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TM 9-2815-237-34

2-41. ENGINE ASSEMBLY FROM SUBASSEMBLIES (Contd)

l. Fuel Injection Pump

1.

2.

3.

4.

5.

6.

7.

8.

Install gasket (5) and injection pump (6) on timing gear cover (3).

Install accelerator cable bracket (12) on fuel injection pump (6) with two capscrews (11). Tightencapscrew s (11) to 13 lb-ft (18 N m).

Install idle return spring (8) on throttle lever (7) and accelerator cable bracket (12).

Align timing marks (4) on injection pump (6) and timing gear cover (3).

Install injection pump (6) to timing gear cover (3) with three washers (10) and nuts (9).

Rotat e cranksha ft unt il t iming ma rk (14) on pump drive gear (13) is str a ight up.

Align timing marks (14) on pump drive gear (13) and pump driven gear (2) and install drivengear (2) into timing gear cover (3).

In sta ll thr ee ca pscrews (1) on driven gear (2) a nd t ight en capscrew s (1) to 13-20 lb-ft (18-27 N m).

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m. Water Pump and Adapter Plate

1.

2.

3.

4.

5.

6.

CAUTION

E nsu re w a ter pump P /N 23500085 is used on 6.5 L engines ordamage to equipment wi l l resul t .

Install gasket (16) and water pump (15) on adapter plate (17) with seven capscrews (18). Tightencaps crew s (18) to 13-20 lb-ft (18-27 N m).

Apply sealer to sealing surfaces on adapter plate (17), following diagram shown.

Apply pipe sealing compound to capscrews (24) and (23).

Install adapter plate (17) and water pump (15) on timing gear cover (3) with two long studs (25),short stud with thick hex (21), stud (22), and capscrew (24).

Inst a ll tw o long capscrews (23), st uds (19), four w a shers (20), a nd capscrews (26). Tight en st uds (19)a nd caps crew s (26) an d (23) t o 13-20 lb-ft (18-27 N m). Tight en st uds (21), (22), a nd (25), a ndcaps crew (24) to 24-37 lb-ft (34-50 N m).

Inst a ll oil fill tube (29) on a da pter pla te (17) wit h t w o wa shers (28) and nut s (27). Tight en nu ts (27)t o 13-20 lb-ft (18-27 N m).

SEALER DIAGRAM

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Cha nge 1 2 -1 8 4 .1

2 - 4 1 . EN GIN E A SSEM BLY FRO M SUBASSEM BLIES (Cont d )

y.1. Turbocharger

1. Install turbocharger oil gasket (12) and turbocharger (15) on engine block (16) with two capscrews (13).

2. Install O-ring (14) on turbocharger (15) outlet.

y.2. Manifold-to-Turbocharger Exhaust Pipe

1. Install two clamps (18) on exhaust pipe (17).

2. Install exhaust pipe (17) on turbocharger (15) and tighten clamp (18).

3. Install exhaust pipe (17) on exhaust manifold (19) and tighten clamp (18).

4. Repeat steps 1 through 3 for opposite side.

NOTE

Perform tasks y.1 through y.4 for 6.5L turbo engines only.


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2 -1 8 4 .2 Cha nge 1

2 - 4 1 . EN G IN E ASSEM BLY FRO M SUBASSEM BLIES (Cont d )

y.3. Wastegate Housing

Install wastegate housing (5) on turbocharger (5.5) with four capscrews (5.4).

y.4. Wastegate Actuator

1. Install wastegate actuator (2) on cylinder head (4) with capscrew (5.3).

2. Install wastegate actuator (2) on wastegate housing (5) with two capscrews (3).

3. Install actuator rod (1) on wastegate bellcrank (5.2) with clip (5.1).


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v. Fuel Injection Lines

1. Install number 1 and 3 injection lines (7) and connect t O fuel injection pump (1) and fuel injection

nozzles (4).2. Using crowfoot wrenches, tighten four nuts (3) and fuel injection lines (7) on fuel injection nozzles (4)

a nd fuel injection pum p (1) to 20 lb-ft (27 N m).

3. Repeat steps 1 and 2 for each set of remaining fuel injection lines (7), number 5 and 7, number 6and 8 , and number 2 and 4 .

4. Install four clamps (5) securing fuel injection lines (7) to support brackets (2) with four screw-aesembled washers (6).

5. Install boot (8) onto fuel injection pump (1) and tighten clamp (9).

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u. Fuel Supply and Return Lines

1. Install fuel supply line (8) on fuel pump (27) and finger tighten tube nut (26).

2. Install fuel return line (17) on timing gear cover (25) with clamp (13), washer (12), andcapscrew (11). Finger tighten capscrew (11).

