6.5l engine slide show - steelsoldiers
TRANSCRIPT
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HMMWV M998A2 Series
6.5L Diesel Engine Systems Construction and Operation
HMMWV M998A2 Series
6.5L Diesel Engine Systems Construction and Operation
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6.5L Diesel Engine6.5L Diesel EngineExploded ViewExploded View INTAKE
MANIFOLDWATER
CROSSOVERHOUSINGPISTON
&RODLIFT
PUMPWATER PUMPBACKING PLATE
GROMMET
OIL FILLERTUBE
WATERPUMP
TIMING CHAIN&
SPROCKETS
PUMP DRIVEGEAR
PUMP DRIVENGEAR
TORSIONALDAMPER
FRONTCOVER
MAINCAP
OILPAN
DIPSTICK
OILFILTEROIL
PUMP
CRANKSHAFT
FLEXPLATEFLYWHEEL
EXHAUSTHEADER
GLOWPLUG
INJECTOR
VALVECOVER
LIFTBRK
REAR MAINOIL SEAL
CAMSHAFT
CYLINDERHEAD
BLOCK
OIL PUMPDRIVE
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Engine Data and SpecificationsEngine Data and SpecificationsDisplacement 6.5L (400 cu. in.)
Type 90° V-8
Bore 103mm (4.06 in.)
Stroke 97mm (3.82 in.)
Compression Ratio 21.3:1
Firing Order 1–8–7–2–6–5–4–3
Oil Pressure 10–15 psi. Idle (Hot) 40–60 psi. Normal Operating Speed
Net Horsepower 160 @ 3400 rpm
Torque 290 (393 N•m) @ 1700 lb-ft
Displacement 6.5L (400 cu. in.)
Type 90° V-8
Bore 103mm (4.06 in.)
Stroke 97mm (3.82 in.)
Compression Ratio 21.3:1
Firing Order 1–8–7–2–6–5–4–3
Oil Pressure 10–15 psi. Idle (Hot) 40–60 psi. Normal Operating Speed
Net Horsepower 160 @ 3400 rpm
Torque 290 (393 N•m) @ 1700 lb-ft
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Gasoline and Diesel Engine ComparisonGasoline and Diesel Engine Comparison
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General Repair SpecificationsGeneral Repair SpecificationsMEASUREMENT METRIC STANDARDCylinder BoreDiameter-1 thru 6 102.972–102.990 mm 4.057–4.058 in.Diameter-7 and 8 102.985–103.003 mm 4.0576–4.0583 in.Out of Round 0.203 mm max. 0.008 in.Taper–Thrust Side 0.203 mm max. 0.008 in.PistonPiston Clearance #1, 2, 3, 4, 5 & 6 0.094–0.120 mm 0.0037–0.0047 in.Piston Clearance #7 & 8 0.107–0.133 mm 0.004–0.005 inCompression RingsGroove ClearanceTop 0.076–0.178 mm 0.003–0.007 in.Second 0.051–0.076 mm 0.002–0.003 in.GapTop 0.30–0.55 mm 0.012–0.003 in.Second .70–1.0 mm 0.030–0.039 in.Oil RingGroove Clearance 0.0541–0.102 mm 0.002–0.004 in.Gap 0.25–0.51 mm 0.010–0.020 in.Piston PinDiameter 30.0061–31.009 mm 1.2203–1.2206 in.Clearance 0.0076–0.0153 mm 0.0003–0.0006 in.Fit In Rod 0.0076–0.025 mm 0.0003–0.0010 in.
