Detroit 8.2 v8

DETROIT DIESEL 8.
2L V8
Article Text
For cyph8r pacific la ca 92101
© 1996 Mitchell International, All Rights Reserved.
Tuesday, September 25, 2012 11:42PM
ARTICLE BEGINNING
DIESEL ENGINES
Detroit Diesel 8.2L V8
ENGINE IDENTIFICATION
The engine model and serial numbers are located on a metal

plate attached to horizontal machined surface on front upper part of
block. Both numbers can also be found attached to the valve cover.
This location lists any optional equipment used on the engine.
All on-highway vehicles have an exhaust emission control
label on the left side valve cover. This emission label lists injector
timing heights for specific cylinder locations.
EXHAUST & INTAKE MANIFOLDS
EXHAUST MANIFOLD
Removal
On turbo engines, remove 2 clamps and exhaust inlet tube. On
all engines, remove manifold bolts securing lifter bracket. Support
manifold and remove all remaining bolts. Remove manifold, gaskets and
all heat shields.
Installation
To install, reverse removal procedure. Position gasket so
that the word OUT is against manifold. Use 2 longer bolts to retain
lifter bracket.
INTAKE MANIFOLD
Removal
On non-turbo engines, remove air cleaner and adapter. On
turbo engines, remove turbocharger and air crossover. Remove manifold
bolts and manifold. Remove old gaskets.
Installation
To install, reverse removal procedure. Perform complete
engine tune-up.
CYLINDER HEAD (REPLACEMENT)
NOTE: Because of various accessory equipment available, only

general cylinder head removal steps are covered.
Removal
1) If engine has accessory equipment that affects cylinder
head removal, note position and arrangement of component before
disconnecting or removal to ensure correct reinstallation.
2) Remove air cleaner. Drain cooling system. Separate exhaust
piping at exhaust manifold. Disconnect fuel lines and remove intake
manifold.
3) Remove water connection at front of cylinder head. Remove
valve rocker covers. Remove fuel rod from between governor and
injector control tube lever. Remove fuel rod cover. Loosen clamp at
turbocharger tube.
4) Remove exhaust manifold, rocker arms, shafts, brackets and
push rods. Remove injectors and check tightness of cylinder head bolts
to reveal possible causes of cylinder head problems.
5) Remove head bolts and separate cylinder head from engine.
Drain oil from engine to remove any coolant that may have entered oil
pan when head was removed.
Inspection
1) Check for cracks in valve and injector ports area. Replace
cylinder head if cracked. Check for loose valve seat inserts by
lightly tapping insert.
2) Inspect cylinder head for flatness by using straightedge
and feeler gauge. See CYLINDER HEAD FLATNESS LIMITS table. Seal off
water holes in head with steel plate and rubber gaskets, secured with
bolts and washer.
3) Drill and tap one of cover plates for air hose connection.
Install scrap or dummy injectors to ensure proper seating of injector
tubes. Tighten injector clamp bolts.
4) Apply 20 psi (1.4 kg/cmý) to water jacket. Immerse
cylinder head into 180-200øF (82-93øC) heated water tank for
20 minutes. Bubbles in tank indicate cracks in head. Replace head if
necessary.
CYLINDER HEAD FLATNESS LIMITS

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Warpage In. (mm)
Longitudinal ........................................... .006 (.152)

Transverse ............................................. .004 (.101)
NOTE: Cylinder head welding is not recommended. If cylinder head is

cracked, replace it.
Installation
1) Install gasket onto block. Attach lifting sling to
cylinder head. Lift head into position over block. Verify that new
gasket is in position before cylinder head is lowered.
2) Install cylinder head over dowel pins in cylinder block.
Place special flat washer on each head bolt and apply small amount of
International Compound No. 2 to threads, both faces of washers and
underside of all cylinder head bolts.
NOTE: All 8.2L engines produced after October, 1985 (Serial

No. 8G0139423), used modified cylinder head bolts (15 mm)
with matching cylinder head and block threads.
Non-interchangeable cylinder head bolts can be identified by
15 mm stamp on bolt head. Old cylinder head bolts were 14 mm.
3) Install head bolts finger tight. Tighten bolts, about

1/2 turn at a time, in sequence, to specification. See Fig. 1. After
completing bolt tightening, retighten all bolts in sequence to
specifications. Turn all bolts in sequence an additional 90ø
(1/4 turn). Cover oil drain holes in cylinder head.
DETROIT DIESEL 8.2L V8Article Text (p. 2)For cyph8r p

