NMWR9-2815-273_6.2L_engine_apr_2005.pdf

NMWR 9-2815-273

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING NATIONAL OVERHAUL STANDARDS

FOR

6.2 Liter

ENGINE/CONVERSION

NSN 2815-01-231-3672 (w/container) NSN 2815-01-168-7892 (Eng. Assy.)

(Pre-1990)

TO

NSN 2815-01-314-7940 (w/container) NSN 2815-01-319-1433 (Eng. Assy.)

(Post 1990)

OR

REPAIR OF

This publication is not available through the AG publication centers. This publication is available thorough U.S. Army TACOM, Warren, MI 48397-5000

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

U.S. ARMY TANK-AUTOMOTIVE AND ARMAMENTS COMMAND

WARREN, MICHIGAN 48397-5000

APRIL 2005

WARNING SUMMARY

• Always wear eye-shields when using compressed air. Failure to wear eye-shields may result in eye injury.

• Compressed air used for cleaning purposes will 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. Spinning a dry bearing with compressed air may cause injury to personnel or damage to equipment.

• Improper cleaning methods and use of unauthorized cleaning solutions will injure personnel and damage equipment. See TM 9-247 for correct information.

• Dry-cleaning solvent is flammable and will not be used near an open flame. A fire extinguisher will be kept nearby when the solvent is used. Use only in well-ventilated places. Failure to do this may result in injury to personnel and/or damage to equipment.

• When steam cleaning, protective clothing must be used. Failure to use protective clothing may result in serous injury.

• Diesel fuel is highly flammable. Do not perform this procedure near fire, flame, or sparks. Severe injury or death may result.

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

Failure to support cylinder block may cause injury to personnel or damage to equipment.

• Crankshaft must be supported during removal and installation. Failure to support crankshaft may cause injury to personnel or damage to equipment.

• Do not place hands or arms near nozzle during testing. Penetrating force of oil may cause serious injury or death.

• Direct personnel to stand clear during hoisting operation. Failure to do this may cause injury to personnel.

• Gaskets installed on some 6.2L engines assembled prior to 1991 may contain asbestos. Gaskets should be removed with a scraper or putty knife and then disposed of IAW current directives. Inhalation of asbestos fibers can cause respiratory ailments.

a/b blank

INSERT LATEST CHANGED PAGES / WORK PACKAGES, DESTROY SUPERSEDED DATA

LIST OF EFFECTIVE PAGES / WORK PACKAGES

NOTE: The portion of text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations by miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.

Dates if issue for original and changed pages / work packages are:

Original… April 5, 2005

TOTAL NUMBER OF PAGES FRONT AND REAR MATTERS 14 AND TOTAL

NUMBER OF WORK PACKAGES IS 18 CONSISTING OF THE FOLLOWING:

Page / WP No. *Chang e No.

Page / WP No.

*Change No.

Page / WP No.

*Change No.

Cover 0

Warning 0 i-ii 0

WP 0001 00 - WP 0043 00 0

*Zero in this column indicates an original page or work package

A/B blank

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING NATIONAL OVERHAUL STANDARDS

FOR

6.2 Liter

ENGINE/CONVERSION

NSN 2815-01-231-3672 (w/container) NSN 2815-01-168-7892 (Eng. Assy.)

(Pre-1990)

TO

OR

REPAIR OF

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

i

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACESS REQUEST FORM.” The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax or E-mail your letter or DA Form 2028 direct to: AMSTA-LC-CI Tech Pubs, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The E-mail address is TACOM-TECH-PUBS@ria.army.mil. The fax number is DSN 793- 0726 or Commercial (309) 782-0726.

National Maintenance Work Requirement HEADQUARTERS, DEPARTMENT OF THE ARMY

WASHINGTON, D.C., 5 April 2005

TABLE OF CONTENTS

WP Sequence No.

WARNING SUMMARY…………………………………………………………………………a

LIST OF EFFECTIVE PAGES/WORK PACKAGES………………………………………..A

General………………………………………………………………………………. 0001 00 Engine Repair/Conversion………………………………………………………… 0002 00 Performance Test…………………………………………………………………… 0003 00 Container Repair & Parts Disposal……………………………………………….. 0004 00 Description, Component Location, & Data……………………………………….. 0005 00 Engine Injection Pump Timing…………………………………………………….. 0006 00 General Maintenance Instructions………………………………………………… 0007 00 Engine Disassembly, Repair, & Assembly Task Summary…………………….. 0008 00 Engine Replacement in Shipping/Storage Container…………………………… 0009 00 Mounting Engine on Repair Stand………………………………………………… 0010 00 Engine Disassembly into Subassemblies………………………………………… 0011 00 Cylinder Block Repair………………………………………………………………. 0012 00 Crankshaft Repair…………………………………………………………………... 0013 00 Connecting Rod & Piston Repair………………………………………………….. 0014 00 Camshaft, Timing Chain, and Drive Gears Repair……………………………… 0015 00 Timing Gear Cover Repair…………………………………………………………. 0016 00 Cylinder Head & Valve Repair…………………………………………………….. 0017 00 Valve Train Repair………………………………………………………………….. 0018 00 Torsional Damper Repair………………………………………………………….. 0019 00 Flywheel Repair……………………………………………………………………... 0020 00 Rocker Arm Cover Repair………………………………………………………….. 0021 00 Oil Pan Repair………………………………………………………………………. 0022 00 Oil Filter Adapter & Oil Pressure Sending Unit Repair…………………………. 0023 00 Exhaust Manifold Repair…………………………………………………………… 0024 00 Intake Manifold Repair……………………………………………………………… 0025 00 Fuel Pump Repair…………………………………………………………………... 0026 00 Fuel Injection Pump Repair………………………………………………………... 0027 00 1990 (6.2L) Fuel Injection Pump (DB2829-4879) Calibration………………….. 0028 00 6.2L Fuel Injection Pumps (DB2829-4879) Calibration Using Fuel Injection Pump Test Stand (FITS) Model A8022……………………………………………

