2-12. Assembly

TM 9-2815-237-34 · Chapter 2 — Engine Maintenance

a. 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.

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

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

           Section V. ENGINE DISASSEMBLY, REPAIR, AND ASSEMBLY

2 - 1 3 . ENGINE DISASSEMBLY, REPAIR, AND ASSEMBLY TASK SUMMARY

TASK                                                                                  PAGE
                                     PROCEDURES
PARA.                                                                                  NO.

2-13.1.          Engine Replacement in Shipping/Storage Container                     2-6.2
2-14.            Mounting Engine on Repair Stand                                      2-8
2-15.            Engine Disassembly into Subassemblies                                2-10
2-16.            Cylinder Block Repair                                                2-40
2-17.            Crankshaft Repair                                                    2-52
2-18.            Connecting Rod and Piston Repair                                     2-54
2-19.            Camshaft, Timing Chain, and Drive Gears Repair                       2-58
2-20.            Timing Gear Cover Repair                                             2-60
2-21.            Cylinder Head and Valve Repair                                       2-62
2-22.            Valve Train Repair                                                   2-72
2-23.            Torsional Damper Repair                                              2-74
2-24.            Flywheel Repair                                                      2-75
2-25.            Rocker Arm Cover Repair                                              2-76
2-26.            Oil Pan Repair                                                       2-77
2-27.            Oil Pump Repair                                                      2-78
2-28.            Oil Filter Adapter and Oil Pressure Sending Unit Repair              2-82
2-29.            Exhaust Manifold Repair                                              2-83
2-30.            Intake Manifold Repair                                               2-84
2-31.            Fuel Pump Repair                                                     2-85
2-32.            Fuel Injection Pump Repair (All Models)                              2-86
2-33.            Pre-1990 (6.2L) Fuel Injection Pump (DB2829-4523) Calibration        2-126
2-34.            1990 (6.2L) Fuel Injection Pump (DB2829-4879) Calibration            2-131
2-35.            (6.5L) Fuel Injection Pump (DB2831-5149) Calibration                 2-136
2-35.1.          (6.5L) Fuel Injection Pump (DB2831-5209) Calibration                 2-140.1
2-35.2.          (6.5L) Fuel Injection Pumps (DB2831-5485 or DB2831-5079)
                 Calibration                                                          2-140.6
2-35.3.          (6.2L or 6.5L) Fuel Injection Pumps (DB2829-4523, DB2829-4879,
                 or DB2831-5149) Calibration Using Fuel Injection Pump Test
                 Stand (FTIS) Model A8022                                             2-140.12
2-36.            Glow Plug Repair                                                     2-141
2-37.            Fuel Injection Nozzle Repair                                         2-142
2-38.            Water Pump Repair                                                    2-144
2-39.            Water Crossover Repair                                               2-146
2-40.            Fan Drive Repair                                                     2-148
2-41.            Engine Assembly from Subassemblies                                   2-153