Appendix F — Torque Limits
TM 9-2815-237-34 · Appendix F
TORQUE LIMITS
F-1 GENERAL
This section provides general torque limits for screws used on the M998 series vehicles. Special torque limits are indicated in the maintenance procedures for applicable components. The general torque limits given in this appendix shall be used when specific torque limits are not indicated in the maintenance procedure. Unless otherwise specified, standard torque tolerance shall be ± 10 percent. These general torque limits cannot be applied to screws that retain rubber components. The rubber components will be damaged before the correct torque limit is reached. If a special torque limit is not given in the maintenance instructions, tighten the screw or nut until it touches the metal bracket, then tighten it one more turn.
F-2. TORQUE LIMITS
Table F-1 lists dry torque limits. Dry torque limits are used on screws that do not have lubricants applied to the threads. Table F-2 lists wet torque limits. Wet torque limits are used on screws that have high pressure lubricants applied to the threads.
F-3. HOW TO USE TORQUE TABLE
c. Under the heading SIZE, look down the left-hand column until you find the diameter of the screw you are installing (there will usually be two lines beginning with the same size).
d. In the second column under SIZE, find the number of threads per inch that matches the number of threads you counted in step b.
CAPSCREW HEAD MARKINGS Manufacturer’s marks may vary. These are all SAE Grade 5 (3-line).
a. Measure the diameter of the screw you are installing.
e. lb find the grade of screw you are installing, match he markings on the head to the correct picture of CAPSCREW HEAD MARKINGS on the torque table.
f. Look down the column under the picture you found in step e. until you find the torque limit (in lb-ft or N•m) for the diameter and threads per inch of the screw you are installing.
b. Count the number of threads per inch.
F-1
PDF page 258
Table F-1. Torque Limits for Dry Fasteners
CAPSCREW HEAD MARKINGS
SIZE SAE GRADE SAE GRADE SAE GRADE SAE GRADE
NO. 1 or 2 No. 5 NO .6 or 7 No. 8
DIA. THREADS MILLIMETERS POUND NEWTON POUND NEWTON POUND NEWTON POUND NEWTON
INCHES PER INCH FEET MIETER5 FEET METERS FEET METERS FEET METERS
1/4 20 6.35 5 6.78 8 10.85 10 13.56 12 16.27
/14 28 6.35 6 8.14 10 13.56 14 18.98
5/16 18 7.94 11 14.92 17 23.05 19 25.76 24 32.52
5/16 24 7.94 13 17.63 19 25.76 27 36.61
3/8 16 9.53 18 24.41 31 42.04 34 46.10 44 59.66
3/8 24 9.53 20 27.12 35 47.46 49 66.44
7/16 14 11.11 28 37.97 49 66.44 55 74.58 70 94.92
7/16 20 — 30 40.68 55 74.58 78 105.77
1/2 13 12.70 39 52.88 75 101.70 85 115.26 105 142.38
1/2 20 41 55.60 85 115.26 120 162.72
9/16 12 14.29 51 69.16 110 149.16 120 162.72 155 210.18
9/16 18 55 74.58 120 162.72 170 230.52
5/8 11 15.88 63 85.43 150 203.40 167 226.45 210 284.76
5/8 18 95 128.82 170 230.52 240 325.44
3/4 10 19.05 105 142.38 270 366.12 280 379.68 375 508.50
3/4 16 115 155.94 295 400.02 420 569.52
7/8 9 22.23 160 216.96 395 535.62 440 596.64 605 820.38
7/8 14 175 237.30 435 589.86 675 915.30
1 8 25.40 235 318.66 590 800.04 660 894.96 910 1233.96
1 14 250 339.00 660 894.96 990 1342.44
1-1/8 25.58 800- 1084.8- 1280- 1735.7-
880 1193.3 1440 1952.8
1-1/4 31.75 1820- 2467.9-
2000 2712.0
1-3/8 34.93 1460- 1979.8 2380- 3227.3-
1680 2278.1 2720 3688.3
l-1/2 38.10 1940- 2630.6- 3160- 4285.0-
2200 2983.2 3560 4827.4
F-2
PDF page 259
Table F-2. Torque Limits for Wet Fasteners
CAPSCREW HEAD MARKINGS
TORQUE
SIZE SAE GRADE SAE GRADE SAE GRADE SAE GRADE
NO. 1 or 2 NO. 5 NO. 6 or 7 NO. 8
DIA. THREADS MILLIMETERS POUND NEWTON POUND NEWTON POUND NEWTON POUND NEWTON
INCHES PER INCH FEET METERS FEET METERS FEET METERS FEET METERS
1/4 20 6.35 4.5 6.10 7.2 9.76 9.0 12.20 10.8 14.64
1/4 28 6.35 5.4 7.33 9.0 12.20 – – 12.6 17.08
5/16 18 7.94 9.9 13.43 15.3 20.75 17.1 23.18 21.6 29.27
5/16 24 7.94 11.7 15.87 17.1 23.18 – – 24.3 32.95
3/8 16 9.53 16.2 21.97 27.9 37.84 30.6 41.49 39.6 53.69
3/8 24 9.53 18.0 24.41 31.5 42.71 – – 44.1 59.80
7/16 14 11.11 25.2 34.17 44.1 59.80 49.5 67.12 63.0 85.42
7/16 20 – 27.0 36.61 49.5 67.12 – – 70.2 95.19
1/2 13 12.70 35.1 47.59 67.5 91.53 76.5 103.73 94.5 128.14
1/2 20 – 36.9 50.04 76.5 103.73 – – 108.0 146.45
9/16 12 14.29 45.9 62.24 99.0 134.24 108.0 146.45 139.5 189.16
9/16 18 – 49.5 67.12 108.0 146.45 – – 153.0 207.47