0029 00 ii

Fuel Injection Nozzle Repair………………………………………………………. 0030 00 Water Pump Repair………………………………………………………………… 0031 00 Water Crossover Repair…………………………………………………………… 0032 00 Fan Drive Repair……………………………………………………………………. 0033 00 Engine Assembly From Subassemblies…………………………………………. 0034 00 General……………………………………………………………………………… 0035 00 Engine Run In………………………………………………………………………. 0036 00 General………………………………………………………………………………. 0037 00 Repair and Replacement Standards……………………………………………… 0038 00 Supporting Info……………………………………………………………………… 0039 00 After Repair Performance Test Report…………………………………………… 0040 00 Appendix A………………………………………………………………………….. 0041 00 Appendix B………………………………………………………………………….. 0042 00 Mandatory Replacement List………………………………………………………. 0043 00 iii/iv blank

GENERAL 0001 00

THIS WORK PACKAGE (WP) COVERS:

Scope, Applicable Documents, Definitions

SCOPE

1. This National Maintenance Work Requirement (NMWR) covers the repair and conversion of the General Motors pre-1990, 6.2L engine and container, NSN 2815- 01-231-3672, to post-1990 6.2L engine and container configuration, NSN 2815-01- 314-7940. We use the engine in the High Mobility Multipurpose Wheeled Vehicle (HMMWV). The procedures contained in this NMWR describe disassembly, inspection, component repair, and assembly/conversion from pre-1990 to post-1990 6.2L engine configuration which is serviceable and issuable to all customers without limitations or restriction, Condition Code A.

2. 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/convert the engines.

APPLICABLE DOCUMENTS

You can receive copies of the applicable documents upon request by contacting:

Commodity Business Unit

USA TACOM

AMSTA-LC-CHL

jody.mcinerney@usarmy.mil Warren MI 48397-5000

The following documents form a part of this NMWR to the extent specified herein.

1. TB 9-289

2. MIL-P14105C

3. MIL-M-45907

4. SPI AK13147940

5. Appendix A – Points of Contact

6. Appendix B – Packaging Instructions

0001 00-1

GENERAL – CONTINUED 0001 00

You may also refer to the following:

1. TACOM Drawing Number 12338064

2. TACOM Drawing Number 12338770

DEFINITIONS

1. Repair: Restoring a component or sub-assemblies to their original performance condition, replacing parts if necessary.

2. Rebuild: Restoring an item to a standard as nearly possible to original or new condition in appearance, performance, and life expectancy. 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. IAW appropriate TMs.

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 original equipment manufacturer 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.

END OF TASK

0001 00-2

ENGINE REPAIR/CONVERSION 0002 00

Description

DESCRIPTION

1. We will provide engine assemblies, NSN 2815-01-168-7892, in various states of disrepair. Some parts may be missing from the engines. You will convert the engines to meet the configuration of engine assembly NSN 2815-01-319-1433. As part of this conversion, you will disassemble, clean, and inspect each engine and its components to determine serviceability of component parts to meet requirements of drawing 12338770 and the performance specifications described in WP 0038 00.

This standard will provide a serviceable component, issuable to users without restrictions, Condition Code A.

2. To accomplish conversion, specific pre-1990 6.2L engine, NSN 2815-01-168-7892, parts will be replaced with post-1990 6.2L engine, NSN 2815-01-319-1433, parts as follows:

NOMENCLATURE ORIGINAL PN/NSN REPLACING PN/NSN QTY

Cylinder, Head (7X677) 14071072 5240-01-440-6626

(11862) 10163712 2815-01-313-4309

2ea

Fuel Injector Nozzle

(11862) 14059057 2910-01-150-0950

(11862) 14063606 2910-01-280-4283

8ea

Fuel Injector Pump (84760) DB2829-4523 2910-01-199-2355 or

(84760) DB2829-4524

NO NSN

(84760) DB2829-4879

2910-01-326-9221

1ea

#1 FI Line (11862)14033911 4710-01-149-5075

(11862) 10149551 4710-01-314-4489

1ea

#2 FI Line (11862) 14033912 4710-01-148-9580

(11862) 10149552 4710-01-314-4483

1ea

#3 FI Line (11862) 14033913 4710-01-148-9581

(11862) 10149553 4710-01-314-4488

1ea

#4 FI Line (11862) 14033914 (11862) 10149554 1ea 0002 00-1

NOTE

Engine component/repair parts for conversion or included on Mandatory Replacement List need not be inspected.

NOTE

Use the REPLACING PN/NSN below in the repair process for any 6.2L previously converted to NSN 2815-01-319- 1433.

