaft and Drive Gears Repair;

Timing Gear Cover Repair; Cylinder Head and Valve Repair; Valve Train Repair; Torsional Damper Repair; Flywheel Repair; Rocker Arm Cover Repair;

Oil Pan Repair; Oil Filter Adapter and Oil Pressure Sending Unit Repair;

Exhaust Manifold Repair; Intake Manifold Repair; Fuel Pump Repair; Fuel Injection Nozzle Repair; Water Pump Repair; Water Crossover Repair;

Assembly From Subassemblies; Engine Run-In; and Flywheel Removal and Installation

Chapter 3

Preservation, Packaging, and Marking; Quality Assurance Requirements;

Torque Limits; Repair Parts Introduction; Repair Parts; NSN Index; Part Number Index; References; Expendable and Durable Items; Tool Identification List;

Mandatory Replacement Parts; Repair and Replacement Specifications; and After Repair Performance Test Report

You can locate specific information in the NMWR by using the Table of Contents located at the front of the NMWR.

x

HOW TO USE THIS NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR) (Cont’d)

FORMAT

Work Package (WP) Format

Each chapter in this NMWR is divided into WPs which group data into stand-alone informational or task-oriented units. As shown in Table 1, Chapter 1 contains informational WPs. Chapter 2 contains primarily task-oriented WPs (maintenance procedures) followed by supplementary information WPs in Chapter 3.

Here are some important things to know about the WP format:

Each WP has its own identification number which appears in the upper right corner of each page. WPs are numbered sequentially throughout the manual.

Each WP starts with page number 1. Page numbers appear at the bottom of the pages following the WP number and change number.

Informational WPs begin with a listing of the specific topics covered in the order in which they appear in the WP. This listing provides you with a quick overview of each WP and enables you to locate specific information easily.

Each task-oriented WP begins with an Initial Setup list that identifies all tools, mandatory replacement parts, and other materials needed to complete the procedure in the WP.

The Initial Setup section also identifies the equipment condition required before the procedure can be started. Before beginning a procedure, review the Initial Setup information to ensure all requirements have been met.

The task-oriented WPs (maintenance procedures) generally appear in the order of logical work sequence. Deviations from logical work sequence are noted. This format makes the NMWR easy to follow and helps improve efficiency as you progress through the procedures.

Text and Illustration Modular Layout

Throughout this NMWR, WPs are set up in two-page modular layouts. This means that illustrations appear either on the same page as or on the page facing the step you are performing. This feature eliminates the need to search for illustrations that correlate with each procedural step.

In addition, procedural text is cross-referenced to numerical callouts in the illustrations, helping you immediately identify and locate specific parts mentioned. Figure and callout numbers referencing the illustrations appear in parenthesis in the text.

xi

SPECIAL FEATURES

Illustration Features

This NMWR utilizes a variety of illustration methods such as locator views and exploded views to help you locate and identify parts easily. Each illustration is identified by a figure number and title printed below it.

The illustrations contain numerical callouts to identify parts, components, etc. mentioned in the text. Numerical callouts generally appear in clockwise order in the illustrations beginning at the 11 o’clock position.

A special feature of this NMWR is that the callout numbers for mandatory replacement parts are circled in the illustrations. This visually distinguishes mandatory replacement parts from those that may be repairable or are otherwise reusable.

Supplemental Information

The WPs at the end of this NMWR contain supplemental information that supports the procedures in the NMWR. This information is cross-referenced in the Initial Setup list of each overhaul WP. The following supplemental information is included in this NMWR:

Preservation, Packaging and Marking – Painting, packaging instructions, container repair, IUID and data plate requirements for the component being overhauled in this

NMWR.

Quality Assurance Requirements – Repair activity quality assurance responsibilities and acceptance of repaired items criteria.

Torque Limits – Torque specifications for all fasteners used to assemble the component being overhauled in this NMWR.

Repair Parts Introduction – Explanation of columns in the repair parts list and how to locate repair parts.

Repair Parts – Source, Maintenance, and Recoverability (SMR) code; NSN; P/N;

CAGEC; and quantity for all parts required for the procedures in this NMWR.

NSN Index – Numerical listing of NIINs with figure and item number reference to the Repair Parts WP.