MEASUREMENT METRIC STANDARDCylinder BoreDiameter-1 thru 6 102.972–102.990 mm 4.057–4.058 in.Diameter-7 and 8 102.985–103.003 mm 4.0576–4.0583 in.Out of Round 0.203 mm max. 0.008 in.Taper–Thrust Side 0.203 mm max. 0.008 in.PistonPiston Clearance #1, 2, 3, 4, 5 & 6 0.094–0.120 mm 0.0037–0.0047 in.Piston Clearance #7 & 8 0.107–0.133 mm 0.004–0.005 inCompression RingsGroove ClearanceTop 0.076–0.178 mm 0.003–0.007 in.Second 0.051–0.076 mm 0.002–0.003 in.GapTop 0.30–0.55 mm 0.012–0.003 in.Second .70–1.0 mm 0.030–0.039 in.Oil RingGroove Clearance 0.0541–0.102 mm 0.002–0.004 in.Gap 0.25–0.51 mm 0.010–0.020 in.Piston PinDiameter 30.0061–31.009 mm 1.2203–1.2206 in.Clearance 0.0076–0.0153 mm 0.0003–0.0006 in.Fit In Rod 0.0076–0.025 mm 0.0003–0.0010 in.
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General Repair SpecificationsGeneral Repair SpecificationsMEASUREMENT METRIC STANDARDCamshaft
Lift 100.990–101.066mm 4.00–4.06 in.
Intake 7.133 ± .05 mm 0.281 ± 0.002 in.
Exhaust 7.133 ± .05 mm 0.281 ± 0.002 in.
Journal Diameter–#1, 2, 3 & 4 54.975–55.025 mm 2.164–2.166 in.
Journal Diameter #5 50.975–51.025 2.007–2.009 in.
Journal Clearance 0.025–0.102 mm 0.001–0.004 in.
Main Journal Diameter #1, 2, 3 & 4 74.917–74.941 mm 2.949–2.950 in.
Main Journal Diameter #5 74.912–74.941 mm 2.949-2.950 in.
Taper 0.0051 mm max. 0.0002 in. max.
Out of Round 0.0051 mm max. 0.0002 in. max.
Main Bearing Clearance #1, 2, 3 & 4 50.051-0.102 mm 0.002–0.004 in.
End Play 0.102z-0.254 mm 0.004–0.010 in.
Crankpin
Diameter 60.913–60.939 mm 2.398–2.399 in.
Taper 0.0051 mm max. 0.0002 in. max.
Out of Round 0.0051 mm max. 0.0002 in. max.
Rod Bearing Clearance 0.051–0.102 mm 0.002–0.004 in.
Rod Side Clearance 0.178–0.635 mm 0.007–0.025 in.
MEASUREMENT METRIC STANDARDCamshaft
Lift 100.990–101.066mm 4.00–4.06 in.
Intake 7.133 ± .05 mm 0.281 ± 0.002 in.
Exhaust 7.133 ± .05 mm 0.281 ± 0.002 in.
Journal Diameter–#1, 2, 3 & 4 54.975–55.025 mm 2.164–2.166 in.
Journal Diameter #5 50.975–51.025 2.007–2.009 in.
Journal Clearance 0.025–0.102 mm 0.001–0.004 in.
Main Journal Diameter #1, 2, 3 & 4 74.917–74.941 mm 2.949–2.950 in.
Main Journal Diameter #5 74.912–74.941 mm 2.949-2.950 in.
Taper 0.0051 mm max. 0.0002 in. max.
Out of Round 0.0051 mm max. 0.0002 in. max.
Main Bearing Clearance #1, 2, 3 & 4 50.051-0.102 mm 0.002–0.004 in.
End Play 0.102z-0.254 mm 0.004–0.010 in.
Crankpin
Diameter 60.913–60.939 mm 2.398–2.399 in.
Taper 0.0051 mm max. 0.0002 in. max.
Out of Round 0.0051 mm max. 0.0002 in. max.
Rod Bearing Clearance 0.051–0.102 mm 0.002–0.004 in.
Rod Side Clearance 0.178–0.635 mm 0.007–0.025 in.
