6.5l engine slide show - steelsoldiers

HMMWV M998A2 Series

6.5L Diesel Engine Systems Construction and Operation

HMMWV M998A2 Series

6.5L Diesel Engine Systems Construction and Operation

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

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

Gasoline and Diesel Engine ComparisonGasoline and Diesel Engine Comparison

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.

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.



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.



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.



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.

Basic Operation 6.5L Diesel EngineBasic Operation 6.5L Diesel EngineIntake StrokeIntake Stroke

Basic Operation6.5L Diesel EngineBasic Operation6.5L Diesel EngineCompression StrokeCompression Stroke

Basic Operation 6.5L Diesel EngineBasic Operation 6.5L Diesel EnginePower StrokePower Stroke

Basic Operation6.5L Diesel EngineBasic Operation6.5L Diesel EngineExhaust StrokeExhaust Stroke

Engine Major Component GroupsEngine Major Component Groups

Air InductionExhaust SystemFuel

Cooling

ElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectricalElectrical

LubricationMechanicalSystems

AccessoryDrive System

Mechanical SystemMechanical System

Injection PumpInjection Pump

Front CoverFront Cover

CamshaftCamshaft

Cylinder BlockCylinder Block

Cylinder Head AssemblyCylinder Head Assembly

Valve TrainValve Train

Valve CoversValve Covers

Mechanical SystemMechanical System

Pre-Combustion Chamber Insert FeaturesPre-Combustion Chamber Insert Features

AlignmentNotch

AlignmentNotch

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.)

Intake & Exhaust Valve OperationIntake & Exhaust Valve Operation

Intake andExhaust Valves

Intake andExhaust Valves

Cylinder Head Gasket InstallationCylinder Head Gasket Installation

14

17 9

10 6

513 4

1

32 7 11

8

12

16

15

Cylinder Head Gasket LeakageCylinder Head Gasket Leakage

Engine BlockEngine Block

Head GasketHead GasketCylinder HeadCylinder Head

Head Gasket Sealing Bead MarkHead Gasket Sealing Bead Mark

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

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

Camshaft Bearing ServiceCamshaft Bearing ServiceView AView A

NotchNotch

View BView B

Oil Hole12 O’ Clock

Position

Oil Hole12 O’ Clock

Position

Camshaft SupportCamshaft Support

View AView A

SpacerSpacer

View BView B

Thrust PlateThrust Plate

CapPlugCapPlug

Cylinder Block FeaturesCylinder Block Features

Cylinder Block ServiceCylinder Block Service

Bottom ViewBottom View

Cylinder BoresCylinder Bores

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

Connecting Rod Design FeaturesConnecting Rod Design Features

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

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

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-

Crankshaft SupportCrankshaft Support

Crankshaft FeaturesCrankshaft Features

Rolled FilletRolled Fillet

#1#1 #2#2 #3#3 #4#4 #5#5

Crankshaft Main Bearing SelectionCrankshaft Main Bearing Selection

Color Markings(Near Journals)Color Markings(Near Journals)

Stamp MarkingsStamp Markings

Crankshaft-FlywheelTorsional DamperCrankshaft-FlywheelTorsional Damper

FlywheelFlywheel

Torsional DamperTorsional Damper

CrankshaftCrankshaft

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

Front Cover InstallationFront Cover Installation

BoltBoltBlue StudBlue StudStudStud

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

Front Cover Sealing SurfaceFront Cover Sealing Surface

No Sealantin TheseGrooves

No Sealantin TheseGrooves

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

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

Camshaft Lobe Lift CheckCamshaft Lobe Lift Check

View AView A View BView B

Camshaft and Injection Pump Timing CheckCamshaft and Injection Pump Timing Check

View AView A View BView B

Timing Chain Wear CheckTiming Chain Wear Check

View BView BView AView A

Valve TrainValve TrainValve Train PartsValve Train Parts

Hydraulic RollerLifterPush RodRocker ArmValve

Hydraulic RollerLifterPush RodRocker ArmValve

CamshaftCamshaft

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

Valve Lifter GuidesValve Lifter Guides

Rocker Arm Assembly FeaturesRocker Arm Assembly FeaturesTop ViewTop View

Hardened EndHardened End

Side ViewSide View Nylon ButtonNylon Button

Crankshaft Positioning For Rocker Arm InstallationCrankshaft Positioning For Rocker Arm Installation