5/8 11 15.88 56.7 76.89 135.0 183.06 150.3 203.80 189.0 256.28
5/8 18 – 85.5 115.94 153.0 207.47 – – 216.0 296.90
3/4 10 19.05 94.5 128.14 243.0 329.51 252.0 341.71 337.5 457.65
3/4 16 – 103.5 140.35 265.5 360.02 – – 378.0 536.87
7/8 9 22.23 144.0 195.26 355.5 482.06 396.0 536.98 544.5 738.34
7/8 14 – 157.5 213.57 391.5 530.87 – – 607.5 823.77
1 8 25.40 211.5 286.79 531.0 720.04 594.0 805.46 819.0 1110.56
1 14 – 225.0 305.10 594.0 805.46 – – 891.0 1208.20
1-1/8 – 25.58 – – 720.0- 976.32- – – 1152.0- 1562.13-
792.0 1073.97 1296.0 1757.52
1-1/4 – 31.75 – – – – – – 1638- 2221.11-
1800 2440.80
1-3/8 – 34.93 – – 1314.0- 1781.82- – – 2142.0- 2904.57-
1512.0 2050.29 2448.0 3319.47
1-1/2 – 38.10 – – 1746.0- 2367.54- – – 2844.0 3856.5-
1980.0 2684.88 3204.0 4344.66
Change 1 F-3/(F-4 blank)
TM page Change 1 Index 1
INDEX
Para. Page Para. Page
A Crankshaft:
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-17a 2-52
Adapter, oil filter:
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-17b 2-52
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-28a 2-82
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17c 2-52
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-28b 2-82
Cylinder block:
Appendix A:
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-16b 2-40
Army regulations . . . . . . . . . . . . . . A-8 A-2
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-16c 2-42
Field manuals . . . . . . . . . . . . . . . . . . A-4 A-1
Preinspection. . . . . . . . . . . . . . . . . . . 2-16a 2-40
Forms . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 A-1
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16d 2-44
Publications index . . . . . . . . . . . . . A-2 A-1
Cylinder head and valves:
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-21f 2-68
Technical bulletins . . . . . . . . . . . . . A-6 A-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-21b 2-64
Technical manuals . . . . . . . . . . . . . A-5 A-2
Disassembly. . . . . . . . . . . . . . . . . . . . 2-21a 2-62
Appendix B:
Grinding valve seats . . . . . . . . . . . 2-21e 2-66
Expendable/durable supplies
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-21c 2-64
and materials list . . . . . . . . . . . . . B-1
Refacing valves . . . . . . . . . . . . . . . . 2-21d 2-66
Appendix C:
Illustrated list of D
manufactured items . . . . . . . . . . C-1
Appendix D: Description . . . . . . . . . . . . . . . . . . . . . . . 1-10 1-2
Mandatory replacement parts. . D-1 Destruction of Army equip-
Appendix E: ment to prevent enemy use. . . . . . 1-3 1-1
Tool identification list. . . . . . . . . . E-1 Drive, fan:
Appendix F: Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-40d 2-152
Torque limits. . . . . . . . . . . . . . . . . . . F-1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-40b 2-150
Disassembly. . . . . . . . . . . . . . . . . . . . 2-40a 2-148
B Inspection . . . . . . . . . . . . . . . . . . . . . . 2-40c 2-150
Drive gears, camshaft,
Block, cylinder:
and timing chain:
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-16b 2-40
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-19a 2-58
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-16c 2-42
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-19b 2-58
Preinspection. . . . . . . . . . . . . . . . . . . 2-16a 2-40
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16d 2-44 E
C Equipment improvement
report and maintenance
Calibration, equipment
digest (EIR MD) . . . . . . . . . . . . . . . . . 1-7 1-1
requiring . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1-1
Equipment requiring
Calibration, fuel injection
calibration . . . . . . . . . . . . . . . . . . . . . . . 1-5 1-1
pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 2-126
Engine assembly from
Calibration, 1990 6.2L fuel
subassemblies:
injection pump . . . . . . . . . . . . . . . . . . 2-34 2-131
Camshaft. . . . . . . . . . . . . . . . . . . . . . . 2-41e 2-163
Calibration, 1994 6.5L fuel
Crankshaft and main
injection pump . . . . . . . . . . . . . . . . . . 2-35 2-136
bearings. . . . . . . . . . . . . . . . . . . . . . . 2-41a 2-154
Camshaft, timing chain,
Crankshaft pulley . . . . . . . . . . . . . . 2-41aa 2-186
and drive gears:
Cylinder heads . . . . . . . . . . . . . . . . . 2-41o 2-173
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-19a 2-58