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Basic Operation 6.5L Diesel EngineBasic Operation 6.5L Diesel EngineIntake StrokeIntake Stroke
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Basic Operation6.5L Diesel EngineBasic Operation6.5L Diesel EngineCompression StrokeCompression Stroke
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Basic Operation 6.5L Diesel EngineBasic Operation 6.5L Diesel EnginePower StrokePower Stroke
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Basic Operation6.5L Diesel EngineBasic Operation6.5L Diesel EngineExhaust StrokeExhaust Stroke
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Engine Major Component GroupsEngine Major Component Groups
Air InductionExhaust SystemFuel
Cooling
ElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectrical
LubricationMechanicalSystems
AccessoryDrive System
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Mechanical SystemMechanical System
Injection PumpInjection Pump
Front CoverFront Cover
CamshaftCamshaft
Cylinder BlockCylinder Block
Cylinder Head AssemblyCylinder Head Assembly
Valve TrainValve Train
Valve CoversValve Covers
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Valve CoversValve Covers
Valve CoversValve Covers
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Mechanical SystemMechanical System
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Pre-Combustion Chamber Insert FeaturesPre-Combustion Chamber Insert Features
AlignmentNotch
AlignmentNotch
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Pre-Combustion ChamberHeat CracksPre-Combustion ChamberHeat Cracks
Head GasketSealing LineHead GasketSealing Line
AcceptableCrack Length
(Not to Exceed 5 mm3/16 in.)
AcceptableCrack Length
(Not to Exceed 5 mm3/16 in.)
UnacceptableCrack Length
( Exceeds 5 mm3/16 in.)
UnacceptableCrack Length
( Exceeds 5 mm3/16 in.)
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Intake & Exhaust Valve OperationIntake & Exhaust Valve Operation
Intake andExhaust Valves
Intake andExhaust Valves
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Cylinder Head Gasket InstallationCylinder Head Gasket Installation
14
17 9
10 6
513 4
1
32 7 11
8
12
16
15
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Cylinder Head Gasket LeakageCylinder Head Gasket Leakage
Engine BlockEngine Block
Head GasketHead GasketCylinder HeadCylinder Head
Head Gasket Sealing Bead MarkHead Gasket Sealing Bead Mark
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Camshaft FeaturesCamshaft Features
#1#1 #2#2 #3#3 #4#4 #5#5
Fuel LiftPump Lobe
Fuel LiftPump Lobe
Lobes for Valve Train OperationLobes for Valve Train Operation
Oil Pump Drive GearOil Pump
Drive Gear
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Camshaft Timing ChainCamshaft Timing Chain
Mark on Torsional Damper Aligns With Timing Bracketat 0° Top Dead Center
Mark on Torsional Damper Aligns With Timing Bracketat 0° Top Dead Center
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Camshaft Bearing ServiceCamshaft Bearing ServiceView AView A
NotchNotch
View BView B
Oil Hole12 O’ Clock
Position
Oil Hole12 O’ Clock
Position
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Camshaft SupportCamshaft Support
View AView A
SpacerSpacer
View BView B
Thrust PlateThrust Plate
CapPlugCapPlug
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Cylinder Block FeaturesCylinder Block Features
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Cylinder Block ServiceCylinder Block Service
Bottom ViewBottom View
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Cylinder BoresCylinder Bores
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Cylinder Bore IdentificationCylinder Bore IdentificationSizes for Cylinders
#2, #4, #6 and #8Sizes for Cylinders
#2, #4, #6 and #8
Sizes for Cylinders#1, #3, #5 and #7
Sizes for Cylinders#1, #3, #5 and #7
JJ JJ JJ JJ
JJ KK JJ JJ
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Connecting Rod Design FeaturesConnecting Rod Design Features