Part Number Index - Numerical listing of part numbers with figure and item number reference to the Repair Parts WP.

References – All publications referenced in this NMWR.

Expendable and Durable Items – National Stock Number (NSN), description, Part Number (P/N), and Commercial and Government Entity Code (CAGEC) for all expendable and durable items necessary to operate or maintain the equipment used in this NMWR.

xii

SPECIAL FEATURES - Continued Supplemental Information - Continued

Tool Identification List – Name, P/N, and NSN for common and special tools required for the procedures in this NMWR.

Mandatory Replacement Parts – Name, P/N, and NSN for all parts that must be replaced during overall of the component.

Repair and Replacement Specifications – Table of tolerances for serviceable components.

After Repair Performance Test Report – Documentation of repaired component performance test and preservation of test result requirements.

CHAPTER 1

GENERAL INFORMATION

6.5 LITER ENGINES

NSN 2815-01-406-6675 NSN 2815-01-410-9710 NSN 2815-01-420-4180

NMWR 9-2815-274 0001 00

0001 00-1

6.5 LITER ENGINE

HMMWV FOV

Detuned 6.5 Liter 6.5 Liter Naturally Aspirated 6.5 Liter Turbo

NSN 2815-01-439-6664 NSN 2815-01-461-7078 NSN 2815-01-439-8164

NSN 2815-01-406-6675 NSN 2815-01-410-9710 NSN 2815-01-420-4180

GENERAL INFORMATION

THIS WORK PACKAGE (WP) COVERS:

Scope; Cost Considerations; Maintenance Forms, Records, and Reports; Definitions; Reporting Equipment Improvement Recommendations (EIR) Corrosion Prevention and Control (CPC);

Destruction of Army Material to Prevent Enemy Use Preparation for Storage or Shipment; Item Unique Identification; List of Abbreviations/Acronyms; Quality Assurance; Quality of Material;

Engineering Change Proposals (ECP); Deviations and Exceptions; and Mobilization Requirements

SCOPE

1. This NMWR covers repair of the 6.5 Liter engine and container. The 6.5 Liter engine is used in the High Mobility Multi-purpose Wheeled Vehicle (HMMWV). The procedures contained in this NMWR describe disassembly, inspection, component repair, and assembly to ensure a product that is serviceable and issuable to all customers without limitation or restriction, Condition Code A.

2. Engines provided to the repair activity may be in various states of disrepair. Some parts may be missing. The repair activity will disassemble, clean, and inspect each engine and its components to determine serviceability of component parts to meet the requirements of drawing 12460200 and the performance schedule in the appropriate Engine Run-In Table. This standard will provide a serviceable component, issuable to users without restriction, Condition Code A.

4. A performance test will be conducted on each engine repaired. For more information see Engine Run-In (WP 0026).

3. A performance test report will be prepared for each engine repaired. Performance reports must be maintained by the repair activity for a minimum of two years. For more information see After Repair Performance Test Report (WP 0040).

4. The repair site shall, in accordance with the terms and conditions set forth herein, furnish all equipment, facilities, and services required to perform inspections and completely repair the engines.

5. Each repair activity will be responsible for disposal of all unserviceable components.

0001 00-2

COST CONSIDERATIONS

This work requirement shall be the basis for establishing the extent of overhaul while taking into consideration cost factors. A determination shall be made on all subassemblies/assemblies to replace worn or damaged components which are available in supply, if acquisition cost is less than the cost to repair and restore to the NMWR standard. The cost to repair/restore any individual item with an established Maintenance Expenditure Limit (MEL) to the NMWR standard shall not exceed the MEL, unless a waiver has been approved in accordance with AMC-R 750-51 (WP 0035). This requirement does not apply to items exempted from MEL in accordance with AMC-R 750-51

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 750-8 (WP 0035), The Army Maintenance Management System (TAMMS) Users Manual.

DEFINITIONS

1. Repair: Restoring a component to its original performance condition, replacing parts if necessary.

2. Rebuild: Restoring an item to a standard as near as possible to original or new condition in appearance, performance, and life expectancy. Rebuild is accomplished by complete disassembly of the item, inspection of parts or components, repair or replacement of worn or unserviceable elements using original manufacturing tolerance and specifications and subsequent reassembly of the item.