Fig. 1: Cylinder Head Tightening Sequence
Courtesy of Detroit Diesel.
4) Install fuel injectors. Install valve and injector push

rods. Install injector control tube assembly. Ensure ball end of each
injector rack control lever engages slot in corresponding injector
control rack.
5) Ensure that racks return to no-fuel position freely by aid
of return spring only. DO NOT bend spring. Replace spring, if
necessary. Install fuel rod, cover boot and clamp.
6) Adjust governor to injector control rack links. Install
rocker arms shafts and brackets. Remove covers from oil drain holes.
Install any other equipment that was previously removed. Adjust valve
clearance and perform complete engine tune-up.
VALVE ARRANGEMENT
I-E-I-E-I-E-I-E (Left bank, front-to-rear).

E-I-E-I-E-I-E-I (Right bank, front-to-rear).
VALVE CLEARANCE ADJUSTMENT
CAUTION: Ensure injectors are in no-fuel position before rotating

crankshaft.
1) Rotate crankshaft in right-hand direction until piston is

near TDC compression and injector rocker arm is moving downward.
Insert feeler gauge between end of appropriate valve stem and rocker
arm.
2) Loosen lock nut and turn adjusting screw until gauge is
snug fit. See VALVE CLEARANCE SPECIFICATIONS table. Tighten adjusting
screw lock nut. Valves can be adjusted while checking injector
settings.
VALVE CLEARANCE SPECIFICATIONS

Engine Intake Exhaust
DETROIT DIESEL 8.2L V8Article Text (p. In.
3)For cyph8r pacific la ca 92101© 1996 Mitchell International, All Rights Reserved.Tuesday, Se
Temperature In. (mm) (mm)
Hot ..................... .011 (.28) .................. .012 (.31)

Cold (1) ................ .012 (.31) .................. .014 (.36)
(1) - 100øF (38øC) or less.

CYLINDER HEAD (OVERHAUL)
VALVES
Removal (Cylinder Head Removed)

1) Remove rocker arm assembly. Remove valve springs using
Compressor (J-8062). Compress valve spring and remove 2-piece tapered
valve lock.
2) Release tool. Remove rotator, valve spring and seal. See
Fig. 2. Repeat procedure for all other valve springs. Turn head on
side and remove valves.
Fig. 2: Exploded View Of Valve Assemblies

Removal (Valve Springs) (Cylinder Head On Engine)

1) Rotate crankshaft clockwise to bring valve and injector
rocker arms in-line horizontally. Remove rocker arm assembly.
2) Rotate crankshaft clockwise until piston is at top of its
stroke. Thread valve spring Compressor Adapter (J-7455-4) into rocker
arm bracket bolt hole.
3) Compress valve spring and remove 2-piece tapered valve
lock. Release tool and remove rotator, valve spring and seal. Repeat
procedure for all remaining valve springs.
Installation (Valves & Springs)

1) To install, reverse removal procedure. With valves
installed in cylinder head, use Spring Checking Gauge (J-25076-B) and
note gauge reading as valve starts to open.
2) Minimum pressure required to start opening valve must not
be less than 50 lbs. (22.67 kg). Check and adjust valve clearances.
After engine has been run, perform complete engine tune-up.
DETROIT DIESEL 8.2L V8Article Text (p. 4)For cyph8r pacific la ca 92101© 1996 Mitchell International,
VALVE STEM OIL SEALS
Removal & Installation

Remove valve springs and valve stem seals. See Fig. 2.
Position plastic seal Installation Cap (J-28612) on end of valve stem.
If cap extends more than .063" (1.60 mm) below groove on stem, remove
cap and cut off excessive length. Lubricate installation cap and start
seal over stem until it rests on top of valve guide bore. Remove cap.
VALVE SPRING HEIGHT
Use Spring Tester (J-22738-02) to check spring load. Replace

spring if load of less than 40 lbs. (18.14 kg) will compress it to 2.
00" (50.8 mm).
ROCKER ARM ASSEMBLY
Removal
1) Remove valve rocker cover. Loosen lock nut and back out
adjusting screw to relieve tension on valve and injector spring.
Loosen rocker arm shaft bolts.
2) Remove rocker arm shaft and bolts. If more than one rocker
arm assembly is to be removed, tag them to ensure installation in
their original position.
Inspection
1) Clean and inspect rocker arm shaft and injector rocker arm
bores for wear. Inspect rocker arms for damage or wear on contact
surfaces.
NOTE: Injector rocker arm is slightly different from valve rocker

arms.
2) If worn, surface may be faced up to maximum of .010"

