2-43. Engine Run-In
TM 9-2815-237-34 · Chapter 2 — Engine Maintenance
This task covers: Out of Chassis Run-In INITIAL SETUP
Test Equipment Manual References
Dynamometer TM 9-2320-280-34
Out of Chassis Run-In
NOTE
This procedure should be performed in a well-ventilated
work area.
If engine dynamometer is available, follow manufacturer’s
instructions for its use. If dynamometer is not available, refer
to TM 9-2320-280-34 for In Chassis Run-In.
1. Connect engine to dynamometer,
CAUTION
lOperating an engine without sufficient lubricating oil will cause
damage to engine.
● If any leaks or abnormal noise is noted, stop engine immediately
and correct as necessary. Any abnormalities must be corrected
before proceeding to the next test interval.
● Oil pressure should be 40-50 psi (276-345 kPa) under load and
10 psi (69 kPa) minimum at idle. If oil pressure does not meet
specifications, stop engine immediately and correct as necessary.
● Oil temperature must not exceed 260°F ( 127°C) and coolant
temperature must not exceed 230°F (110°C). If coolant
temperature or oil temperature exceed limits, stop engine
immediately and correct as necessary.
2. Start engine and run-in according to schedule in table 2-1.
TM page Change 1 2-189
Table 2-1. 6.2 L Engine Run-In Schedule.
Torque
Speed (rpm) Time (Minutes)
Lb-Ft N•m
650 5 0 0
1200 30 80 109
2000 30 94 128
3000 40 140 190
3600 15 WOT*
4000 0.5 WOT*
* WOT – Wide OpenThrottle. Final test interval at 3600 rpm will
verify the power level of the engine. Power output should be
approximately 150 hp (112 kW) and 219 lb-ft (297 N•m) of torque.
NOT E
Power output should be 135 hp (100.8 kW) and 197.1 lb-ft
(267.3 N•m) of torque when using JP-8 fuel.
Table 2-1.1. 6.5 L (NA) and 6.5 L (T) Engine Run-In Schedule.
Torque
Speed (rpm) Time (Minutes)
Lb-Ft N•m
725 5 0 0
2000 30 103 140
3000 30 133 180
3400 30 146 198
Max 30 No Load
3400 30 WOT*
* WOT – Wide OpenThrottle. Final test interval at 3400 rpm will
verify the power level of the engine. Power output should be
approximately 160 hp (119 kw) at 247 lb-ft (335 N•m) of torque for
naturally aspirated engine. For turbocharged engine, power output
should be 190 hp (142 kw) at 293.5 lb-ft (398 N•m) of torque.
3. Remove engine load and idle until temperatures drop.
3.1. Test governor speed with a WOT no-load test for 30 seconds.
4. Stop engine and inspect for and correct any leaks.
5. Disconnect engine from dynamometer.
TM page 2-190
Section VII. REPAIR AND REPLACEMENT STANDARDS
2-44. GENERAL
All parts, components or assemblies which do not meet the standards specified in para. 2-45 will be
replaced with new material. Parts must be closely inspected to ensure there is no damage in areas not
listed, which would make them unfit for further use.
2-45. REPAIR AND REPLACEMENT STANDARDS
Tables 2-2 and 2-3 list general specifications to be utilized while repairing the engine.
Table 2-2. General Repair Standards (6.2L).
STANDARD METRIC
Cylinder Bore
Diameter 3.976-3.979 in. 100.990-101.066 mm
Out of Round 0.0008 in. 0.0203 mm max.
Taper - Thrust Side 0.0008 in. 0.0203 mm max.
Piston
Piston Clearance – # 1,2, 3,4,5,6 0.0035-0.0045 in. 0.0889-0.1143 mm
Piston Clearance - #7, 8 0.004-0.005 in. 0.102-0.127 mm
Compression Rings
Groove Clearance:
Top 0.003-0.007 in. 0.076-0.178 mm
Second 0.002-0.003 in. 0.051-0.076 mm
Gap:
Top 0.012-0.022 in. 0.30-0.55 mm
Second 0.030-0.039 in. 0.76-1.0 mm
Oil Ring
Groove Clearance 0.002-0.004 in. 0.051-0.102 mm
Gap 0.010-0.020 in. 0.25-0.51 mm
Piston Pin
Diameter 1.2203-1.2206 in. 30.9956-31.0032 mm
Clearance 0.0003-0.0006 in. 0.0076-0.0153 mm
Fit in Rod 0.0003-0.0010 in. 0.0076-0.025 mm
Camshaft
Lift:
Intake 0.281±.002 in. 7.137±0.05 mm
Exhaust 0.281±.002 in. 7.137±0.05 mm
Journal Diameter – # 1,2,3,4 2.164-2.166 in. 54.965-55.016 mm
Journal Diameter - # 5 2.007-2.009 in. 50.978-51.029 mm
Journal Clearance 0.001-0.004 in. 0.025-0.102 mm
Crankshaft
Main Journal Diameter - # 1,2,3,4 2.949-2.950 in. 74.905-74.930 mm
Main Journal Diameter – # 5 2.949-2.950 in. 74.905-74.930 mm
Taper 0.0002 in. max. 0.0051 mm max.
Out of Round 0.0002 in. max. 0.0051 mm max.
Main Bearing Clearance - # 1,2,3,4,5 0.002-0.004 in. 0.051-0.102 mm
End Play 0.004-0.010 in. 0.102-0.254 mm
TM page 2-191