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CONTENTS (cont’d)
SUBJECT
PAGE
Coolant Crossover Installation........................................................................................................................ .....6A 7-49
Dipstick Tube Installation........................................................................................................................................6A7-50
Exhaust Manifold Installation.......................................................... ...................................................................... 6A7-50
Glow Plug Installation.............................................................................................................................................. 6A7-50
Injection Nozzle Installation................................................................................................................................... 6A7-51
Injection Line Installation........................................................................................................................................6A7-51
Intake Manifold Installation.................................................................................................................................... 6A7-52
Oil Pump Drive Installation.................................................................................................................................... 6A7-52
Engine Accessory Installation...............................................................................................................................6A7-53
Rear Crankshaft Oil Seal Installation..................................................................................................................6A7-53
Flywheel Installation................................................................................................................................................. 6A7-54
Engine Setup and Testing...................................................................................................................................... 6A7-54
S pecificatio n s.................................................................................................................................................................6A7-55
Fastener Tightening Specifications...................................................................................................................... 6A7-55
Engine S pecifications.............................................................................................................................................. 6A7-56
Service Piston and Cylinder Bore Specifications........................................................................................... 6A7-57
Crankshaft Main Bearing Selection and Specifications................................................................................ 6A7-58
Case, Camshaft and Camshaft Bearings Specifications.............................................................................. 6A7-58
Crankshaft Pin Journals and Connecting Rod B earin g s............................................................................. 6A7-58
Connecting Rod to Crankshaft Journal Bearing Clearance......................................................................... 6A7-58
Special T o o ls ........................................................................................... ...................................................................... 6A7-59
GENERAL DESCRIPTION
The 6.5L diesel engine is a 90-degree V8 type, with
indirect type combustion chambers. There are four ver
sions of the 6.5L engine. Two of the engines are turbo
charged (L56, VIN S and L65, VIN F) and the other two
are non-turbocharged naturally aspirated (L49, VIN P
and L57, VIN Y).
The crankshaft is supported by five precision insert
main bearings, with crankshaft thrust taken at the num
ber three (center) main bearing.
The camshaft is supported by five plain type bearings
and is chain driven. Motion from the camshaft is trans
mitted to the overhead valves by roller type hydraulic
lifters, pushrods, and shaft-mounted rocker arms. The
valve guides are integral to the cylinder head.
The connecting rods are forged steel with precision
insert type crankpin bearings. The piston pins are held
in place by retaining rings.
For engine identification information, refer to SEC
TION OA.
For disassembled views of the 6.5L engine, refer to
figures 1 through 8.
ENGINE LUBRICATION
A lubrication schematic is shown in figure 9.
The gear-type oil pump is driven from a drive gear.
The drive gear is driven by the camshaft. Oil is drawn
into the pump through a pickup screen and pipe.
Pressurized oil is routed to the oil cooler located
either inside of the radiator or in front of the radiator. A
bypass valve is provided to prevent against high oil
pressure on cold start up. Oil flows from the cooler to a
full-flow oil filter.
Oil flows from the oil filter to the oil galleries, provid
ing pressurized lubrication to various components,
including the turbocharger.
The hydraulic valve lifters receive oil from the oil gal
leries. Oil flows from the hydraulic lifters through hollow
pushrods to the rocker arms. Oil from the overhead
drains back to the crankcase through oil drain holes.
The pistons, piston rings, cylinder walls, and connect
ing rod small end bearings are lubricated by oil splash.
Summary of Contents for S Series 1994
Page 1: ......
Page 11: ...VIEW A p n n n j VIEW C F7554 Figure 10 Hydra Matic 4L60 E Transmission I D Location...
Page 24: ...NOTES...
Page 26: ......
Page 69: ...NOTES...
Page 71: ...3 2 STEERING...
Page 73: ......
Page 84: ......
Page 102: ...40...
Page 130: ...NOTES...
Page 146: ...NOTES...
Page 162: ...NOTES...
Page 166: ...Figure 5 Removing the Pinion Flange Figure 6 Pressing the Drive Pinion from the Cage...
Page 178: ...Figure 3 Spreading the Differential Case Figure 4 Removing the Differential...
Page 190: ...NOTES...
Page 202: ...NOTES...
Page 206: ...F5785...
Page 212: ...B Button Moved Out of Bearing Bore F5791...
Page 228: ...NOTES...
Page 232: ......
Page 234: ......
Page 236: ...Adjuster 63 Bolt 64 Lock Figure 10 Turning the Adjuster Plug K3 Models...
Page 237: ...Figure 13 Removing the Pinion Seal 39 Bearing Cup Figure 16 Removing the Inner Bearing Cap...
Page 261: ...F7475...
Page 267: ...B Button Moved Out of Bearing Bore F5791...
Page 294: ...NOTES...
Page 300: ...NOTES...
Page 318: ...NOTES...
Page 322: ...SR207LN2 EDS...
Page 324: ......
Page 326: ...OVERHEAD OILING AND RETURN MAIN OIL GALLERY N30005 6A2 J EDS...
Page 368: ...103 153 127 V1200...
Page 370: ......
Page 372: ......
Page 374: ...F9375 Figure 7 Engine Lubrication Diagram Engines Without Balance Shaft...
Page 376: ...Figure 9 Engine Lubrication Diagram Engines With Balance Shaft...
Page 399: ...V2974...
Page 410: ......
Page 412: ...195 196 201 174 252 163 165 164 244 3706r3924...
Page 452: ......
Page 454: ...163 164 V1202...
Page 456: ...20 21x 302 210 4 0 41 2 5 2 5 1 2 51 4 2 e3 54 3 9 252 252 S 255 255 25 6 256 209 V1196...
Page 458: ...100 1 8 4 185 183 177 v 75 201 3706r1204...
Page 460: ......
Page 510: ......
Page 512: ...V2131...
Page 514: ...110 106 106 103 90 93 89 88 87 86 v 7 7 7 7 j A _ 111 f t 2 a a s 53 49 L 47 46 3706r4751...
Page 516: ...259 260 150 237 S lM 180 167180 J 1 82 183 170 169 1 1 78 1 7 9 213212 2 0 7 205 r i 3706r4752...
Page 566: ...NOTES...
Page 574: ...NOTES...
Page 618: ...SPECIAL TOOLS...
Page 620: ...NOTES...
Page 672: ......
Page 682: ......
Page 686: ......
Page 694: ...RH0213 4L60 E...
Page 695: ...657 659 m i J 8092 H J 34196 4 3 34196 5 657 658 665 J 23907 J 7004 1 J 8092 RH0214 4L60 E...
Page 696: ...J 8092 J 34196 4 33 31 J 8092 RH0215 4L60 E...
Page 697: ...SPECIAL TOOLS...
Page 698: ...SPECIAL TOOLS...
Page 758: ...RH0194 4L80 E...
Page 764: ......
Page 770: ...SPECIAL TOOLS...
Page 771: ...SPECIAL TOOLS CONT...
Page 772: ......
Page 775: ......
Page 776: ......
Page 785: ......
Page 804: ...NOTES...
Page 806: ......
Page 808: ......
Page 822: ...3707r5079...
Page 840: ......
Page 848: ...NOTES...
Page 852: ......
Page 860: ...F5435...
Page 866: ......
Page 878: ...F9167...
Page 882: ...16 FrontOutputShaft 18 DrivtQNr 19 DrivenGm t 20 DriveChain 22 FrontOutputBearing V2836...
Page 890: ...F9168...
Page 908: ......
Page 919: ......