3. Install return line (17) to valve cover stud (21) with clamp (20), washer (19), and nut (18). Tightennu t (18) to 13-20 lb-ft (18-27 N m).

4, Install supply line (8) and return line (17) to cylinder block (29) with two clamps (28), washer (24),a nd s tu d (23). Tight en st ud (23) and capscrew (11) to 25 lb-ft (34 N m).

5. Tighten tube nut (26).

6. Connect three rubber hoses (16) to front fuel injection nozzles (22) and fuel injection pump (14)with, three clamps (15).

7. Connect fuel filter inlet hose (10) to fuel supply line (8) with hose clamp (9).


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Change 1 2-11

2 - 1 5 . EN G IN E DISA SSEM BLY IN TO SUBA SSEM BLIES (Con t d )

b. Crankshaft Pulley

Remove four capscrews (9), crankshaft pulley (6), and spacer (8) (if installed) from torsional damper (7).

2. Using a 5/16-in. hex-head driver, remove four socket-head screws (1) and fan drive (2) from waterpump pulley (3).

3. Using a 6-mm hex-head driver, remove four socket-head screws (5) and water pump pulley (3)from water pump (4).


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2 - 1 5 . EN G IN E DISA SSEM BLY IN TO SUBA SSEM BLIES (Con t d )

c.3. Manifold-to-Turbocharger Exhaust Pipe

1. Loosen clamp (5) and remove exhaust pipe (1) from exhaust manifold (4). Slide clamp (5) ontoexhaust pipe (1).

2. Loosen clamp (2) and remove exhaust pipe (1) from turbocharger (3). Slide clamp (2) onto exhaustpipe (1).

3. Remove clamps (2) and (5) from exhaust pipe (1).

4. Repeat steps 1 through 3 for opposite side of engine.

c.4. Turbocharger

NOTE

Center inlet manifold must be removed before removingturbocharger.

1. Remove two capscrews (5.2) and turbocharger (5.4) from engine block (5.5).

2. Remove turbocharger oil gasket (5.1) from engine block (5.5). Discard gasket (5.1).3. Remove O-ring (5.3) from turbocharger (5.4) outlet. Discard O-ring (5.3).


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2-14 Change 1

2 - 1 5 . EN GIN E DISA SSEM BLY IN TO SUBA SSEM BLIES (Con t d )

e. Intake Manifold

1. Remove fuel filter line clamp (1) from stud (2).

NOTE Note location of studs for installation.

Perform step 2 for 6.2L engines. Perform step 3 for 6.5L engines.

2. Remove six intake manifold capscrews (5), ten studs (2), and sixteen washers (3).

3. Remove four intake manifold capscrews (5), twelve studs (2), and sixteen washers (3).

4. Remove four injection line clips (4).

5. Remove intake manifold (6) and two gaskets (7) from cylinder heads (8). Discard gaskets (7).

NOTE

Perform steps 6 through 8 for turbo engines.

Outer intake manifold is removed before engine is removed fromvehicle.

6. Remove eight intake manifold studs (8.1) from intake manifold (8.2).

.WARNING.

Gaskets installed on some 6.2L engines assembled prior to 1991may contain asbestos. Gaskets should be removed with a scraperor putty knife and then be disposed of IAW current directives.Inhalation of asbestos fibers can cause respiratory ailments.

7. Remove intake manifold (8.2) and gasket (8.3) from cylinder head (8.4). Discard gasket (8.3).

8. Repeat steps 6 and 7 for opposite side.


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2 -2 6 Change 1

2 - 1 5 . EN GIN E DISA SSEM BLY IN TO SUBA SSEM BLIES (Con t d )

q. Fuel Injection Pump

1. Remove three capscrews (1) and pump driven gear (2) from fuel injection pump (5).

2. Remove idle return spring (7) from throttle lever (6).3. Remove three nuts (8) and washers (9) from fuel injection pump (5) and timing gear cover (3).

4. Remove two capscrews (10) and accelerator cable bracket (11) from fuel injection pump (5).

.WARNING.

Gaskets installed on some 6.2L engines assembled prior to 1991may contain asbestos. Gaskets should be removed with a scraperor putty knife and then be disposed of IAW current directives.Inhalation of asbestos fibers can cause respiratory ailments.

5. Remove the fuel injection pump (5) and gasket (4) from cover (3). Discard gasket (4).

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