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Piston FeaturesPiston Features
Ni-resistInsert
Ni-resistInsert Keystone
RingKeystone
Ring
Oil Control Ring(2-Piece)
Oil Control Ring(2-Piece)
2nd Compression
Ring
2nd Compression
Ring
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Piston Service ProceduresPiston Service Procedures
TopCompression
Ring Gap
TopCompression
Ring Gap
Oil ControlRing Expander
Gap
Oil ControlRing Expander
Gap
OilControl
Ring Gap
OilControl
Ring Gap
SecondCompression
Ring Gap
SecondCompression
Ring GapCenter of Piston PinCenter of Piston Pin
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Connecting Rod Bearing SelectionConnecting Rod Bearing Selection
Color Markings(Near Journals):
60.926 To 60.939mmJournal DiameterUse STD Insert In Rod Cap
60.913 To 60.926mmJournal Diameter Use 0.026mm UndersizedInsert In Rod Cap
Color Markings(Near Journals):
60.926 To 60.939mmJournal DiameterUse STD Insert In Rod Cap
60.913 To 60.926mmJournal Diameter Use 0.026mm UndersizedInsert In Rod Cap
STD (All)STD (All)
STD or 0.026mmUndersized
STD or 0.026mmUndersized
Yellow-Yellow-
Green-Green-
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Crankshaft SupportCrankshaft Support
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Crankshaft FeaturesCrankshaft Features
Rolled FilletRolled Fillet
#1#1 #2#2 #3#3 #4#4 #5#5
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Crankshaft Main Bearing SelectionCrankshaft Main Bearing Selection
Color Markings(Near Journals)Color Markings(Near Journals)
Stamp MarkingsStamp Markings
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Crankshaft-FlywheelTorsional DamperCrankshaft-FlywheelTorsional Damper
FlywheelFlywheel
Torsional DamperTorsional Damper
CrankshaftCrankshaft
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Front Cover AssemblyFront Cover Assembly
Centerline of EngineCenterline of Engine
93°93°
30°30°
Mounting Hole ForEngine Speed Sensor
Mounting Hole ForEngine Speed Sensor
Center of Timing NotchCenter of Timing Notch
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Front Cover InstallationFront Cover Installation
BoltBoltBlue StudBlue StudStudStud
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Static Timing Mark Installation on a New Front CoverStatic Timing Mark Installation on a New Front Cover
View AView ADriven GearDriven Gear
J33042J33042View BView B
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Front Cover Sealing SurfaceFront Cover Sealing Surface
No Sealantin TheseGrooves
No Sealantin TheseGrooves
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Front Cover Sealing SurfacesFront Cover Sealing SurfacesView AView A Sealant for
Lubrication SystemSealant for
Lubrication System
View BView B View CView C
Sealant for Cooling SystemSealant for Cooling System
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Fuel Injection Pump DriveFuel Injection Pump DriveView AView A
PlungerButton
PlungerButton
View BView BSpringSpring
Drive ShaftDrive Shaft
DowelDowel Oil FillPipe
Oil FillPipe
GrommetGrommet
Access to BoltsAccess to Bolts
Note: A Snap Ring (Not Shown)
Holds the Drive Shaft in the Injection Pump
Note: A Snap Ring (Not Shown)
Holds the Drive Shaft in the Injection Pump
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Camshaft Lobe Lift CheckCamshaft Lobe Lift Check
View AView A View BView B
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Camshaft and Injection Pump Timing CheckCamshaft and Injection Pump Timing Check
View AView A View BView B
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Timing Chain Wear CheckTiming Chain Wear Check
View BView BView AView A
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Valve TrainValve TrainValve Train PartsValve Train Parts
Hydraulic RollerLifterPush RodRocker ArmValve
Hydraulic RollerLifterPush RodRocker ArmValve
CamshaftCamshaft
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Hydraulic Roller Lifter OperationHydraulic Roller Lifter OperationView AView A
Lifter BodyLifter Body
View BView B View CView C
RollerRollerPlungerSpring