3. OEM: The original equipment manufacturer. The company that originally manufactured, fabricated, or supplied an engine component or part. OEM may include items manufactured by a subcontractor for an original equipment manufacturer, provided that the name or trademark of the OEM is shown on the item, label, or container.

4. After Market Part: Any part or component that has been manufactured or fabricated by a company other than the OEM or their approved subcontractors and sold as a replacement part for an OEM part or component.

5. Serviceable Part: Any part that is capable of meeting or exceeding the minimum OEM standards for performing the function for which it was originally designed.

6. Non-serviceable Part: Any part that no longer meets minimum OEM standards.

0001 00-3

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE

Procedures for destruction of Army equipment to prevent enemy use can be found in TM 750- 244-6 (WP 0035), Procedures for Destruction of Tank-Automotive Equipment To Prevent Enemy Use (U.S. Army TACOM Life Cycle Management Command).

If your equipment needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you do not like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to follow the instructions and links below.

ALL non-Aviation/Missile Warranty EIRs and PQDRs must be submitted through the Web Product Quality Deficiency Reporting (PQDR) site. The Web PQDR site is:

http://www.nslcptsmh.csd.disa.mil/webpqdr/webpqdr.htm. New accounts can be established at the following address: http://www.nslcptsmh.csd.disa.mil/accessforms/uarform.htm.

You may also submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 using e-mail, regular mail, or fax using the addresses/fax numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply.

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items.

Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron.

Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking.

Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking.

SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

0001 00-4

PREPARATION FOR STORAGE OR SHIPMENT

1. Military preservation, Level A packing, and marking shall be accomplished in accordance with the specific packaging instructions in WP 0028.

NOTE

Guidance for downloading IMAGE R and ADOBE ACROBAT READER is in the Packaging Website. If you do not have these viewers go to the Packaging Database Query and click on “Need Help?”. Instructions for downloading the viewers are in paragraph 2.

2. Overhauled and inspected components shall be preserved, packed, and marked to preclude damage during transit and storage and to properly identify contents. The repair activity must perform packing, packaging, preservation and marking requirements in accordance with applicable Special Packaging Instructions (SPI). Packaging information can be found at https://www-tdps.tacom.army.mil/PackagingHome.htm by searching by engine NSN.

For information see Preservation, Packaging, and Marking (WP 0028).

3. Each engine provided for repair may or may not be in an engine container, NSN 8145-01-231- 3747. All repaired engines must be packaged in a container regardless of how that engine was received. Extra metal containers will be provided upon request. For more information see Preservation, Packaging, and Marking (WP 0028).

ITEM UNIQUE IDENTIFICATION

All engines must be marked IAW Item Unique Identification (IUID) instructions in WP 0028.

Reference the OSD Web Link: http://www.acq.osd.mil/dpap/pdi/uid/index.html for the latest information on Directives; Guides; and National and International Standards, Policy, and Regulation along with other information and clarification for Item Unique Identification.

0001 00-5

LIST OF ABBREVIATIONS/ACRONYMS

Table 1. Common Abbreviations.

