2-45. Repair and Replacement Standards
TM 9-2815-237-34 · Chapter 2 — Engine Maintenance
Table 2-2. General Repair Standards (6.2L) (Cont’d).
STANDARD METRIC
Crankshaft (Cent’d)
Crankpin:
Diameter 2.398-2.399 in. 60.909-60.935 mm
Taper 0.0002 in. max. 0.0051 mm max.
Out of Round 0.0002 in. max. 0.0051 mm max.
Rod Bearing Clearance 0.002-0.004 in. 0.051-0.102 mm
Rod Side Clearance 0.007-0.025 in. 0.178-0.635 mm
Valve Train
Rocker Arm Ratio 1.5:1 1.5:1
Face Angle 45° 45°
Seat Angle 46° 46°
Seat Runout 0.002 in. 0.05 mm
Seat Width:
Intake 0.035-0.060 in. 0.89-1.52 mm
Exhaust 0.062-0.093 in. 1.57-2.36 mm
Stem Clearance:
Intake 0.001-0.003 in. 0.025-0.076 mm
Exhaust 0.001-0.003 in. 0.025-0.076 mm
Valve Spring Force
Closed 80 lb @ 1.8 in. 356 N @ 46.0 mm
Open 230 lb@ 1.39 in. 1023 N @ 35.3 mm
Installed Height 1.8 in. 46.0 mm
Timing Chain Deflection
New Chain 0.5 in. max. 12.7 mm max.
Old Chain 0.81 in. max. 20.6 mm max.
Table 2-3. General Repair Standards (6.5L).
STANDARD METRIC
Cylinder Bore
Diameter 3.978-3.981 in. 101.041-101.12 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
TM page 2-192
Table 2-3. General Repair Standards (6.5L) (Cont’d).
STANDARD METRIC
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±0.002 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
Crankpin:
Diameter 2.398-2.399 in. 60.909-60.935 mm
Taper 0.0002 in. max. 0.0051 mm max.
Out of Round 0.0002 in. max. 0.0051 mm max.
Rod Bearing Clearance 0.002-0.004 in. 0.051-0.102 mm
Rod Side Clearance 0.007-0.025 in. 0.178-0.635 mm
Valve Train
Rocker Arm Ratio 1.5:1 1.5:1
Face Angle 45° 45°
Seat Angle 46° 46°
Seat Runout 0.002 in. 0.05 mm
Seat Width:
Intake 0.035-0.060 in. 0.89-1.52 mm
Exhaust 0.062-0.093 in. 1.57-2.36 mm
Stem Clearance:
Intake 0.001-0.003 in. 0.025-0.076 mm
Exhaust 0.001-0.003 in. 0.025-0.076 mm
Valve Spring Force
Closed 80 lb @ 1.8 in. 356 N @ 46.0 mm
Open 230 lb@ 1.39 in. 1023 N @ 35.3 mm
Installed Height 1.8 in. 46.0 mm
Timing Chain Deflection
New Chain 0.5 in. max. 12.7 mm max.
Old Chain 0.81 in. max. 20.6 mm max.
PDF page 241
Table 2-4. 6.2L Diesel Engine Piston-Cylinder Specification. PISTON CODE PISTON SIZE CYLINDER SIZE Standard S5 3.9749 in. to 3.9754 in. 3.9778 in. to 3.9784 in. PN 23500391 (100.962-100.975 mm) (101.036-101.051 mm) Standard Hi-Limit S7 3.9759 in. to 3.9765 in. 3.9788 in. to 3.9794 in. PN 23500392 (100.988-101.003 mm) (101.061-101.077 mm) Oversized 2 4.0044 in. to 4.0050 in. 4.0074 in. to 4.0079 in. PN 23500393 (101.712-101.727 mm) (101.788-101.801 mm) Oversized 3 4.0050 in. to 4.0055 in. 4.0079 in. to 4.0085 in. PN 23500393 (101.727-101.740 mm) (101.801-101.816 mm) Use standard ring set, part number (11862) 15537018, NSN 2815-01-163-7838, with standard and standard Hi-Limit pistons. Oversized piston (0.75 mm) ring set part number is (11862) 15537020, NSN 2815-01-163-9999. Table 2-5. 6.5L Diesel Engine Piston-Cylinder Specification. PISTON CODE PISTON SIZE CYLINDER SIZE Standard 4.0529 in. to 4.0534 in. 4.0571 in. to 4.0576 in. (11862) 12550059 (102.944-102.956 mm) (103.050-103.063 mm) 0.50 mm Oversized 4.0739 in. to 4.0745 in. 4.0782 in. to 4.0787 in. (11862) 12550062 (103.477-103.492 mm) (103.586-103.599 mm) Piston ring set part numbers are: Standard – (11862) 12510752 0.50 mm Oversized – (11862) 12510753 The 6.5L engine does not have a standard Hi-Limit piston. Change 1 2-193/(2-194 blank)
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