ENGINE REPAIR/CONVERSION – CONTINUED 0002 00

NOMENCLATURE ORIGINAL PN/NSN REPLACING PN/NSN QTY

#4 FI Line cont. 4710-01-149-5076 4710-01-316-0222 1 ea #5 FI Line (11862) 14033915

4710-01-153-1636 (11082) 10149555 4710-01-149-5077

1ea

#6 FI Line (11862) 14033916 4710-01-150-0971

(11082) 10149556 4710-01-314-4485

1ea

#7 FI Line (0A002) 14033917 4710-01-149-5077

(11862) 10149557 4710-01-314-4486

1ea

#8 FI Line (11862) 14033918 4710-01-148-9582

(11862) 10149558 4710-01-314-4484

1ea

Bracket LH & RH

(11862) 14033824 5340-01-159-6626

RH (11862) 14033824

5340-01-159-6626

LH (11862) 10163716

5340-01-440-9678

1ea

1 ea

Water Pump (11862) 14061698 2390-01-193-7802

(11862) 12534418 2390-01-353-5794

1ea

3. With the exception of the Fuel Injection Pump (FIP), you can use OEM or equivalent after market repair parts when repairing the engine. When using other than OEM parts, the parts used must be able to be repaired or replaced using the existing procedures, tools and repair parts specified in the HMMWV technical manuals. Local purchase of repair parts, within these guidelines, is authorized.

4. Engine to vehicle interface must be the same as NSN 2815-01-314-7940 for converted/repaired engine assemblies.

5. You won’t repair cracked engine blocks or heads. Any crack is cause for disposal of the block or head. You may use serviceable or repairable parts from cracked block or head assemblies when repairing other engine assemblies.

6. You may cannibalize serviceable or repairable parts from any unrepairable engine assembly for use when repairing other engine assemblies.

7. On every converted/repaired engine, you will replace the glow plug controller, part number 12338772, with a new controller. (The controller is installed into the engine.)

8. The following parts are peculiar to the HMMWV application of the 6.2L engine.

Replacements for these parts must meet the requirement specified on the part’s drawing.

0002 00-2

ENGINE REPAIR/CONVERSION – CONTINUED 0002 00

Part Part Number

Elbow 12339408

Bracket 12338783 Fitting 12339415

Adapter 12338780 Nipple 12339396 Bolt 12339410 Gasket 12339409 Bracket 12338774 Screw 12339240 Drive Assembly 12339407 Screw 12340845-1 Stud 12339406-3 Manifold 12338787 Manifold 12338785 Gasket 12339414 Rivet 12339238 Boot 12339491-1 Switch 12338599 Manifold 12338788 Manifold 12338797 Switch 12338596 Temperature Transmitter 12339486 Shouldered Stud 12339406-2 Connector 12339405 Modulator Bracket 12339141 Modulator Linkage 12339149 Idle Return Spring 12339492 Accelerator Cable Bracket 12339142 Accelerator Cable Bracket 12339143 Glow Plug Controller 12338772 Switch and Mounting Plate 12339494 Cap 12339358

9. During the course of conversion/repair, any subcomponents/parts of the engine assembly showing obvious signs of imminent failure, excessive wear, or deterioration will be replaced with a fully serviceable replacement.

10. Paint only the external steel surfaces of the converted/repaired engine in accordance with MIL-P-14105C, Heat Resistant Paint for Steel.

0002 00-3/4 blank

PERFORMANCE TEST 0003 00

Performance Test

1. You will do a performance test on every engine converted/repaired. A quality assurance/control representative must witness the testing following the instructions contained in Paragraph WP 0036 00, for testing the engine.

2. As part of the performance test you will complete WP 0040 00, Performance Test

Report. After testing, return the completed data sheet to:

Commander

USA TACOM

Attn: AMSTA-LC-CHL HarriRob@tacom.army.mil

Warren MI 48397-5000

3. Pipe plugs must be removed from oil passages in order to perform the tasks outlined in WP 0012 00, Cleaning 1.c and Cleaning 2.c. The instructions do not state how to remove these plugs and there is no tool specified to remove the plugs. The Repair Facility shall use the method best suited to remove the pipe plugs. The following method could be used:

Step 1. Drill a hole in the plug. Locate a nut (approximately 1/2" in height), the inner diameter must be bigger than the outer diameter of the plug.

Step 2. Locate a washer with a smaller inside diameter than the nut.

Step 3. Locate a screw, a little smaller than the hole you drilled in the plug, but long enough to go through the nut with a little length to spare.

Step 4. Assemble the screw/washer/nut and pull the plug out of the oil passage.

0003 00-1/2 blank

CONTAINER REPAIR AND PARTS DISPOSAL 0004 00

Description and Disposal

DESCRIPTION

1. Each engine we provide may or may not be in an engine container, NSN 8145-01-

231-3747. You will inspect and recondition the containers in accordance with TB 9- 289 and drawing package 12338064. You will notify TACOM, AMSTA-LC-CHL of containers which are determined to be nonrepairable in accordance with TB 9-289, and verified by the government quality assurance representative, for proper disposal. Any engine not provided to you in a metal container must be packaged in a metal container after rebuild. Extra metal containers will be provided upon request.

2. You can use OEM or equivalent parts when repairing the container. When using other than OEM parts, the parts used must meet the requirements specified on the OEM part’s drawing.

DISPOSAL

1. You are responsible for disposal of any unrepairable or unused parts or assemblies.

0004 00-1/2 blank

Container Repair does NOT apply to Recap vehicle program.