PlungerSpring
Check BallSpring
Check BallSpring
CheckBall
CheckBall
Oil MeteringValve
Oil MeteringValve Retainer
RingRetainer
Ring
PlungerPlungerCheck BallRetainer
Check BallRetainer
Push RodSeat
Push RodSeat
Oil GalleryOil Gallery
Check Ball(Open)
Check Ball(Open)
PushRod
PushRod
PlungerPlunger
LifterBodyLifterBody
Push RodPush Rod
Check Ball(Closed)
Check Ball(Closed)
PlungerPlungerOilGallery
OilGallery
LifterBodyLifterBody
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Valve Lifter GuidesValve Lifter Guides
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Rocker Arm Assembly FeaturesRocker Arm Assembly FeaturesTop ViewTop View
Hardened EndHardened End
Side ViewSide View Nylon ButtonNylon Button
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Crankshaft Positioning For Rocker Arm InstallationCrankshaft Positioning For Rocker Arm Installation
First LowerWater Pump
Bolt
First LowerWater Pump
Bolt
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Intake Valve AssemblyIntake Valve Assembly
Valve PartsValve PartsO-Ring SealKeepers, Retainer and ShieldSprings (Outer Shown)
O-Ring SealKeepers, Retainer and ShieldSprings (Outer Shown)
Note: ShimBetweenSprings andCylinder Head
Note: ShimBetweenSprings andCylinder Head
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Exhaust Valve AssemblyExhaust Valve AssemblyValve Parts:Valve Parts:
O-Ring SealKeepers, Rotator and ShieldSprings (Outer Shown)Lip-Type Seal
O-Ring SealKeepers, Rotator and ShieldSprings (Outer Shown)Lip-Type Seal
Note: ShimBetweenSprings andCylinder Head
Note: ShimBetweenSprings andCylinder Head
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Valve Spring Squareness CheckValve Spring Squareness Check
Not More than 1/16”Variance WhileRotating Spring
Not More than 1/16”Variance WhileRotating Spring
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Lubrication System OverviewLubrication System Overview
Oil Pump AssemblyOil Pump Assembly
Oil Cooler System
Oil Cooler System
Oil FilterOil Filter
Cylinder Blockand Crankshaft
Passages
Cylinder Blockand Crankshaft
Passages
Crankshaft Seals
Crankshaft Seals
Sealing SurfacesSealing
Surfaces
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Engine Oil Temperature Range Recommendation ChartEngine Oil Temperature Range Recommendation Chart
°C –30 –20 –10
32
10 20 30 40
–20 0 20 40
0
60 80 100
–65°F OEA PREFERRED
+5
SAE 15W-40 PREFERRED
°F
Temperature Range You Expect Before Next Oil ChangeTemperature Range You Expect Before Next Oil Change
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Engine Oil Lubricating SystemEngine Oil Lubricating SystemRocker ArmRocker Arm
Push RodPush Rod
To Oil Pressure Sensor
To Oil Pressure Sensor
Valve LifterValve Lifter
Cam BearingsCam Bearings Trubocharger Oil FeedTrubocharger Oil Feed
Cooler Bypass ValveCooler Bypass Valve
Filter BypassValve
Filter BypassValve
OilFilterOil
Filter
MainBearing
MainBearing
OilSprayer
OilSprayer
ToOil
Pump
ToOil
Pump
ToOil
PumpToOil
PumpToOil
Pump
From OilPump
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Engine Oil Cooling SystemEngine Oil Cooling System
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Engine Oil FilterEngine Oil Filter
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Oil Pump OperationOil Pump Operation
Main BearingCap #5
Main BearingCap #5
Six SidedRod
Six SidedRod
Oil PumpAssemblyOil PumpAssembly
BoltBolt
AlignmentDowel
AlignmentDowel
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Crankshaft Oil PassagesCrankshaft Oil Passages
From RearPassage
From RearPassage
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Crankshaft Rear Main SealCrankshaft Rear Main Seal
Rear MainSeal
Rear MainSeal
Rear MainSeal
Installer
Rear MainSeal
Installer
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RTV Sealing SurfacesRTV Sealing Surfaces
A 5mm bead of R.T.V. must be applied and sealer must be wet to touch when bolts are torqued.
A 5mm bead of R.T.V. must be applied and sealer must be wet to touch when bolts are torqued.
