GM/DDA 6.2L & 6.5L Diesel Service Manual

TM 9-2815-237-34 — Direct Support and General Support Maintenance — 6.2L and 6.5L V8 diesels (CUCV and HMMWV family) · Joint Army / Air Force / Marine Corps publication

Start Here

• Engine Troubleshooting — symptoms, tests, and remedies
• Engine Disassembly into Subassemblies
• Engine Assembly from Subassemblies
• Engine Specifications (Tabulated Data)
• Torque Limits (Appendix F)
• Mandatory Replacement Parts — part numbers and NSNs (Appendix D)

Contents

• Front Matter

Chapter 1 — Introduction

• 1-1. Scope
• 1-2. Maintenance Forms, Records, and Reports
• 1-3. Destruction of Army Equipment To Prevent Enemy Use
• 1-4. Preparation For Shipment
• 1-5. Equipment Requiring Calibration
• 1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)
• 1-8. Metric System
• 1-9. Mandatory Replacement Parts
• 1-10. Description
• 1-11. Component Location
• 1-12. Tabulated Data

Chapter 2 — Engine Maintenance

• Section I. REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE), AND SUPPORT EQUIPMENT
• 2-1. Common Tools and Equipment
• 2-2. Special Tools and Support Equipment
• 2-3. Test, Measurement, and Diagnostic Equipment (Tmde)
• 2-4. Repair Parts
• 2-5. Engine Inspection
• 2-6. General
• 2-7. Engine Troubleshooting
• 2-8. General Maintenance Instructions Task Summary
• 2-9. Cleaning
• 2-10. Inspection
• 2-11. Repair
• 2-12. Assembly
• 2-13.1. Engine Replacement In Shipping/Storage Container
• 2-14. Mounting Engine on Repair Stand
• 2-15. Engine Disassembly Into Subassemblies
• 2-16. Cylinder Block Repair
• 2-17. Crankshaft Repair
• 2-18. Connecting Rod and Piston Repair
• 2-19. Camshaft, Timing Chain, and Drive Gears Repair
• 2-20. Timing Gear Cover Repair
• 2-21. Cylinder Head and Valve Repair
• 2-22. Valve Train Repair
• 2-23. Torsional Damper Repair
• 2-24. Flywheel Repair
• 2-25. Rocker Arm Cover Repair
• 2-26. Oil Pan Repair
• 2-27. Oil Pump Repair
• 2-28. Oil Filter Adapter and Oil Pressure Sending Unit Repair
• 2-29. Exhaust Manifold Repair
• 2-30. Intake Manifold Repair
• 2-31. Fuel Pump Repair
• 2-32. Fuel Injection Pump Repair
• 2-33. Pre-1990 (6.2L) Fuel Injection Pump (Db2829-4523) Calibration
• 2-34. 1990 (6.2L) Fuel Injection Pump (Db2829-4879) Calibration
• 2-35. (6.5L) Fuel Injection Pump (Db2831-5149) Calibration
• 2-35.1. (6.5L) Fuel Injection Pump (Db2831-5209) Calibration
• 2-35.2. (6.5L) Fuel Injection Pumps (Db2831-5485 Or Db2831-5079) Calibration
• 2-35.3. (6.2L or 6.5L) FUEL INJECTION PUMPS (DB2829-4523, DB2829-4879, or
• 2-36. Glow Plug Repair
• 2-37. Fuel Injection Nozzle Repair
• 2-38. Water Pump Repair
• 2-39. Water Crossover Repair
• 2-40. Fan Drive Repair
• 2-41. Engine Assembly from Subassemblies
• 2-42. General
• 2-43. Engine Run-In
• 2-45. Repair and Replacement Standards

Appendix A

• Appendix A — References

Appendix B

• Appendix B — Expendable/Durable Supplies and Materials List

Appendix C

• Appendix C — Illustrated List of Manufactured Items

Appendix D

• Appendix D — Mandatory Replacement Parts

Appendix E

• Appendix E — Tool Identification List

Appendix F

• Appendix F — Torque Limits