DESCRIPTION, COMPONENT LOCATION AND DATA 0005 00

Component Location and Tabulated Data

The engine used in the M998 series vehicles is an eight-cylinder, four-cycle, liquid-cooled, naturally aspirated diesel engine. The 6.2L engine has a compression ratio of 21.5:1 and develops approximately 150 horsepower (112 kW) at 3600 rpm. For proper orientation, the left and right sides of the engine are as viewed from the rear.

1990 and above 6.2L engines have the following new and revised parts:

*Cylinder Heads. The 1990 cylinder heads have been revised to meet 1990 emissions standards.

Precombustion Valves. The 1990 engine is equipped with reverse throat precombustion chambers.

Exhaust Valves. The 1990 exhaust valves are coated with chrome to prevent burning and to increase durability.

*Exhaust Valve Stem Seal. The 1990 engine is equipped with a new exhaust valve stem seal that is not available for previous model engines.

Cylinder Head Gaskets. The 1990 cylinder head gaskets have new circular combustion seals and are made of a non-asbestos material.

Fuel Injection Pump. The 1990 fuel injection pump has a new governor and a revised calibration procedure.

*Fuel Injection Nozzles. The 1990 fuel injection nozzles are shorter and are orientated ten degrees from the vertical.

*Fuel Injection Lines. The 1990 engine is equipped with high pressure fuel injection lines.

0005 00-1

DESCRIPTION, COMPONENT LOCATION AND DATA - CONTINUED 0005 00

Fuel Injection Line Brackets. The 1990 fuel injection line brackets have been revised to provide clearance for the injection nozzles.

*These 1990 parts are not interchangeable with parts for previous model engines.

Differences in maintenance procedures are identified where applicable. Refer to engine decal number on left rocker arm cover before ordering replacement parts.

The 1990 6.2L engine is identified by a decal, which is adhered to the left rocker arm cover.

0005 00-2

COMPONENT LOCATION

The locations of components described below are common to all engines in the M998 series vehicles. Special differences are described in WP 0005 00.

TABULATED DATA

Engine tabulated data is listed in table 1. This information includes only those data applicable to direct support and general support maintenance.

TABULATED DATA ABBREVIATIONS

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

MEASUREMENT ABBREVIATION

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

0005 00-3

Table 1. Tabulated Data 6.2L

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Detroit Diesel Allison Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 L Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cycle, liquid-cooled, naturally aspirated

STANDARD METRIC

Dimensions:

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 in. 89 cm Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 in. 71 cm Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 28 in. 71 cm New weight, dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650 lbs 295 kg

Cylinders:

Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Eight Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90° V Firing order . . . . . . . . . . . . . . . . . . . . 1-8-7-2-6-5-4-3 (clockwise) Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.98 in. 10.1 cm Stroke (nominal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.82 in. 9.7 cm Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 392 cu-in. 6.2 L Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5:1 Maximum Torque (gross) . . . . . . . . . . . . . . 260 lb-ft @ 2000 rpm 353 N•m @ 2000 rpm

Governed Speed:

Full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600 rpm No load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 rpm Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650±25 rpm

Lubrication System:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure feed Operating pressure (normal) . . . . . . . . . . . . . . . . . . . . . 40-50 psi 276-345 kPa Operating pressure (at idle) . . . . . . . . . . . . . . . . . . . . . . . . 10 psi 69 kPa System capacity (including filter) . . . . . . . . . . . . . . . . . . . . . . 8 qts 7.6 L Operating temperature (normal) . . . . . . . . . . . . . . . . .. 180°-260°F 82°-126°C Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear-driven

0005 00-4

Standard and metric measurements will be used in this table.

A list of their abbreviations is provided above.

Cooling system:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid with fan and radiator Operating temperature (normal) . . . . . . . . . . . . . . . .. . 190°-230°F 88°-110°C

0005 00-5/6 blank

ENGINE INJECTION PUMP TIMING 0006 00

Initial Setup, Timing Check, Timing Adjustment

INITIAL SETUP

Tools

General mechanics tool kit: Automotive NSN 5180-00-177-7033

Special Tools

Timing bracket gauge: NSN 6620-01-231-3671; PN MT95 Dynamic timing meter: NSN 5180-01-186-3114; PN J 33127

Materials/Parts

Metallic wool: NSN 5350-00-242-4404 1 Pound Package

General Safety Instructions

Never adjust timing while engine is running.

TIMING CHECK

1. Insert timing bracket gauge into magnetic pickup receptacle (8) on timing bracket

(1).

2. Rotate timing bracket gauge so pointer on gauge fits into TDC notch (9) in timing bracket (1).

3. If pointer on gauge does not fit exactly into TDC notch (9), bend magnetic pickup receptacle (8) until pointer on gauge fits exactly into TDC notch (9).

4. Remove timing bracket gauge from pickup receptacle (8) on timing bracket (1).

0006 00-1

Magnetic pickup receptacle on timing bracket must be correctly positioned or timing meter will not register correctly.

ENGINE INJECTION PUMP TIMING - CONTINUED 0006 00

5. Install magnetic pickup (7) into magnetic pickup receptacle (8) and connect pickup lead (6) to timing meter.

6. Clean cylinder number one injection line (2) with metallic wool.

7. Install pickup (4) on injection line (2).

8. Connect ground clip (3) to fuel injection line (2) and connect pickup lead (5) to timing meter.

9. Route red power lead of timing meter to 24 Volt power source.

10. Connect black ground lead to negative ground. Display should light up and read: SE-

1 20.0.