FrontFront
FrontFront
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Cooling SystemCooling SystemThermostatThermostatCoolant
CrossoverTube
CoolantCrossover
Tube
Cylinder Blockand
Head Passages
Cylinder Blockand
Head Passages
Coolant PumpAssembly
Coolant PumpAssembly
Cooling FanAssembly
Cooling FanAssembly
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Thermostat FunctionThermostat Function
Water CrossoverWater Crossover ThermostatThermostat
GasketGasketThermostat
HousingThermostat
Housing
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Cylinder Block Expansion PlugsCylinder Block Expansion Plugs
Block HeaterBlock Heater
Cylinder Block PlugsCylinder Block Plugs
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Coolant PassagesCoolant Passages
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Cylinder Head Cooling FeaturesCylinder Head Cooling Features
Cup PlugsCup Plugs
PlatePlateGasketGasket
TemperatureSending
Unit
TemperatureSending
Unit
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Coolant Pump AssemblyCoolant Pump Assembly
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Coolant Crossover TubeCoolant Crossover Tube
Glow PlugControllerGlow PlugController
WaterCrossover
Tube
WaterCrossover
Tube
FanThermostatic
Switch
FanThermostatic
Switch
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Cooling Fan and Fan Clutch AssemblyCooling Fan and Fan Clutch Assembly
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RadiatorRadiator
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Accessory Drive SystemAccessory Drive System
FanFan
FanClutch
FanClutch
Power Steering PumpPower Steering PumpWater PumpWater Pump
DualVoltage
Alternator
DualVoltage
Alternator
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Accessory Drive BeltsAccessory Drive BeltsIdler
PulleyIdler
Pulley
BeltTensioner
BeltTensioner
CrankshaftPulley
CrankshaftPulley
IdlerPulleyIdler
Pulley IdlerPulleyIdler
Pulley
AlternatorPulley
AlternatorPulley
Power SteeringPulley
Power SteeringPulley
Water PumpPulley
Water PumpPulley
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200 AMP Alternator 12/24 Volts200 AMP Alternator 12/24 Volts
12/24 Volt200 AMP Alternator
12/24 Volt200 AMP Alternator
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Power Steering PumpPower Steering Pump
Power Steering PumpPower Steering Pump
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Crankshaft Pulley AssemblyCrankshaft Pulley Assembly
PulleyPulleySpacerSpacer
TorsionalDamper
TorsionalDamper
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Water PumpWater Pump
Front CoverFront Cover
Water Pump GasketWater Pump Gasket
Water PumpWater Pump
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Induction/Exhaust SystemInduction/Exhaust SystemAir Intake FilterAir Intake Filter
IntakeManifoldIntake
Manifold
Catalytic ConverterCatalytic Converter
Exhaust HeadersExhaust Headers Exhaust Pipes/MufflerExhaust Pipes/Muffler
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Intake ManifoldIntake Manifold
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Air Intake Filter SystemAir Intake Filter System
RingClampRing
ClampCoverCover
GasketGasket
FilterElement
FilterElement
StudStud
WeatherCap
WeatherCap
Air CleanerAssembly
Air CleanerAssembly
Nutand
Washer
Nutand
Washer
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Exhaust HeadersExhaust Headers
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Crankcase Ventilation SystemCrankcase Ventilation SystemView AView A
CrankcaseVapors
to Induction System
CrankcaseVapors
to Induction System
Inlet ManifoldRunners
Inlet ManifoldRunners
Blow-ByLeakageat Valves
and Pistons
Blow-ByLeakageat Valves