ABBREVIATION OFFICIAL NOMENCLATURE

BOI Basis of Issue

BPN Business Partner Network

CAGEC Commercial and Government Entity Code

CARC Chemical Resistant Coating

CPC Corrosion Prevention and Control

ECP Engineering Change Proposal

EDRS Electronic Deficiency Reporting System

EIR Equipment Improvement Recommendations

FIR Final Inspection Report

FOV Family of Vehicles

HMMWV High Mobility Multipurpose Wheeled Vehicle

IAW In Accordance With

IROAN Inspect and Replace Only As Necessary

IUID Item Unique Identification Device

LEAD Letterkenny Army Depot

LLRC Long Life Reusable Container

MAC Maintenance

MEL Maintenance Ezpenditure Limit

MSL Military Shipping Label

N.A. Naturally Aspirated

NMWR National Maintenance Work Requirement

NSN National Stock Number

OEM Origional Equipment Manufacturer

P/N Part Number

POC Point of Contact

PQDR Product Quality Deficiency Report

QA Quality Assurance

QDR Quality Deficiency Report

RPSTL Repair Parts and Special Tools List

SMR Source, Maintenance, and Recoverability

SOR Source of Repair

SPI Special Packaging Instructions

SRA Specialized Repair Activity

TAMMS The Army Maintenance Management System

TB Technical Bulletin

TM Technical Manual

TMDE Test, Measurement, and Diagnostic Equipment

TULSA TACOM Unique Logistics Support Applications

UOC Usable On Code

WCA Warranty Claim Action

WP Work Package

0001 00-6

QUALITY ASSURANCE

Each repair activity will implement and maintain a Quality Assurance program that complies with ISO 9002, “Quality System- Model for Quality Assurance in Production, Installation and Servicing.”

QUALITY OF MATERIAL

Material used for replacement, repair, or modification must meet the requirements of this NMWR. If quality of material requirement is not stated in this NMWR, the material must meet the requirements of the drawings, standards, specifications, or approved engineering change proposals applicable to the component. Only approved sources of supply will be utilized.

ENGINEERING CHANGE PROPOSALS (ECP)

Engineering Change Proposals (ECPs) will be submitted IAW AR 70-1 (WP 0035), Army Acquisition Policy, directly to Commander, U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LC-HL, Mail Stop 420, 6501 E. 11 Mile Road, Warren, MI 48397- 5000. A reply will be furnished to you.

DEVIATIONS AND EXCEPTIONS

Request for deviations or exceptions to this NMWR will be processed IAW ISO 9000 Series standards (WP 0035) or equivalent.

MOBILIZATION REQUIREMENTS

All requirements of this NMWR will be exempted or revised in the event of mobilization. Only those procedures necessary to return the engine to a serviceable condition will be performed.

END OF WORK PACKAGE

NMWR 9-2815-274 0002 00

0002 00-1

NSN 2815-01-406-6675 NSN 2815-01-410-9710 NSN 2815-01-420-4180

EQUIPMENT DESCRIPTION AND DATA

Equipment Description; Location and Description of Major Components; and Equipment Data

EQUIPMENT DESCRIPTION

The engine used in the HMMWV series of vehicles is an eight-cylinder, four-cycle, liquid-cooled, either naturally aspirated or turbocharged diesel engine. The Detuned 6.5L engine has a compression ratio of 21.5:1 and develops approximately 150 horsepower (112 kW) at 3600 rpm.

The 6.5L Naturally Aspirated (N.A.) engine has a compression ratio of 21.5:1 and develops approximately 160 horsepower (119 kW) at 3400 rpm. The 6.5L Turbo engine has a compression ratio of 21.5:1 and develops approximately 190 horsepower (142kW) at 3400rpm.

For proper orientation, the left and right sides of the engine are as viewed from the rear.

0002 00-2

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

The locations of components described in Figure 1 are common to all engines in the HMMWV series of vehicles.

Figure 1.

I INTAKE MANIFOLD

J FUEL INJECTION PUMP

K WATER CROSSOVER

L WATER PUMP

M FUEL PUMP

N GLOW PLUGS (8)

A FAN CLUTCH

B ROCKER ARM COVERS (2)

C FUEL INJECTORS (8)

D OIL FILTER

E EXHAUST MANIFOLDS (2)

F OIL PAN

G TIMING GEAR COVER

H CRANKSHAFT PULLEY

0002 00-3

EQUIPMENT DATA

Table 1. Data Abbreviations.

MEASUREMENT ABBREVIATION 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

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

0002 00-4

EQUIPMENT DATA - Continued

Table 2. Tabulated Data.

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM General Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 L Type . . .Four-cycle, liquid-cooled, naturally aspirated or turbocharged

Dimensions:

Length Width Height New weight, dry

Cylinders:

Number Arrangement Firing order

Bore:

Stroke (nominal) Displacement Compression ratio Maximum torque (gross)

Governed Speed:

Full load No load Idle speed

Lubrication System:

Type Operating pressure (normal) Operating pressure (at idle) System capacity (including filter) Operating temperature (normal) Oil pump

Cooling System:

Type

Operating temperature (normal):

N.A. and Detuned Turbo

STANDARD

METRIC

35 in.