0006 00-2

End of magnetic pickup must be .06 in. (1.5 mm) from torsional damper.

NOTE

Clamp-on pickup must be used on a straight section of tube no further than 4 in. (10 cm) from injection nozzle.

CAUTION

Do not over tighten clamp-on pickup or damage to pickup will result.

11. Depress offset adjustment switch (3) and hold.

12. Operate increase/decrease switch (2) until offset adjustment reads 9.5 for 6.2L engines. Release offset adjustment switch (3). Display (4) should not read: 0000 ...

0.0.

13. Start engine and warm up to operating temperature.

14. Position sensor switches (1) to clamp-on and magnetic pickup positions.

For vehicles with 1990 engines and above, timing must be 5° before top dead center.

15. Raise engine speed to 1300 rpm and read injection pump timing on display (4).

Timing must be 4° before top dead center. If timing is not 4° before top dead center, stop engine (TM 9-2320-280-10) and adjust timing (Timing Adjustment , below).

Ensure all cables and wires are clear from fan, belts, and exhaust manifolds before starting engine, or damage to equipment will result.

If sensor light is not blinking, check clamp-on pickup fuel injection line for proper installation.

0006 00-3

16. Disconnect timing meter.

TIMING ADJUSTMENT

1. Loosen three nuts (7) securing injection pump (6) to timing chain cover (5).

2. Move injection pump (6) clockwise to retard timing or counterclockwise to advance timing.

3. Tighten three nuts (7) securing injection pump (6) to timing chain cover (5) and recheck timing.

END OF TASK 0006 00-4

WARNING

Never adjust injection pump timing with engine running or injury to personnel and damage to equipment may result.

NOTE

Moving injection pump .03 in. (.8 mm) is equal to approximately 1° of injection pump timing.

GENERAL MAINTENANCE INSTRUCTIONS 0007 00

Cleaning, Inspection, Repair, Assembly

CLEANING

1. General Instructions. Cleaning procedures will be the same for the majority of parts and components, which make up engine subassemblies. 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 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.

3. External Engine Cleaning. All electrical equipment and other parts that could be damaged by steam cleaning or moisture must be removed, and all openings covered before cleaning. Dry with compressed air.

4. Disassembled Parts Cleaning. Place all disassembled parts in wire baskets for cleaning.

(a) Dry and cover all cleaned parts.

(b) Place on or in “racks” and hold for inspection or repair.

(c) All parts subject to rusting must be lightly oiled and wrapped.

(d) Keep all related parts and components together. Do not mix parts.

0007 00-1

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

WARNING

Improper cleaning methods and use of unauthorized cleaning solutions will injure personnel and damage equipment. See TM 9- 247 for correct information.

GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED 0007 00

5. Castings

(a) Clean inner and outer surfaces of castings and all areas subject to grease and oil with cleaning solvents. Refer to TM 9-247.

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

(c) Use compressed air to blow out all tapped capscrew holes and dry castings after cleaning.

6. Oil Passages

Particular attention must be given to all oil passages in castings and machined parts. Oil passages must be clean and free of any obstructions.

(a) Clean passages with wire probes to breakup any sludge or gum deposits.

(b) Wash passages by flushing with solvents. See TM 9-247,

(c) Dry passages with compressed air.

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

8. Bearings

(1) Bearings require special cleaning. After removing surface oil and gum deposits wipe bearings dry with a Iint-free cloth; do not use compressed air.

(2) See TM 9-214 for information and care of bearings.

9. Electrical Components

(1) Clean electrical components with clean cloth dampened with dry-cleaning solvent. Care must be taken not to damage protective insulation.

0007 00-2

Do not allow dry cleaning solvents 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 making them unserviceable.

WARNING

Do not use compressed air to dry bearings. Spinning a dry bearing with compressed air may cause injury to personnel or damage to equipment.

INSPECTION

1. General Instructions. Procedures for inspections will be the same for many parts and components, which make up the engine subassemblies. General procedures are detailed in steps 2-11. Dimensional standards for parts have been fixed at extremely close tolerances, so use specification tables. Use specified inspection equipment for inspection where cracks and other damage cannot be spotted visually. Exercise extreme care in all phases of inspection. Repair or replace all unserviceable components; refer to REPAIR, WP 0007 00.

2. Castings

(a) Inspect all ferrous and nonferrous castings for cracks. See MIL-I-6866, Inspection, Penetrant Methods, and MIL-I-6868, Inspection Process, Magnetic Particles. Particularly check areas around studs, pipe plugs, threaded inserts, and sharp comers. 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 damaged or threads are stripped.

(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. Bearings.

4. 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.

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). (2) Use compressed air to dry electrical components.

CAUTION

All engine connecting rod and main bearings will be replaced if one or more bearings fail. Check all bearings for conformance to applicable repair standards.

0007 00-3

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

5. Machined Parts

(1) Check machined parts for cracks, distortion, and damage.

(2) Check all surfaces for nicks, burrs, and raised metal.

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

7. Gears.

(a)Inspect all gears for cracks and missing teeth. Replace if 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.

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

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

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

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

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 steps 2-8.

0007 00-4

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

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.

(4) Remachining of machined surfaces to repair damage, warpage, or uneven surfaces is not permitted. Replace castings.

(c) Repair damaged threaded pipe plug and/or capscrew holes with a thread tap or repair oversize holes with threaded inserts.

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 with a stud remover, use extractor to remove.