Exhaust manifolds . . . . . . . . . . . . . 2-41y 2-184
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-19b 2-58
Fan drive and water
Component location . . . . . . . . . . . . . . 1-11 1-3
pump pulley . . . . . . . . . . . . . . . . . . 2-41bb 2-187
Connecting rod and piston:
Flywheel . . . . . . . . . . . . . . . . . . . . . . . 2-41b 2-158
Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-18d 2-56
Fuel injection lines . . . . . . . . . . . . . 2-41v 2-180
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-18b 2-54
Fuel injection nozzles . . . . . . . . . . 2-41q 2-175
Disassembly. . . . . . . . . . . . . . . . . . . . 2-18a 2-54
Fuel injection pump . . . . . . . . . . . . 2-41l 2-170
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-18c 2-54
Fuel pump . . . . . . . . . . . . . . . . . . . . . 2-41j 2-168
Cover, rocker arm:
Fuel supply and return lines . . . 2-41u 2-179
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-25a 2-76
Glow plugs . . . . . . . . . . . . . . . . . . . . . 2-41p 2-174
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-25b 2-76
Intake manifold . . . . . . . . . . . . . . . . 2-41x 2-182
Cover, timing gear:
Modulator link . . . . . . . . . . . . . . . . . 2-41t 2-178
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-20a 2-60
Manifold-to-turbocharger
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-20b 2-60
exhaust pipe . . . . . . . . . . . . . . . . . . 2-41y.2 2-184.1
TM page Index 2 Change 2
INDEX (Cont’d)
Para. Page Para. Page
E (Cont’d) Engine disassembly into
Engine assembly from subassemblies (cont’d):
subassemblies (cont’d): Wastegate actuator . . . . . . . . . . . . 2-15c.1 2-12.1
Oil filter and adapter . . . . . . . . . . 2-41i 2-167 Wastegate housing . . . . . . . . . . . . . 2-15c.2 2-12.1
Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . 2-41h 2-166 Water crossover . . . . . . . . . . . . . . . . 2-15f 2-15
Oil pump . . . . . . . . . . . . . . . . . . . . . . . 2-41d 2-162 Water pump and adapter plate . 2-15p 2-25
Oil pump drive . . . . . . . . . . . . . . . . . 2-41k 2-169 Engine disassembly, repair, and
Pistons and connecting rods. . . . 2-41c 2-159 assembly task summary. . . . . . . . . 2-6.1
Rocker arm covers . . . . . . . . . . . . . 2-41s 2-177 Engine replacement in shipping/
Rocker arm shafts storage container:
and pushrods . . . . . . . . . . . . . . . . . 2-41r 2-176 Installation. . . . . . . . . . . . . . . . . . . . . 2-13.1b 2-6.2
Timing chain and Removal. . . . . . . . . . . . . . . . . . . . . . . . 2-13.1a 2-6.2
drive sprockets. . . . . . . . . . . . . . . . 2-41f 2-164 Engine run-in:
Timing gear cover . . . . . . . . . . . . . . 2-41g 2-165 Out of chassis run-in . . . . . . . . . . . 2-43 2-188
Torsional damper . . . . . . . . . . . . . . 2-41z 2-185 Engine run-in schedule, 6.2L
Turbocharger. . . . . . . . . . . . . . . . . . . 2-41y.1 2-184.1 (table 2-1): . . . . . . . . . . . . . . . . . . . . . . . 2-189
Valve lifters . . . . . . . . . . . . . . . . . . . . 2-41n 2-172 Engine run-in schedule, 6.5L
Wastegate actuator . . . . . . . . . . . . 2-41y.4 2-184.2 (table 2-1.1): . . . . . . . . . . . . . . . . . . . . . 2-189
Wastegate housing . . . . . . . . . . . . . 2-41y.3 2-184.2 Exhaust manifold:
Water pump and Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-29a 2-83
adapter plate . . . . . . . . . . . . . . . . . 2-41m 2-171 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-29b 2-83
Water crossover . . . . . . . . . . . . . . . . 2-41w 2-181 F
Engine disassembly into
subassemblies: Fan drive:
Camshaft. . . . . . . . . . . . . . . . . . . . . . . 2-15y 2-34 Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-40d 2-152
Crankshaft and main Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-40b 2-150
bearings. . . . . . . . . . . . . . . . . . . . . . . 2-15bb 2-37 Disassembly. . . . . . . . . . . . . . . . . . . . 2-40a 2-148
Crankshaft pulley . . . . . . . . . . . . . . 2-15b 2-11 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-40c 2-150
Cylinder heads . . . . . . . . . . . . . . . . . 2-15n 2-23 Final inspection:
Exhaust manifolds . . . . . . . . . . . . . 2-15d 2-13 General . . . . . . . . . . . . . . . . . . . . . . . . 2-42 2-188
Fan drive and water Flywheel:
pump pulley . . . . . . . . . . . . . . . . . . 2-15a 2-10 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-24a 2-75