First LowerWater Pump

Bolt

First LowerWater Pump

Bolt

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


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



Valve Spring Squareness CheckValve Spring Squareness Check

Not More than 1/16”Variance WhileRotating Spring

Not More than 1/16”Variance WhileRotating Spring

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

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

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

Engine Oil Cooling SystemEngine Oil Cooling System

Engine Oil FilterEngine Oil Filter

Oil Pump OperationOil Pump Operation

Main BearingCap #5

Main BearingCap #5

Six SidedRod

Six SidedRod

Oil PumpAssemblyOil PumpAssembly

BoltBolt

AlignmentDowel

AlignmentDowel

Crankshaft Oil PassagesCrankshaft Oil Passages

From RearPassage

From RearPassage

Crankshaft Rear Main SealCrankshaft Rear Main Seal

Rear MainSeal

Rear MainSeal

Rear MainSeal

Installer

Rear MainSeal

Installer

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

Cooling SystemCooling SystemThermostatThermostatCoolant

CrossoverTube

CoolantCrossover

Tube

Cylinder Blockand

Head Passages

Cylinder Blockand

Head Passages

Coolant PumpAssembly

Coolant PumpAssembly

Cooling FanAssembly

Cooling FanAssembly

Thermostat FunctionThermostat Function

Water CrossoverWater Crossover ThermostatThermostat

GasketGasketThermostat

HousingThermostat

Housing

Cylinder Block Expansion PlugsCylinder Block Expansion Plugs

Block HeaterBlock Heater

Cylinder Block PlugsCylinder Block Plugs

Coolant PassagesCoolant Passages

Cylinder Head Cooling FeaturesCylinder Head Cooling Features

Cup PlugsCup Plugs

PlatePlateGasketGasket

TemperatureSending

Unit

TemperatureSending

Unit

Coolant Pump AssemblyCoolant Pump Assembly

Coolant Crossover TubeCoolant Crossover Tube

Glow PlugControllerGlow PlugController

WaterCrossover

Tube

WaterCrossover

Tube

FanThermostatic

Switch

FanThermostatic

Switch

Cooling Fan and Fan Clutch AssemblyCooling Fan and Fan Clutch Assembly

RadiatorRadiator

Accessory Drive SystemAccessory Drive System

FanFan

FanClutch

FanClutch

Power Steering PumpPower Steering PumpWater PumpWater Pump

DualVoltage

Alternator

DualVoltage

Alternator

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

200 AMP Alternator 12/24 Volts200 AMP Alternator 12/24 Volts

12/24 Volt200 AMP Alternator

12/24 Volt200 AMP Alternator

Power Steering PumpPower Steering Pump

Power Steering PumpPower Steering Pump

Crankshaft Pulley AssemblyCrankshaft Pulley Assembly

PulleyPulleySpacerSpacer

TorsionalDamper

TorsionalDamper

Water PumpWater Pump

Front CoverFront Cover

Water Pump GasketWater Pump Gasket

Water PumpWater Pump

Induction/Exhaust SystemInduction/Exhaust SystemAir Intake FilterAir Intake Filter

IntakeManifoldIntake

Manifold

Catalytic ConverterCatalytic Converter

Exhaust HeadersExhaust Headers Exhaust Pipes/MufflerExhaust Pipes/Muffler

Intake ManifoldIntake Manifold

Air Intake Filter SystemAir Intake Filter System

RingClampRing

ClampCoverCover

GasketGasket

FilterElement

FilterElement

StudStud

WeatherCap

WeatherCap

Air CleanerAssembly

Air CleanerAssembly

Nutand

Washer

Nutand

Washer

Exhaust HeadersExhaust Headers

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

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

Fuel SystemFuel SystemInjection PumpInjection Pump

Fuel Lift PumpFuel Lift Pump

Injection LinesInjection Lines

Injection NozzlesInjection NozzlesFuel Return SystemFuel Return System

Fuel FilterFuel Filter

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

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

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.

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

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

Fuel Return SystemFuel Return SystemView AView A

View BView BView CView C

Fuel Filter/Water SeparatorFuel Filter/Water Separator

Fuel FilterFuel Filter

Water SeparatorWater Separator

Fuel Filter/WaterSeparator HousingFuel Filter/WaterSeparator Housing

DrainDrain

Bleeder PlugBleeder Plug

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

Fuel Injection NozzleConstruction and OperationFuel Injection NozzleConstruction and Operation

Residual Pressure

Injection Pressure

Return Pressure

Residual Pressure

Injection Pressure

Return Pressure

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

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)

Electrical SystemsElectrical Systems

Glow PlugsGlow Plugs Cranking/ChargingCranking/Charging

Cold AdvanceCold Advance Fuel Shut-OffFuel Shut-Off

Glow Plug Construction and OperationGlow Plug Construction and Operation

MagnesiumOxide PackMagnesiumOxide Pack

InsulatorInsulator TerminalTerminal

Center TerminalCenter

TerminalHexHexTapered SeatTapered SeatSheathSheathHeater Coil

ElementHeater Coil

Element

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

Cold Advance SystemCold Advance System

SolenoidSolenoid

PlungerPlunger

RightCylinder

Head

RightCylinder

Head

InjectorInjector

Cold AdvanceSwitch

Cold AdvanceSwitch

Engine Cranking SystemEngine Cranking System

BatteriesBatteries

Starter SolenoidStarter Solenoid

StarterStarter

FlywheelFlywheel

6A6A

Engine Charging SystemEngine Charging SystemNeihoff 12/24 Dual Voltage

100 or 200 Ampere AlternatorNeihoff 12/24 Dual Voltage

100 or 200 Ampere Alternator

External Shunt and Buss BarExternal Shunt and Buss Bar

Buss BarBuss BarExternalShunt

ExternalShunt

Valve Spring Pressure TestingValve Spring Pressure Testing

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AA

BB CC

6.5l engine slide show - steelsoldiers

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