(c) Replacement studs have a special coating and must have a small amount of antiseize compound, NSN 8030-00-753-4953, applied on threads before stud is installed. Install replacement stud slowly to prevent heat buildup and snapping off.

5. Gears

(a) Remove gears using pullers, as required.

(b) Use the same methods described in REPAIR section 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.

CAUTION

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

0007 00-5

7. Oil Seals

(1) Remove oil seals, being careful not to damage casting or adapter bore.

(2) 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 0012 00 and WP 0017 00. Cylinder block or cylinder head must be replaced if measurements are outside tolerance limits listed in table 1, WP 0038 00.

ASSEMBLY

1. Cleanliness is essential in all component assembly operations. Dirt and dust, even in minute quantities, are abrasive. Parts must be cleaned as specified, and kept clean.

Wrap or cover parts and components when assembly procedures are not immediately completed.

2. Coat all bearings and contact surfaces with engine oil (MIL-L-2104) to ensure lubrication of parts during initial operation after repair.

3. Use new gaskets and preformed packings during assembly of all components.

0007 00-6

ENGINE DISASSEMBLY, REPAIR, AND ASSEMBLY TASK SUMMARY 0008 00

Task Summary

TASK PROCEDURES WP.

PAGE NO.

0009 00-1 Engine Replacement in Shipping/Storage Container 0009 00 0010 00-1 Mounting Engine on Repair Stand 0010 00 0011 00-1 Engine Disassembly into Subassemblies 0011 00 0012 00-1 Cylinder Block Repair 0012 00 0013 00-1 Crankshaft Repair 0013 00 0014 00-1 Connecting Rod and Piston Repair 0014 00 0015 00-1 Camshaft, Timing Chain, and Drive Gears Repair 0015 00 0016 00-1 Timing Gear Cover Repair 0016 00 0017 00-1 Cylinder Head and Valve Repair 0017 00 0018 00-1 Valve Train Repair 0018 00 0019 00-1 Torsional Damper Repair 0019 00 0020 00-1 Flywheel Repair 0020 00 0021 00-1 Rocker Arm Cover Repair 0021 00 0022 00-1 Oil Pan Repair 0022 00 0023 00-1 Oil Filter Adapter and Oil Pressure Sending Unit Repair 0023 00 0024 00-1 Exhaust Manifold Repair 0024 00 0025 00-1 Intake Manifold Repair 0025 00 0026 00-1 Fuel Pump Repair 0026 00 0027 00-1 Fuel Injection Pump Repair (All Models) 0027 00 0028 00-1 1990 (6.2L) Fuel Injection Pump (DB2829-4879) Calibration 0028 00 0029 00-1 6.2L Fuel Injection Pumps (DB2829-4879) Calibration Using

Fuel Injection Pump Test Stand (FTIS) Model A8022 0029 00 0030 00-1 Fuel Injection Nozzle Repair 0030 00 0031 00-1 Water Pump Repair 0031 00 0032 00-1 Water Crossover Repair 0032 00 0033 00-1 Fan Drive Repair 0033 00 0034 00-1 Engine Assembly from Subassemblies 0034 00

0008 00-1/2 blank

ENGINE REPLACEMENT IN SHIPPING/STORAGE CONTAINER 0009 00

Removal and Installation

General mechanics tool kit: Automotive NSN 5180-00-177-7033

Special Tools

Engine lifting sling: NSN 4910-01-193-7808; PN J33139

Materials/Parts

Eight lock-washers: NSN 5310-00-637-9541; PN MS35338-46

General Safety Instructions

Direct personnel to stand clear during hoisting operation.

REMOVAL

1. If engine container (5) is closed and sealed, press air-release button (1) located at center of breather valve (2) before opening engine container (5).

2. Remove twenty-six nuts (19), washers (18), capscrews (16), and upper container (4) from lower container (13).

3. Position engine lifting sling on engine assembly (6) and install sling on right cylinder head (25) with two capscrews (24).

4. Install sling bracket (21) to engine lifting sling with pin (22) and on left cylinder head

(20) with two capscrews (23). Tighten capscrews (23).

5. Remove four capscrews (14), lockwashers (8), and washers (7) from two engine mounts (12). Discard lockwashers (8).

0009 00-1

WP 0009 DOES NOT APPLY to engines being repaired in conjunction with vehicle Recap programs.

ENGINE REPLACEMENT IN SHIPPING/STORAGE CONTAINER – CONT. 0009 00

6. Remove four capscrews (9), lockwashers (8), and washers (7) from two rear engine mounts (10). Discard lockwashers (8).

7. Attach hoist to engine lifting sling and remove engine assembly (6) from lower container (13).

8. Position engine on repair stand (WP 0010 00).

INSTALLATION

1. Install engine assembly (6) in lower container (13).

2. Install engine assembly (6) on two rear engine mounts (10) with four washers (7), lockwashers (8), and capscrews (9).

3. Install engine assembly (6) on two engine mounts (12) with four washers (7), lockwashers (8), and capscrews (14).

4. Remove pin (22) from sling bracket (21).

5. Remove two capscrews (24) and lifting sling from right cylinder head (25).

6. Remove two capscrews (23) and sling bracket (21) from left cylinder head (20).

7. Visually check humidity indicator (17) for discolorization. If indicator (17) is dark purple, replace desiccant (3).

8. Using alignment pins (15), position upper container (4) on gasket (11) and lower container (13).

9. Install upper container (4) on lower container (13) with twenty-six capscrews (16), washers (18), and nuts (19).

0009 00-2

Direct personnel to stand clear during hoisting operation. Failure to do this may cause injury to personnel.