28 in.

28 in.

650 lbs.

90° V 1-8-7-2-6-5-4-3 (clockwise)

4.06 in.

3.82 in.

395 cu-in.

21.5:1 285 lb-ft @ 2000 rpm

3400 rpm 3650 rpm 725 ± 25 rpm

Pressure feed 25-65 psi 10 psi 8 qts 180°-260°F Gear-driven

Liquid with fan and radiator

190°-240°F 190°-255°F

89 cm 71 cm 71 cm 295 kg

10.3 cm

9.7 cm 6.5L

386 N•m @ 2000 rpm

207-345 kPa 69 kPa 7.6L 82°-127°C

88°-115°C 88°-124°C

NMWR 9-2815-274 0003 00

0003 00-1

NSN 2815-01-406-6675 NSN 2815-01-410-9710 NSN 2815-01-420-4180

GENERAL MAINTENANCE INSTRUCTIONS

Cleaning; Inspection; and Repair

CLEANING

1. General Instructions. Cleaning procedures will be the same for the majority of parts and components which make up engine subassemblies. Cleaning should be done in accordance with the best commercial and/or local practices. Parts and/or components that require special or specific procedures will be addressed within the component’s work package. General cleaning procedures are detailed in steps 2 – 9.

2. The Importance of Cleaning. Great care and effort are required in all cleaning operations.

The presence of dirt and foreign material is a constant threat to satisfactory engine operation and maintenance.

The following will apply to all cleaning operations:

a. Hands, work space, and tools must be kept free of any accumulation of grease, which can collect dust and grit.

b. Clean all parts before inspection, after repair, and before assembly.

c. After cleaning, all parts must be covered or wrapped in plastic or paper to protect them from dust and/or dirt.

d. Parts being stored will be lightly coated with oil covered or wrapped in plastic or paper to protect from dust and/or dirt.

0003 00-2

CLEANING - Continued

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure to comply may result in injury to personnel and/or damage to equipment.

3. Engine Surface Cleaning.

a. Clean inner and outer surfaces subject to grease and oil with cleaning solvents.

b. Use a stiff brush to remove sludge and gum deposits.

4. Disassembled Parts Cleaning.

a. Dry and cover all cleaned parts.

b. A clean pan should be available in which parts may be placed during disassembly and a pan of clean fuel or calibrating oil must be available in which parts may be flushed.

c. Deep pans with rounded corners are recommended to lessen the chance of dirt pockets.

d. All parts subject to rusting must be lightly oiled and wrapped.

e. Keep all related parts and components together. Do not mix parts.

f. Place disassembled parts in wire baskets for cleaning.

5. Castings. Castings will be cleaned according to the best commercial and/or local practices.

Two methods that may be used at the repair activity’s discretion are Hot Tank Cleaning and Steam Cleaning. Procedures for these methods follow.

1. Hot tank cleaning:

a. Clean castings by submerging in tank of heated cleaning solution.

b. Run rods with brushes through all oil passages and repeat step a.1.

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa).

Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure to comply may result in injury to personnel.

c. Blow all dirt and cleaning solution from capscrew holes and oil passages with compressed air.

d. Coat all machined surfaces with OE/HDO.

0003 00-3

2. Steam cleaning:

Protective clothing must be used when steam cleaning.

Failure to comply may result in serious injury to personnel.

a. Thoroughly steam castings.

b. Run rods with brushes through all oil passages and repeat b.1.

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

c. Blow all dirt and cleaning solution from capscrew holes and oil passages with compressed air.

d. Coat all machined surfaces with OE/HDO.

CAUTION

Particular attention must be given to all oil passages in castings and machined parts. Oil passages must be clean and free of any obstructions. Failure to comply may affect engine performance.

6. Oil Passages.

a. Clean passages with wire probes to break up any sludge or gum deposits.

b. Wash passages by flushing with solvents.

c. Dry passages with compressed air.

Do not allow solvent cleaning compound 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 resulting in them being unserviceable.

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

0003 00-4

8. Bearings.

Do not use compressed air to dry bearings. Spinning a dry bearing with compressed air may result in injury to personnel and/or damage to equipment.

a. Bearings require special cleaning. After removing surface oil and gum deposits wipe bearings dry with a lint-free cloth. Do not use compressed air.

b. See TM 9-214 for information and care of bearings.