(.25 mm). When surface grinding, maintain radius and finish as close
to original surface as possible.
Installation
1) Apply engine oil to shaft and install through rocker arms.
Place bracket over each end of shaft. Insert bolts through brackets
and tighten bolts. Allow slight clearance between rocker arm.
2) Verify ball end of rocker arm adjusting screw is seated in
cup of push rod when bolts are tightened. Align push rods with rocker
arm adjusting screws. Adjust valve clearance and time injectors. If
necessary, perform complete engine tune-up.
CAM FOLLOWERS
Removal
1) Remove valve covers, push rod and rocker arm assemblies.
Remove intake manifolds and valley cover. Remove cam follower guide.
See Fig. 3.
DETROIT DIESEL 8.2L V8Article Text (p. 5)For cyph8r pacific la ca 92101© 1996 Mitchell International, All Rights Reserved.Tuesday, Se
Fig. 3: Locating Cam Follower & Guide
2) Remove spring from center group of 3 cam followers. Remove

cam followers from bores in block.
NOTE: If change in injector timing or valve clearance occurs during

engine operation, remove cam followers and their related
parts and inspect.
Inspection
1) Clean cam followers with clean engine oil and wipe dry.
Examine cam follower rollers for scoring, pitting and/or flat spots.
Rollers must turn freely on their pins.
2) Measure total diameter clearance and side clearances on
cam roller. See CAM FOLLOWER LIMITS table. Examine cam follower bore
in cylinder block to ensure bore is clean, smooth and free of score
marks.
CAM FOLLOWER LIMITS

Application Clearances
In. (mm)
Cam Follower-To-Cylinder Block .......................... .004 (.10)

Injector & Cam Follower Pin-To-Bushing ..... .0013-.0040 (.033-.102)
Injector Cam Follower Side Clearance ........... .011-.023 (.28-.58)
3) Examine camshaft lobes for scoring, pitting or flat spots.

Replace camshaft, if necessary. Inspect push rods for wear and
straightness. Examine cam follower springs for wear or damage.
4) Check spring load using Spring Tester (J-22738-02).
Replace spring when load of less than 115 lbs. (52.16 kg) compresses
spring to length of 1.25" (31.7 mm).
Installation
To install, reverse removal procedure. When installing used
cam follower guides, check clearance between guide and follower body.
Clearance
DETROITisDIESEL
.005" (.12 mm)V8Article
8.2L for each leg.
Text (p. 6)For cyph8r pacific la ca 92101© 1996 Mitchell International, All Rights Reserved.Tuesday, Se
CAMSHAFT & TIMING GEARS
ENGINE FRONT COVER
Removal
Disconnect battery ground. Drain cooling system. Remove
crankshaft pulley and damper assembly with Puller (J-29025). Remove
water pump and remaining front cover bolts. With oil pan bolts loose,
lift cover from dowel pins in cylinder block.
Installation
Position new gasket on block. Align front cover dowel pins
holes with dowel pins in block. Install cover with 3 bolts and
tighten. Apply RTV and install front cover seal. See Fig. 4.
Fig. 4: Installing Oil Pan Seal

FRONT COVER SEAL
Removal (Cover On Engine)

Remove drive belts. Remove crankshaft pulley and damper
assembly with Puller (J-29025). Remove front cover seal, using Seal
Removal (J-29007-A). See Fig. 5.
DETROIT DIESEL 8.2L V8Article Text (p. 7)For cyph8r pacific la ca 92101© 1996 Mitchell International, All Rights Rese
Fig. 5: Locating Front Cover Seal
Installation (Cover On Engine)

1) Using Seal Installer (J-29008-A), pull seal into front
cover until seal contacts cover.
2) If alternate seal location is desired due to wear or
grooving on crankshaft pulley sealing surface, install alternate
location Adapter (J-29008-5) onto seal installer and install seal.
Removal (Front Cover Removed)