Flywheel . . . . . . . . . . . . . . . . . . . . . . . 2-15aa 2-36 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-24b 2-75
Fuel injection lines . . . . . . . . . . . . . 2-15g 2-16 Fuel injection nozzle:
Fuel injection nozzles . . . . . . . . . . 2-15l 2-21 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-37a 2-142
Fuel injection pump . . . . . . . . . . . . 2-15q 2-26 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-37b 2-142
Fuel pump . . . . . . . . . . . . . . . . . . . . . 2-15w 2-32 Testing . . . . . . . . . . . . . . . . . . . . . . . . . 2-37c 2-142
Fuel supply and return lines . . . 2-15h 2-17 Fuel injection pump:
Glow plugs . . . . . . . . . . . . . . . . . . . . . 2-15m 2-22 Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-32d 2-107
Intake manifold . . . . . . . . . . . . . . . . 2-15e 2-14 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-32b 2-98
Manifold-to-turbocharger Disassembly. . . . . . . . . . . . . . . . . . . . 2-32a 2-86.2
exhaust pipe . . . . . . . . . . . . . . . . . . 2-15c.3 2-12.2 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-32c 2-98
Modulator link . . . . . . . . . . . . . . . . . 2-15i 2-18 Fuel injection pump (DB2831-5209)
Oil filter, adapter, and oil calibration (6.5L):
pressure sending unit. . . . . . . . . 2-15t 2-29 Injection pump check
Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . 2-15u 2-30 (prior to service) . . . . . . . . . . . . . . . 2-35.1c 2-140.2
Oil pump . . . . . . . . . . . . . . . . . . . . . . . 2-15v 2-31 Injection pump information. . . . . 2.35.1b 2-140.2
Oil pump drive . . . . . . . . . . . . . . . . . 2-15x 2-33 Injection pump settings
Pistons and connecting rods. . . . 2-15z 2-35 (following pump repair). . . . . . . . 2.35.1d 2-140.3
Rocker arm covers . . . . . . . . . . . . . 2-15j 2-19 Test bench requirements . . . . . . . 2-35.1a 2-140.1
Rocker arm shafts Fuel injection pumps (DB2829-4523,
and pushrods . . . . . . . . . . . . . . . . . 2-15k 2-20 DB2829-4879, or DB2831-5149)
Timing chain and calibration using fuel injection
drive sprockets. . . . . . . . . . . . . . . . 2-15s 2-28 pump test stand (FTIS) model
Timing gear cover . . . . . . . . . . . . . . 2-15r 2-27 A8022 (6.2L or 6.5L):
Torsional damper . . . . . . . . . . . . . . 2-15c 2-12 Mounting fuel injection pump
Turbocharger. . . . . . . . . . . . . . . . . . . 2-15c.4 2-12.2 on test stand . . . . . . . . . . . . . . . . . . 2.35.3a 2-140.12
Valve lifters . . . . . . . . . . . . . . . . . . . . 2-15o 2-24 Removal of fuel injection pump
from test stand . . . . . . . . . . . . . . . . 2.35.3c 2-140.21
Test stand setup procedures . . . . 2.35.3b 2-140.18
TM page Change 2 Index 3
INDEX (Cont’d)
Para. Page Para. Page
F (Cont’d) H
Head, cylinder and valves:
Fuel injection pumps (DB2831-5485 Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-21f 2-68
or DB2831-5079) calibration (6.5L): Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-21b 2-64
Injection pump check Disassembly. . . . . . . . . . . . . . . . . . . . 2-21a 2-62
(prior to service) . . . . . . . . . . . . . . . 2.35.2c 2-140.7 Grinding valve seats . . . . . . . . . . . 2-21e 2-66
Injection pump information. . . . . 2.35.2b 2-140.7 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-21c 2-64
Injection pump settings Refacing valves . . . . . . . . . . . . . . . . 2-21d 2-66
(following pump repair). . . . . . . . 2.35.2d 2-140.8
Test bench requirements . . . . . . . 2.35.2a 2-140.6 I
Fuel injection pump Intake manifold:
calibration, 1990 and above (6.2L) 2-34 2-131 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-30a 2-84
Fuel injection pump Inspection . . . . . . . . . . . . . . . . . . . . . . 2-30b 2-84
calibration, (6.5L) . . . . . . . . . . . . . . . 2-35 2-131
Fuel injection pump M
calibration, pre-1990 (6.2L) . . . . . 2-33 2-126
Fuel pump: Maintenance forms, records,
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-31a 2-85 and reports . . . . . . . . . . . . . . . . . . . . . . 1-2 1-1
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-31b 2-85 Mandatory replacement parts . . . . 1-9 1-2
Manifold, exhaust:
G Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-29a 2-83
General information, Inspection . . . . . . . . . . . . . . . . . . . . . . 2-29b 2-83
introduction: Manifold, intake:
Component location . . . . . . . . . . . . 1-11 1-3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-30a 2-84
Description . . . . . . . . . . . . . . . . . . . . . 1-10 1-2 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-30b 2-84
Destruction of army equip- Metric system . . . . . . . . . . . . . . . . . . . . 1-8 1-2
ment to prevent enemy use . . . 1-3 1-1 Mounting engine on
Equipment improvement repair stand:
report and maintenance Installation. . . . . . . . . . . . . . . . . . . . . 2-14a 2-8
digest (EIR MD) . . . . . . . . . . . . . . 1-7 1-1 Removal. . . . . . . . . . . . . . . . . . . . . . . . 2-14b 2-8
Equipment requiring
calibration . . . . . . . . . . . . . . . . . . . . 1-5 1-1 N
Maintenance forms, Nozzle, fuel injection:
records, and reports. . . . . . . . . . . 1-2 1-1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-37a 2-142
Mandatory replacement parts. . 1-9 1-2 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-37b 2-142
Metric system . . . . . . . . . . . . . . . . . . 1-8 1-2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . 2-37c 2-142
Preparation for shipment . . . . . . 1-4 1-1
Reporting equipment improve- O
ment recommendations (EIR 5) 1-6 1-1
Scope of manual. . . . . . . . . . . . . . . . 1-1 1-1 Oil filter adapter and
Tabulated data . . . . . . . . . . . . . . . . . 1-12 1-4 oil pressure sending unit:
General maintenance instructions: Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-28a 2-82
Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-12 2-6 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-28b 2-82
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-9 2-3 Oil pan:
General maintenance instruc- Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-26a 2-77
tions task summary. . . . . . . . . . . 2-8 2-3 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-26b 2-77
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-10 2-4 Oil pump:
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2-5 Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-27d 2-80
General repair standards, Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-27b 2-78
(6.2L) engine (table 2-2). . . . . . . . 2-190 Disassembly. . . . . . . . . . . . . . . . . . . . 2-27a 2-78
General repair standards, Inspection . . . . . . . . . . . . . . . . . . . . . . 2-27c 2-78
(6.5L) engine (table 2-3). . . . . . . . 2-191
Glow plugs: P
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-36a 2-141 Pan, oil:
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-36b 2-141 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-26a 2-77
Testing . . . . . . . . . . . . . . . . . . . . . . . . . 2-36c 2-141 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-26b 2-78
TM page Index 4 Change 2
INDEX (Cont’d)
Para. Page Para. Page
P (Cont’d) T
Piston and connecting rod: Tables:
Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-18d 2-56 6.2L diesel engine piston-
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-18b 2-54 cylinder specifications
Disassembly. . . . . . . . . . . . . . . . . . . . 2-18a 2-54 (table 2-4) . . . . . . . . . . . . . . . . . . . . . 2-45 2-193
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-18c 2-54 6.5L diesel engine piston-
Plugs, glow: cylinder specifications
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-36a 2-141 (table 2-5) . . . . . . . . . . . . . . . . . . . . . 2-45 2-193
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-36b 2-141 Engine run-in schedule (6.2L)
Testing . . . . . . . . . . . . . . . . . . . . . . . . . 2-36c 2-141 (table 2-1) . . . . . . . . . . . . . . . . . . . . . 2-43 2-189
Preparation for shipment . . . . . . . . . 1-4 1-1 Engine run-in schedule (6.5L)
Pump, fuel injection: (table 2-1.1) . . . . . . . . . . . . . . . . . . . 2-43 2-189
Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-32d 2-107 General repair standards (6.2L)
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-32b 2-98 (table 2-2) . . . . . . . . . . . . . . . . . . . . . 2-45 2-190
Disassembly. . . . . . . . . . . . . . . . . . . . 2-32a 2-86.2 General repair standards (6.5L)
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-32c 2-98 (table 2-3) . . . . . . . . . . . . . . . . . . . . . 2-45 2-191
Pump, fuel: Standard torque