Ensure gasket is seated properly.

ENGINE REPLACEMENT IN SHIPPING/STORAGE CONTAINER – CONT. 0009 00

0009 00-3/4 blank

MOUNTING ENGINE ON REPAIR STAND 0010 00

Installation, and Removal

General mechanics tool kit: Automotive NSN 5180-00-177-7033

Special Tools

Engine repair stand: NSN 4910-00-506-0037; PN 1725A

Engine lifting sling: NSN 4910-01-193-7808; PN J33139

INSTALLATION

1. Position engine lifting sling on engine (4) and secure to right cylinder head (10) with two bolts (11). Finger tighten bolts (11).

2. Install sling bracket (2) to engine lifting sling with pin (3) and on left cylinder head (1) with two bolts (9). Tighten bolts (9) and (11).

3. Attach hoist to engine lifting sling and hoist engine (4) into position over engine repair stand.

4. Loosen four capscrews (5) securing repair stand arms (6) on engine repair stand and align arms (6) with holes in rear of engine (4).

5. Install repair stand arms (6) to engine (4) with four washers (8) and capscrews (7).

NOTE

Do not perform step 1 if engine lifting sling has been previously installed.

WARNING

Direct personnel to stand clear during hoisting operation. Failure to do this may cause injury to personnel.

0010 00-1

MOUNTING ENGINE ON REPAIR STAND - CONTINUED 0010 00

6. Tighten capscrews (5) and (7).

7. Disconnect hoist and remove two bolts (11) and (9), engine lifting sling, and bracket

(2) from engine (4).

REMOVAL

1. Position engine lifting sling on engine (4) and secure to right cylinder head (10) with two bolts (11). Finger tighten bolts (11).

2. Install sling bracket (2) to engine lifting sling with pin (3) and on left cylinder head (1) with two bolts (9). Tighten bolts (9) and (11).

3. Attach hoist to engine lifting sling and hoist engine (4) to relieve pressure on engine repair stand.

4. Remove four capscrews (7) and washers (8) from repair stand arms (6) and hoist engine away from engine repair stand.

0010 00-2

MOUNTING ENGINE ON REPAIR STAND - CONTINUED 0010 00

0010 00-3/4 blank

ENGINE DISASSEMBLY INTO SUBASSEMBLIES 0011 00

(a) Fan Drive and Water Pump Pulley, (b) Crankshaft Pulley, (c) Torsional Damper, (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

General mechanics tool kit: Automotive NSN 5180-00-177-7033 Puller: NSN 5120-00-595-9305 Cylinder ridge reamer: NSN 5110-00-237-8598 Dial indicator: NSN 5210-00-277-8840

Special Tools

Hydraulic valve lifter remover: NSN 5120-01-209-6870; PN J29834 Injection nozzle socket: NSN 5120-01-171-5233; PN J29873 Glow plug socket: NSN 5120-00-277-1463; PN FUS121 Hex-head driver, 6 mm: NSN 5120-01-055-1308; PN FAM 6 Hex-head driver, 8 mm: NSN 5120-01-053-4159; PN FAM 8 Hex-head driver, 5/16-in.: NSN 5120-00-683-8602; FA10B

Equipment Condition

Engine mounted on repair stand (WP 0010 00).

0011 00-1

ENGINE DISASSEMBLY INTO SUBASSEMBLIES - CONTINUED 0011 00

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

1. Position pry bar between water pump pulley (3) and crankshaft pulley (6) and apply pressure.

2. Using a 5/16-in. hex-head driver, remove four socket-head screws (1) and fan drive

(2) from water pump pulley (3).

3. Using a 6-mm hex-head driver, remove four socket-head screws (5) and water pump pulley (3) from water pump (4).

0011 00-2

• 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 engines are basically the same. Any differences in procedures are noted. Refer to WP 0005 00 to determine engine model before ordering replacement parts.

NOTE

It may be necessary to apply compressed air to fan drive fitting. This disengages fan drive and allows access to socket head capscrews.

(b) CRANKSHAFT PULLEY

Remove four capscrews (9), crankshaft pulley (6), and spacer (8) (if installed) from torsional damper (7).

0011 00-3

(c) TORSIONAL DAMPER

1. Hold flywheel stationary with pry bar.

2. Remove capscrew (1) and washer (2) from torsional damper (3) and crankshaft (5).

3. Reinstall capscrew (1) and remove torsional damper (3) with puller.

4. Remove capscrew (1) and woodruff key (4) from crankshaft (5). Discard woodruff key (4).

(d) EXHAUST MANIFOLDS

1. Remove stud (6) and washer (7) securing left exhaust manifold (8) to cylinder head

(9).

2. Using 8-mm hex-head driver, remove seven socket-head screws (12), washers (11), left exhaust manifold (8), and gasket (10) from cylinder head (9). Discard gasket (10).

3. Using 8-mm hex-head driver, remove eight socket-head screws (17), washers (16), right exhaust manifold (15), and gasket (14) from cylinder head (13). Discard gasket (14).

0011 00-4

Early production vehicles may have a socket-head screw in place of stud.