Support front face of cover on 2 wood blocks beside oil seal
bore. Push seal out of front cover using Oil Seal Remover (J-29008-A).
Thoroughly clean oil seal bore before installing new seal. See Fig. 5.
Installation (Front Cover Removed)
To install, reverse removal procedure. If an alternate seal
location is desired due to wear or grooving on crankshaft pulley
sealing surface, install alternate location Adapter (J-29008-5) onto
seal installer and install seal.
CAMSHAFT
Removal
1) Remove intake manifold, valley cover, governor and
cylinder heads. Remove front cover. Remove 3 camshaft mounting bolts.
2) Remove gear off dowel pin in end of camshaft. Remove
thrust washer attached to block with 2 bolts. Remove camshaft from
bore.
Installation
To install, reverse removal procedure. Ensure that mating
gears are timed. See Fig. 6. Check gear backlash with dial indicator.
See GEAR BACKLASH LIMIT table.
Fig. 6: Engine Gear Train & Timing Marks
GEAR BACKLASH LIMIT

Camshaft-to-Crankshaft In. (mm)
New .......................................... .003-.007 (.076-.177)

Used ................................................... .009 (.228)
PISTONS, PINS & RINGS
PISTON & ROD ASSEMBLY
Removal
1) Drain cooling system. Remove oil pan. Remove oil pump
inlet pipe. Remove cylinder head. Stamp cylinder number on bolt bosses
of connecting rod and cap for identification when reinstalling into
respective cylinder bore.
2) Examine cylinder bore above ring travel. If ridge exists,
remove ridge with Reamer (J-24270) before removing piston and rod
assembly. Remove connecting rod bearing cap and bearing.
3) Push piston and rod assembly out through top of cylinder
bore. Reassemble bearing and bearing cap to connecting rod. Remove
remaining piston and rod assemblies in same manner.
Installation
1) Stagger rings on piston. See Fig. 7. Apply engine oil to
rings and piston. Install piston Ring Compressor (J-29614) on piston.
Fig. 7: Staggering Rings On Piston
2) Install each piston and rod assembly in its respective

bore. Ensure valve depression on top of piston is toward outboard side
of cylinder block.
3) Lubricate crankshaft connecting rod journal and install
connecting rod bearing and cap, with bearing index tag in rod and cap
on same side. Tighten cap bolts. Check connecting rod side clearance.
PISTON PINS
Removal
Secure connecting rod in soft-jaw vise. Remove snap ring
retainer with snap ring pliers. See Fig. 8. Remove piston pin.
DETROIT DIESEL
Fig. 8: Piston 8.2L V8Article
& Connecting Text (p. 10)For cyph8r pacific la ca 92101© 1996 Mitchell International, All Rights Reserved.Tuesday, S
Rod Assembly
Inspection
1) Check connecting rod bushings for scoring, overheating or
other damage. Inspect piston for signs of fretting.
2) Replace piston and piston pin when clearance between them
exceeds specifications.
3) Replace connecting rod and piston pin when clearance
between them exceeds specifications. See PISTONS, PINS, RINGS table.
Installation
To install, reverse removal procedure. After installation,
check for piston pin end clearance by cocking connecting rod and
shifting pin in bushing. Pin must be free to rotate.
FITTING & INSTALLING RINGS
1) Pistons have 3 rings (2 compression rings and 1 oil ring).

See Fig. 9. Top compression ring used in turbo engine has keystone
fire ring. Top ring used in non-turbo engine is rectangular ring.
Fig. 9: Locating Ring For Turbo & Non-Turbo Engines

2) Second ring used in both type engines uses rectangular

ring, identified by bevel on top I.D. surface. This second ring may or
may not have face chrome flashed. It must be installed with pip mark
and inside beveled edge toward top of engine.
3) Insert one ring at a time inside cylinder bore with ring
positioned at bottom ring travel. See Fig. 10. Use piston to push ring
down to ensure ring is parallel with top of cylinder bore.
DETROIT DIESEL 8.2L V8Article Text (p. 11)For cyph8r

Fig. 10: Measuring Piston Ring Gap
4) Measure ring gap with feeler gauge. If gap on compression

ring is insufficient, it may be increased by filing ends of rings.
5) Measure ring side clearance with feeler gauge fitted
between ring land and ring. See Fig. 11. Move ring around entire
circumference of piston. Ring must not bind in groove.
Fig. 11: Measuring Piston Ring Side Clearance