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-31a 2-85 specifications (table F-1) . . . . . . F-1
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-31b 2-85 Tabulated data (table 1-1) . . . . . 1-12 1-4
Pump, oil: Timing chain, drive gears,
Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-27d 2-80 and camshaft:
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-27b 2-78 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-19a 2-58
Disassembly. . . . . . . . . . . . . . . . . . . . 2-27a 2-78 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-19b 2-58
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-27c 2-78 Timing gear cover:
Pump, water: Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-20a 2-60
Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-38d 2-144 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-20b 2-60
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-38b 2-144 Torsional dampener:
Disassembly. . . . . . . . . . . . . . . . . . . . 2-38a 2-144 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-23a 2-74
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-38c 2-144 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23b 2-74
R V
Repair and replacement Valve train:
standards: Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-22d 2-72
General . . . . . . . . . . . . . . . . . . . . . . . . 2-44 2-190 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-22b 2-72
Repair and replacement Disassembly. . . . . . . . . . . . . . . . . . . . 2-22a 2-72
standards . . . . . . . . . . . . . . . . . . . . . 2-45 2-190 Inspection . . . . . . . . . . . . . . . . . . . . . . 2-22c 2-72
Table 2.2, general repair
standards (6.2L) . . . . . . . . . . . . . . 2-45 2-190 W
Rocker arm cover: Water crossover:
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-25a 2-76 Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-39d 2-147
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-25b 2-76 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-39b 2-146
Disassembly. . . . . . . . . . . . . . . . . . . . 2-39a 2-146
S Inspection . . . . . . . . . . . . . . . . . . . . . . 2-39c 2-146
Scope of manual . . . . . . . . . . . . . . . . . . 1-1 1-1 Water pump:
Specifications: Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-38d 2-144
Piston-cylinder, diesel engine, Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-38b 2-144
6.2L (table 2-4). . . . . . . . . . . . . . . . 2-193 Disassembly. . . . . . . . . . . . . . . . . . . . 2-38a 2-144
Piston-cylinder, diesel engine, Inspection . . . . . . . . . . . . . . . . . . . . . . 2-38c 2-144
6.5L (table 2-5). . . . . . . . . . . . . . . . 2-193
PDF page 264
By Order of the Secretary of the Army: DENNIS J. REIMER General, United States Army Chief of Staff
Official:
YVONNE M. HARRISON Administrative Assistant to the Secretary of the Army 01399
By Order of the Secretary of the Air Force: RONALD R. FOGLEMAN General, United States Air Force Chief of Staff Official:
HENRY VICCELLIO, JR. General, United States Air Force Commander, Air Force Materiel Command
By Order of the Marine Corps:
D. R . B L O O M E R Colonel, United States Marine Corps Director, Program Support Marine Corps Systems Command
Distribution:
To be distributed in accordance with DA Form 12-38-E (Block 0623) requirements for, “ TM 9-2815-237-34.
PDF page 265
RECOMMENDED CHANGES TO Use Part II (reverse) for Repair Parts and DATE:
PUBLICATIONS AND BLANK FORMS Special Tools Lists (RPSTL) and Supply
14 Dec 2001
For use of this form, see AR 25-30; the proponent Catalogs/Supply Manuals (SC/SM).
agency is ODISC4.
TO: (Forward to proponent of publication or form) (include ZIP code) FROM: (Activity and location) (include ZIP code)
AMSTA-LC-CI Tech Pubs, TACOM-RI Co. B, 1st BN, 2nd Brigade
1 Rock Island Arsenal Ft. Hood, TX 76445
Rock Island, IL 61299-7630
PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER: DATE: TITLE:
TECHNICAL MANUAL, DIRECT SUPPORT AND
TM 9-2320-237-34 31 JANUARY 96
GENERAL SUPPORT MAINTENACE
ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO.* NO. NO. (Provide exact wording of recommended changes, if possible).
1 2-45 2-16 In step f, cross-hatch pattern can
range from 45º to 65º.
2 1-5 1-2 Normal operating temperature of the
cooling system is 190º - 230ºF
(88º - 110ºC).
SAMPLE
*Reference to line numbers within the paragraph or subparagraph.