and PistonsCrankcase VaporsCrankcase Vapors
CrankcaseDepression
Regulator Valve
CrankcaseDepression
Regulator Valve
DiaphragmDiaphragm BodyBody
SpringSpringCover Cover
Outlet Tube(Gases to Intake
Manifold)
Outlet Tube(Gases to Intake
Manifold)
Inlet Port(Gases fromCrankcase)
Inlet Port(Gases fromCrankcase)
View BView B
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Crankcase Depression Regulator Valve OperationCrankcase Depression Regulator Valve OperationView A Idle SpeedView A Idle Speed
SpringSpring
To IntakeManifoldTo IntakeManifold
CrankcaseVapors
CrankcaseVapors
CrankcaseVapors
CrankcaseVapors
To IntakeManifoldTo IntakeManifold
SpringSpringView B 2000 RPMView B 2000 RPM
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Fuel SystemFuel SystemInjection PumpInjection Pump
Fuel Lift PumpFuel Lift Pump
Injection LinesInjection Lines
Injection NozzlesInjection NozzlesFuel Return SystemFuel Return System
Fuel FilterFuel Filter
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Fuel Injection PumpFuel Injection Pump
Fuel Pump Housing
Fuel Pump Housing
DriveShaftDriveShaft
GovernorGovernor
PumpingPlungersPumpingPlungers
AutomaticAdvance
AutomaticAdvance
InternalCam RingInternal
Cam RingDistributor
RotorDistributor
Rotor
Pressure RegulatorAssembly
Pressure RegulatorAssembly
TransferPump Blades
TransferPump Blades
Hydraulic HeadAssembly
Hydraulic HeadAssembly
MeteringValve
MeteringValve
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Injection Pump Mounting and Drive GearInjection Pump Mounting and Drive Gear
View AView AFuel Injection
PumpFuel Injection
PumpTiming MarksTiming Marks
Alignment MarksAlignment Marks
Drive GearDrive Gear
View BView B
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Fuel Injection Pump Driveshaft End-PlayFuel Injection Pump Driveshaft End-Play
View AView A
PlungerPlunger
View BView BSpringSpring
DowelDowel
Drive ShaftDrive Shaft
Access to BoltsAccess to Bolts
Note: A snap ring (not shown)holds the drive shaft in theinjection pump.
Note: A snap ring (not shown)holds the drive shaft in theinjection pump.
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Fuel Injection Lines
Fuel Injection Lines
Cyl #1Cyl #1
Cyl #2Cyl #2
Cly #3Cly #3
Cly #4Cly #4
Cly #5Cly #5
Cly #6Cly #6
Cly #7Cly #7
Cly #8 Cly #8
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Fuel Injection Lines Operation and ServiceFuel Injection Lines Operation and Service
LeftBankLeft
BankRightBankRightBank
#1#1#3#3
#5#5
#7#7
#2 #2 #4 #4
#6 #6 #8 #8
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Fuel Return SystemFuel Return SystemView AView A
View BView BView CView C
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Fuel Filter/Water SeparatorFuel Filter/Water Separator
Fuel FilterFuel Filter
Water SeparatorWater Separator
Fuel Filter/WaterSeparator HousingFuel Filter/WaterSeparator Housing
DrainDrain
Bleeder PlugBleeder Plug
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High-Pressure InletHigh-Pressure Inlet
Leak-Off PortLeak-Off Port
ShimShim
PressureSpring
PressureSpring
ColorRing
ColorRing
NeedleVavle
NeedleVavle
Fuel Injection NozzleFuel Injection NozzleHigh Pressure InletHigh Pressure Inlet
ShimShim
Pressure SpringPressure Spring
Pressure SpindlePressure Spindle
Intermediate PlateIntermediate Plate
Pintle NozzlePintle Nozzle
Heat ShieldHeat Shield
Nozzle NutNozzle Nut
NozzleNut
NozzleNut
PressureSpindle
PressureSpindle
IntermediatePlate
IntermediatePlate
Heat ShieldWave WasherHeat Shield
Wave Washer
PintleNozzlePintleNozzle
Leak-OffLeak-Off
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Fuel Injection NozzleConstruction and OperationFuel Injection NozzleConstruction and Operation
Residual Pressure