(e) INTAKE MANIFOLD

1. Remove fuel filter line clamp (1) from stud (2).

2. Remove six intake manifold capscrews (5), ten studs (2), and sixteen washers (3).

3. Remove four injection line clips (4).

4. Remove intake manifold (6) and two gaskets (7) from cylinder heads (8). Discard gaskets (7).

0011 00-5

Note location of studs for installation.

WARNING.

Gaskets installed on some 6.2L engines assembled prior to 1991 may contain asbestos. Gaskets should be removed with a scraper or putty knife and then be disposed of IAW current directives.

Inhalation of asbestos fibers can cause respiratory ailments.

(f) WATER CROSSOVER

1. Remove four capscrews (9) securing water crossover (14) to cylinder heads (8).

2. Loosen hose clamp (12) and disconnect thermostat bypass hose (11) from water crossover nipple (13).

3. Remove water crossover (14) and two gaskets (10). Discard gaskets (10).

0011 00-6

WARNING.

Gaskets installed on some 6.2L engines assembled prior to 1991 may contain asbestos. Gaskets should be removed with a scraper or putty knife and then be disposed of IAW current directives. Inhalation of asbestos fibers can cause respiratory ailments.

(g) FUEL INJECTION LINES

1. Loosen and disconnect eight fuel injection line nuts (4) at injection nozzles (3).

2. Remove four screw-assembled washers (5) and clamps (6) from support brackets

(2).

3. Remove clamp (8) and boot (9) from fuel injection pump (1). Disconnect and remove eight fuel injection lines (7) at fuel injection pump (1).

0011 00-7

Diesel fuel is highly flammable. Do not perform this procedure near fire, flame, or sparks. Severe injury or death by result.

CAUTION

Plug fuel injection pump openings to prevent contamination.

Tag lines by cylinder number for assembly.

(h) FUEL SUPPLY AND RETURN LINES

1. Loosen clamp (11) and remove fuel filter inlet hose (12) from fuel supply line (10).

2. Disconnect fuel supply line (10) at fuel pump (27).

3. Remove stud (24), washer (25), two clamps (28) and fuel supply line (10) from fuel return line (18) and cylinder block (29).

4. Remove nut (19), washer (20), and clamp (21) from fuel return line (18) and rocker arm cover stud (22).

0011 00-8

5. Remove capscrew (13), washer (14), and clamp (15) from fuel return line (18) and timing gear cover (26).

6. Loosen three clamps (16) and disconnect three hoses (17) at fuel injection pump (1) and front fuel injection nozzles (23).

7. Remove fuel return line (18).

(i) MODULATOR LINK

1. Remove two capscrews (2) securing modulator link bracket (3) to cylinder head (6).

0011 00-9

Removal of the modulator link is applicable only to 6.2L engines.

2. Slide modulator link (1) forward and disconnect from fuel injection pump (7) and remove bracket (3), modulator link (1), water jacket cover (4), and gasket (5).

Discard gasket (5).

(j) ROCKER ARM COVERS

1. Remove two nuts (8) and injection line support bracket (9) from rocker arm cover studs (14).

2. Remove a combination of three capscrews (10), five studs (14), eight washers (11), rocker arm cover (12), and gasket (13) (if applicable) from cylinder head (6).

3. Repeat steps 1 and 2 for opposite side.

0011 00-10

.WARNING.

Gaskets installed on some 6.2L engines assembled prior to 1991 may contain asbestos. Gaskets should be removed with a scraper

(k) ROCKER ARM SHAFTS AND PUSHRODS

1. Remove four capscrews (3) and four retainer’s (2) from rocker arm and shaft assembly (4) and cylinder head (5).

2. Remove two rocker arm and shaft assemblies (4).

3. Remove eight pushrods (1).

4. Repeat steps 1 through 3 for opposite side.

0011 00-11

Tag rocker arm and shaft assembly for assembly.

Tops of pushrods are hardened and must be tagged for assembly.

(l) FUEL INJECTION NOZZLES

1. Remove seven clamp’s (10), one cap (9), and three hose’s (8) from fuel injection nozzle’s (6).

2. Using injection nozzle socket, remove four fuel injection nozzles (6) and gaskets (7) from cylinder head (5). Discard gasket’s (7).

0011 00-12

(m) GLOW PLUGS

1. Using glow plug socket, remove four glow plugs (1) from cylinder head (2).

2. Repeat step 1 for opposite side.

0011 00-13

(n) CYLINDER HEADS

Remove seventeen capscrews (3), cylinder head (2), and cylinder head gasket (4) from cylinder block (5). Discard cylinder head gasket (4).

1. Repeat step 1 for opposite side.

0011 00-14

Gaskets installed on some 6.2L engines assembled prior to 1991 may contain asbestos. Gaskets should be removed with a scraper or putty knife and then be disposed of IAW current directives. Inhalation of asbestos fibers can cause respiratory ailments.

(o) VALVE LIFTERS

1. Remove two capscrews (3), guide plate clamps (2), and four guide plates (4) from cylinder block (5).

2. Remove eight valve lifters (1) from cylinder block (5) with hydraulic valve lifter remover.

0011 00-15

Tag lifters for assembly.

(p) WATER PUMP AND ADAPTER PLATE

1. Remove two nuts (6), washers (7), and oil fill tube (8) from adapter plate (9).

2. Remove two studs (10), (14), and (17), four capscrews (18), washers (11), two capscrews (15), capscrew (16), water pump (13), and adapter plate (9) from timing gear cover (12).

3. Remove seven capscrews (20) from water pump (13) and separate water pump (13) and gasket (19) from…