9. Electrical Components.

a. All electrical equipment and other parts that could be damaged by steam cleaning or moisture must be removed and all openings covered before cleaning.

b. Clean electrical components with clean cloth dampened with cleaning solvent. Care must be taken not to damage protective insulation.

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure to comply may result in injury to personnel and/or damage to equipment.

c. Use compressed air to dry electrical components.

END OF TASK

INSPECTION

1. General Instructions. Procedures for inspections will be the same for many parts and components that make up the engine assemblies. General procedures are detailed in steps 2 – 12. Dimensional standards for parts have been fixed at extremely close tolerances, so use specification tables in WP 0039. Exercise extreme care in all phases of inspection.

Repair or replace all unserviceable components.

2. Castings.

a. Inspect all ferrous and nonferrous castings for cracks. Particularly check areas around studs, pipe plugs, threaded inserts, and sharp corners. Replace cracked castings.

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

c. Inspect all pipe plugs, pipe plug openings, capscrews, and capscrew openings for damaged and stripped threads. Replace if threads are damaged and cannot be repaired in accordance with procedures on page 0003 00-7 of this WP.

0003 00-5

INSPECTION - Continued

d. 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.

e. Check all castings for conformance to applicable repair standards.

3. Bushings and Bushing-Type Bearings.

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

b. Check for dirt in lubrication holds or grooves. Holes and grooves must be clean and free from damage.

4. Machined Parts.

a. Check machined parts for cracks, distortion, and damage.

b. Check all surfaces for nicks, burrs, and raised metal.

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

6. Gears

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

a. Inspect all gears for cracks and missing teeth. Replace if gears are cracked or teeth are missing.

b. Inspect gear teeth for wear, sharp fins, burrs, and galled or pitted surfaces.

c. Inspect splines for wear, burrs, and galled or pitted surfaces.

d. Check keyway slots for wear and/or damage.

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

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

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

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

0003 00-6

INSPECTION - Continued

11. Non-metallic Parts. Replace if obvious damage or general deterioration is found.

12. Threads. Inspect threads for irregularities. Replace components containing threads which are not repairable.

END OF TASK

REPAIR

1. General Instructions. Repair of most parts and components is limited to general procedures outlined in applicable maintenance instructions and the following detailed procedures.

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

2. Castings.

a. All cracked castings will be replaced.

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

(1) Fine mill file.

(2) Abrasive crocus cloth dipped in cleaning solvent.

(3) Lapping across a surface plate.

c. Rematching of machined surfaces to repair damage, warpage, or uneven surfaces is not permitted.

d. Repair damaged threaded pipe plug and/or capscrew holes with a thread chaser or threaded inserts when possible. Replace components with damaged threads that cannot be repaired IAW procedures on page 0003 00-7.

3. Bearings. See TM 9-214

4. 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:

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

b. If studs break off too short to use a stud remover, use extractor to remove.

c. Replacement studs have a special coating and must have a small amount of anti-seize compound applied on threads before stud is installed. Install replacement stud slowly to prevent heat buildup and snapping off.

0003 00-7/8 blank

REPAIR - Continued

5. Gears.

a. Remove gears using pullers, as required.

b. Use the same methods described in step 2.b for castings to remove minor nicks, burrs, or scratches on gear teeth.

c. If keyways are worn or enlarged, replace gear.

6. Bushings and Bushing Type 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.

7. Oil Seals.

a. Remove oil seals, being careful not to damage casting or adapter bore.

b. Always install new seal in bore using proper seal replacing tool.

8. Cylinder Block or Cylinder Head. Repair of cylinder block and cylinder head is limited to procedures outlined in WP 0007 and WP 0012.

Cylinder head, bearing cap, rod cap, intake manifold, crankshaft, and transmission mounting bolt holes may not be repaired with threaded inserts.

9. Threads. Repair threads in tapped holes having minor irregularities by re-tapping with correct size previously used hole tap. Drill-out tapped holes having badly damaged threads and install a threaded insert. Follow kit manufacturers and NASM 33537 instructions when installing threaded inserts.