Injection Pressure
Return Pressure
Residual Pressure
Injection Pressure
Return Pressure
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Fuel Injection Nozzle Selection ChartFuel Injection Nozzle Selection Chart
Application Nozzle Spring Color Opening Opening Type Ring Pressure Pressure PSI New PSI Used KPa New KPa Used
M998A2 304 150-266 Purple 1,783-1,960 PSI 1,500-1,960 KPa6.5L AMG # 12,294-13,514 KPa 10,343-15,514 KPa
M1114A2 304 200 Red 2,030-2,204 PSI 1,783-2,204 PSI6.5L Turbo 13,997-15,197 KPa 12,194-15,197 KPa
M998 & M998A1 304 200 White 1,783-1,960 PSI 1,500-1,960 KPa6.2L 1990 & Above 12,294-13,514 KPa 10,343-15,514 KPa
M998 & M998A1 253 200 Green 1,783-1,960 PSI 1,500-1,960 KPa6.2L 1991 & Above AMG # 12,294-13,514 KPa 10,343-15,514 KPa 5742548
Commercial 304 150-266 Orange 2,030-2,204 PSI 1,783-2,204 PSI6.5L L57 13,997-15,197 KPa 12,194-15,197 KPa
Application Nozzle Spring Color Opening Opening Type Ring Pressure Pressure PSI New PSI Used KPa New KPa Used
M998A2 304 150-266 Purple 1,783-1,960 PSI 1,500-1,960 KPa6.5L AMG # 12,294-13,514 KPa 10,343-15,514 KPa
M1114A2 304 200 Red 2,030-2,204 PSI 1,783-2,204 PSI6.5L Turbo 13,997-15,197 KPa 12,194-15,197 KPa
M998 & M998A1 304 200 White 1,783-1,960 PSI 1,500-1,960 KPa6.2L 1990 & Above 12,294-13,514 KPa 10,343-15,514 KPa
M998 & M998A1 253 200 Green 1,783-1,960 PSI 1,500-1,960 KPa6.2L 1991 & Above AMG # 12,294-13,514 KPa 10,343-15,514 KPa 5742548
Commercial 304 150-266 Orange 2,030-2,204 PSI 1,783-2,204 PSI6.5L L57 13,997-15,197 KPa 12,194-15,197 KPa
Fuel Injection NozzlesFuel Injection Nozzles
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Fuel Injection Nozzle IdentificationFuel Injection Nozzle Identification
1996-6.5L Military(Purple)
1996-6.5L Military(Purple)
1996-6.5L Military, Turbo(Red)
1996-6.5L Military, Turbo(Red)
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Electrical SystemsElectrical Systems
Glow PlugsGlow Plugs Cranking/ChargingCranking/Charging
Cold AdvanceCold Advance Fuel Shut-OffFuel Shut-Off
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Glow Plug Construction and OperationGlow Plug Construction and Operation
MagnesiumOxide PackMagnesiumOxide Pack
InsulatorInsulator TerminalTerminal
Center TerminalCenter
TerminalHexHexTapered SeatTapered SeatSheathSheathHeater Coil
ElementHeater Coil
Element
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Fuel Shutoff SolenoidFuel Shutoff SolenoidPlungerPlunger
No Fuel Position(De-Energized)
No Fuel Position(De-Energized)
Metering Valve(Rotates to
Stop Fuel Flow)
Metering Valve(Rotates to
Stop Fuel Flow)ArmArmRunning Position(Energized)
Running Position(Energized)
ElectricShutoff
Solenoid
ElectricShutoff
Solenoid
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Cold Advance SystemCold Advance System
SolenoidSolenoid
PlungerPlunger
RightCylinder
Head
RightCylinder
Head
InjectorInjector
Cold AdvanceSwitch
Cold AdvanceSwitch
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Engine Cranking SystemEngine Cranking System
BatteriesBatteries
Starter SolenoidStarter Solenoid
StarterStarter
FlywheelFlywheel
6A6A
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Engine Charging SystemEngine Charging SystemNeihoff 12/24 Dual Voltage
100 or 200 Ampere AlternatorNeihoff 12/24 Dual Voltage
100 or 200 Ampere Alternator
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External Shunt and Buss BarExternal Shunt and Buss Bar
Buss BarBuss BarExternalShunt
ExternalShunt
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Valve Spring Pressure TestingValve Spring Pressure Testing
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
11
12
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
11
12
AA
BB CC