2-15. ENGINE DISASSEMBLY INTO SUBASSEMBLIES
This task covers:
Fan Drive and Water Pump Pulley
c.1. Wastegate Actuator
c.2. Wastegate Housing
c.3. Manifold-to-Turbocharger Exhaust Pipe
Fuel Injection Lines
Fuel Supply and Return Lines
Rocker Arm Covers
Rocker Arm Shafts and Pushrods
Fuel Injection Nozzles
Water Pump and Adapter Plate
Fuel Injection Pump
Timing Gear Cover
Timing Chain and Drive Sprockets
Oil Filter, Adapter, and Oil Pressure Sending Unit
Oil Pump Drive
Pistons and Connecting Rods
Crankshaft and Main Bearings
Engine mounted on repair stand (para. 2-14).
General Safety Instructions
Do not perform this procedure near fire, flame,
Gaskets installed on some 6.2L engines
assembled prior to 1991 may contain asbestos.
Gaskets should be disposed of IAW current
a. Fan Drive and Water Pump Pulley
It may be necessary to apply compressed air to fan drive fitting. This disengages
fan drive and allows access to socket head capscrews.
Position pry bar between water pump pulley (3) and crankshaft pulley (6) and apply pressure.
General mechanics tool kit:
automotive (Appendix E, Item 1)
Puller (Appendix E, Item 19)
Cylinder ridge reamer (Appendix E, Item 11)
Dial indicator (Appendix E, Item 10)
Hydraulic valve lifter remover
(Appendix E, Item 4)
Injection nozzle socket (Appendix E, Item 5)
Glow plug socket (Appendix E, Item 6)
Hex-head driver, 6 mm (Appendix E, Item 7)
Hex-head driver, 8 mm (Appendix E, Item 8)
Hex-head driver, 5/16-in.
(Appendix E, Item 9)
Work area should be clean, well-ventilated, and free from blowing dirt and dust.
In some cases, flanged head fasteners may be present instead of standard
fasteners and washers. In all cases, washers should be used when replacing a
flanged head fastener with a standard fastener.
Disassembly procedures for pre-1990, 1990 and above 6.2L and 6.5L engines are
basically the same. Any differences in procedures are noted. Refer to para.
1-10 to determine engine model before ordering replacement parts.