TYPED NAME, GRADE, OR TITLE: TELEPHONE EXCHANGE/AUTOVON, SIGNATURE:
PLUS EXTENSION:
Pat Smith, ILT AV272-4162 Pat Smith, ILT
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00
PDF page 266
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (include ZIP code) DATE: AMSTA-LC-CI Tech Pubs, TACOM-RI 1 Rock Island Arsenal Rock Island, IL 61299-7630 PART II - REPAIR PARTS AND SPECIAL TOOLS LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION/FORM NUMBER: DATE: TITLE:
TM 9-2320-237-34 TECHNICAL MANUAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENACE TOTAL NO. OF MAJOR
PAGE COLM LINE NATIONAL REFERENCE FIGURE ITEM ITEMS RECOMMENDED NO. NO. NO. STOCK NUMBER NO. NO. NO. SUPPORTED ACTION
SAMPLE
P A R T I I I - R E M A R K S (any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
TYPED NAME, GRADE, OR TITLE: TELEPHONE EXCHANGE/AUTOVON, SIGNATURE: PLUS EXTENSION:
USAPPC V3.00
PDF page 267
RECOMMENDED CHANGES TO Use Part II (reverse) for Repair Parts and DATE:
PUBLICATIONS AND BLANK FORMS Special Tools Lists (RPSTL) and Supply
For use of this form, see AR 25-30; the proponent Catalogs/Supply Manuals (SC/SM).
agency is ODISC4.
TO: (Forward to proponent of publication or form) FROM: (Activity and location) (include ZIP code)
(include ZIP code)
AMSTA-LC-CI Tech Pubs, TACOM-RI
1 Rock Island Arsenal
Rock Island, IL 61299-7630
PA RT I - A L L P U B L I C AT I O N S ( E X C E P T R P S T L A N D S C / S M ) A N D B L A N K F O R M S
PUBLICATION/FORM NUMBER DATE TITLE
TM 9-2320-237-34 31 JAN 96 TECHNICAL MANUAL, DIRECT SUPPORT AND
GENERAL SUPPORT MAINTENANCE
ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO.* NO. NO. (Provide exact wording of recommended changes, if possible).
*Reference to line numbers within the paragraph or subparagraph.
TYPED NAME, GRADE, OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00
PDF page 268
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) DATE:
(include ZIP code)
AMSTA-LC-CI Tech Pubs, TACOM-RI
1 Rock Island Arsenal
Rock Island, IL 61299-7630
PA RT I I - R E PA I R PA RT S A N D S P E C I A L T O O L S L I S T S A N D S U P P LY C ATA L O G S / S U P P LY M A N U A L S
PUBLICATION/FORM NUMBER DATE TITLE
TM 9-2320-237-34 31 JAN 96 TECHNICAL MANUAL, DIRECT SUPPORT
AND GENERAL SUPPORT MAINTENANCE
TOTAL NO.
OF MAJOR
PAGE COLM LINE NATIONAL REFERENCE FIGURE ITEM ITEMS RECOMMENDED
NO. NO. NO. STOCK NUMBER NO. NO. NO. SUPPORTED ACTION
PA RT I I I - R E M A R K S (Any general remarks or recommendations, or suggestions for improvement of publications and blank forms.
Additional blank sheets may be used if more space is needed.)
TYPED NAME, GRADE, OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
USAPPC V3.00
PDF page 269
PIN: 058004-002
PDF page 270
THE METRIC SYSTEM AND EQUIVALENTS
LINEAR MEASURE LIQUID MEASURE
1 Centimeter = 10 Millimeters = 0.01 Meters = 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces
0.3937 Inches 1 Liter = 1,000 Milliliters = 33.82 Fluid Ounces
1 Meter = 100 Centimeters = 1,000 Millimeters = TEMPERATURE
39.37 Inches Degrees Fahrenheit (F) = °C • 9 ÷ 5 + 32
1 Kilometer = 1,000 Meters = 0.621 Miles Degrees Celsius (C) = F° - 32 • 5 ÷ 9
SQUARE MEASURE 212° Fahrenheit is equivalent to 100° Celsius
1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 90° Fahrenheit is equivalent to 32.2° Celsius
1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 32° Fahrenheit is equivalent to 0° Celsius
1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles WEIGHTS
CUBIC MEASURE 1 Gram = 0.001 Kilograms = 1,000 Milligrams =
1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 0.035 Ounces
1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet 1 Kilogram = 1,000 Grams = 2.2 Lb
1 Metric Ton = 1,000 Kilograms = 1 Megagram = 1.1 Short Tons
APPROXIMATE CONVERSION FACTORS
TO CHANGE . . . . . . . . . . . . . . . . . . . TO . . . . . . . . . . . . . . . . . . . . . . .MULTIPLY BY
Inches . . . . . . . . . . . . . . . . . . . . . . . . Millimeters . . . . . . . . . . . . . . . . . 25.4
Inches . . . . . . . . . . . . . . . . . . . . . . . . Centimeters . . . . . . . . . . . . . . . . 2.540
Feet . . . . . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . 0.305
0
0
INCHES
CENTIMETERS
Yards . . . . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . 0.914
Miles . . . . . . . . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . . . . . 1.609
Square Inches . . . . . . . . . . . . . . . . . Square Centimeters . . . . . . . . . . 6.451
1
Square Feet . . . . . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . 0.093
Square Yards . . . . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . 0.836
2
Square Miles . . . . . . . . . . . . . . . . . . Square Kilometers . . . . . . . . . . . 2.590
Acres . . . . . . . . . . . . . . . . . . . . . . . . Square Hectometers . . . . . . . . . . 0.405
1
Cubic Feet . . . . . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . 0.028
3
Cubic Yards . . . . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . 0.765
Fluid Ounces . . . . . . . . . . . . . . . . . . Milliliters . . . . . . . . . . . . . . . . . . 29.573
Pints . . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . 0.473
4
Quarts . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . 0.946
Gallons . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . 3.785
Ounces . . . . . . . . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . . . . . . 28.349
5
2
Pounds . . . . . . . . . . . . . . . . . . . . . . . Kilograms . . . . . . . . . . . . . . . . . . 0.4536
Short Tons . . . . . . . . . . . . . . . . . . . . Metric Tons . . . . . . . . . . . . . . . . 0.907
6
Pound-Feet . . . . . . . . . . . . . . . . . . . . Newton-Meters . . . . . . . . . . . . . . 1.356
Pounds Per Square Inch . . . . . . . . . Kilopascals . . . . . . . . . . . . . . . . . 6.895
Miles Per Gallon . . . . . . . . . . . . . . . Kilometers Per Liter . . . . . . . . . 0.425
7
Miles Per Hour . . . . . . . . . . . . . . . . Kilometers Per Hour . . . . . . . . . 1.609
TO CHANGE . . . . . . . . . . . . . . . . . . . TO . . . . . . . . . . . . . . . . . . . . . . .MULTIPLY BY 3
8
Millimeters . . . . . . . . . . . . . . . . . . . . Inches . . . . . . . . . . . . . . . . . . . . . 0.03937
Centimeters . . . . . . . . . . . . . . . . . . . Inches . . . . . . . . . . . . . . . . . . . . . 0.3937
Meters . . . . . . . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . . . . 3.280 9
Meters . . . . . . . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . . . . 1.094
Kilometers . . . . . . . . . . . . . . . . . . . . Miles . . . . . . . . . . . . . . . . . . . . . . 0.621
10
Square Centimeters . . . . . . . . . . . . . Square Inches . . . . . . . . . . . . . . . 0.155
4
Square Meters . . . . . . . . . . . . . . . . . Square Feet . . . . . . . . . . . . . . . . 10.764
Square Meters . . . . . . . . . . . . . . . . . Square Yards . . . . . . . . . . . . . . . 1.196
11
Square Kilometers . . . . . . . . . . . . . . Square Miles . . . . . . . . . . . . . . . 0.386
Square Hectometers . . . . . . . . . . . . . Acres . . . . . . . . . . . . . . . . . . . . . . 2.471
Cubic Meters . . . . . . . . . . . . . . . . . . Cubic Feet . . . . . . . . . . . . . . . . . 35.315
12
Cubic Meters . . . . . . . . . . . . . . . . . . Cubic Yards . . . . . . . . . . . . . . . . 1.308
Milliliters . . . . . . . . . . . . . . . . . . . . . Fluid Ounces . . . . . . . . . . . . . . . 0.034
5
Liters . . . . . . . . . . . . . . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . . . . . . . 2.113
13
Liters . . . . . . . . . . . . . . . . . . . . . . . . Quarts . . . . . . . . . . . . . . . . . . . . 1.057
Liters . . . . . . . . . . . . . . . . . . . . . . . . Gallons . . . . . . . . . . . . . . . . . . . . 0.264
14
Grams . . . . . . . . . . . . . . . . . . . . . . . Ounces . . . . . . . . . . . . . . . . . . . . 0.035
Kilograms . . . . . . . . . . . . . . . . . . . . . Pounds . . . . . . . . . . . . . . . . . . . . 2.2046
Metric Tons . . . . . . . . . . . . . . . . . . . Short Tons . . . . . . . . . . . . . . . . . 1.102
15
Newton-Meters . . . . . . . . . . . . . . . . Pound-Feet . . . . . . . . . . . . . . . . . 0.738
6
Kilopascals . . . . . . . . . . . . . . . . . . . . Pounds Per Square Inch . . . . . . . 0.145
Kilometers Per Liter . . . . . . . . . . . . Miles Per Gallon . . . . . . . . . . . . 2.354
Kilometers Per Hour . . . . . . . . . . . . Miles Per Hour . . . . . . . . . . . . . . 0.621
PDF page 271
PIN: 058004-000
PDF page 272
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PDF page 273