CRANKSHAFT & ROD BEARINGS
MAIN BEARINGS
NOTE: The following procedures are with oil pan, oil inlet pipe and
screen assembly removed.
1) Remove one main bearing cap at a time with lower bearing

shell. Check clearance between main bearing and journals using
DETROIT DIESELIf 8.2L
Plastigage method. V8Article
clearance Text
between any(p.
one12) For cyph8r
crankshaft pacific
journal andla ca 92101© 1996 Mitchell International, All Rights Reserved.Tuesday, S
bearing exceeds .005" (.127 mm), replace all bearings.
2) To remove upper bearing shell, insert flattened cotter pin
or roll pin in oil passage hole in crankshaft. Rotate crankshaft in
direction opposite of cranking rotation.
3) Clean bearings and inspect them for scoring, pitting,
flaking, etching, loss of babbitt or signs of overheating. Inspect
backs of bearing shells for bright spots which indicate they have been
moving in bearing caps or bearing supports. Replace bearing if any of
these signs are present.
4) Measure thickness of bearing shells, from middle of
bearing, with Adapter (J-4757) placed between bearing shell and
micrometer. See MAIN BEARING THICKNESS LIMITStable. Replace all
bearing shells if any bearing shell is less than .124" (3.15 mm).
MAIN BEARING THICKNESS LIMITS

Bearing Size Bearing Minimum
Thickness Thickness
In. (mm) In. (mm)
Standard ......... .1250-.1255 (3.175-3.188) ......... .124 (3.15)

CONNECTING ROD BEARINGS
1) Remove one connecting rod bearing cap. Check clearance

between main bearing and journals using Plastigage method. If
clearance between any one connecting rod journal and bearing exceeds .
006" (.15 mm), replace all bearings.
2) To remove bearings, push connecting rod and piston
assembly up into cylinder to remove upper bearing shell. Clean
bearings and inspect them for scoring, pitting, flaking, etching, loss
of babbitt or signs of overheating.
3) Inspect backs of bearing shells for bright spots which
indicate they have been moving in bearing caps or bearing supports.
Replace bearing if any of these signs are present.
4) Measure thickness of bearing shells from middle of bearing
using micrometer and Adapter (J-4757). See
CONNECTING ROD BEARING THICKNESS table. Replace all bearing shells if
any bearing shell is less than .0933" (2.370 mm).
CONNECTING ROD BEARING THICKNESS LIMITS

Bearing Size Bearing Minimum
Thickness Thickness
In. (mm) In. (mm)
Standard ......... .0950-.0955 (2.413-2.416) ...... .0933 (2.370)

THRUST BEARING ALIGNMENT
1) Move crankshaft toward dial indicator with pry bar. See

Fig. 12. Keep constant pressure on pry bar and set indicator to zero.
Remove and insert pry bar on other side of bearing cap.
DETROIT DIESEL 8.2L V8Article Text (p. 13)For cyph8r pacific

Fig. 12: Checking Crankshaft End Play
2) Force crankshaft in opposite direction and note amount of

end play on indicator. See CRANKSHAFT MAIN & CONNECTING ROD BEARINGS
table. Insufficient end play can be result of burr or dirt on inner
face of thrust bearing.
REAR OIL SEAL & OIL SLEEVE
Removal (Flywheel Housing Installed)

Remove flywheel. See FLYWHEEL. Remove seal using Seal Remover
(J-29007-A).
Removal (Flywheel Housing Removed)

Support rear face of housing on 2 wood blocks. Press or drive
seal out of housing. Clean oil seal bore in housing thoroughly before
installing new seal.
Sleeve Installation (For Oversize Oil Seal)

1) If excessive rear crankshaft wear or grooving is present,
install oversize oil seal sleeve as follows.
2) Stone high spots from oil seal contact surface on
crankshaft. Coat area of shaft where sleeve will be positioned with
sealant.
3) Drive sleeve squarely on shaft with Sleeve Installer
(J-33426). Wipe any excess sealant. Coat outside diameter of sleeve
with engine oil. Install oversize seal.
Seal Installation (Flywheel Housing Installed)

1) Place standard size Oil Seal Expander (J-29009-A) or
oversize Seal Expander (J-33873) against end of crankshaft. Install 2
mounting studs.
2) Coat lip of oil seal lightly with engine oil. Position
DETROIT
seal with lipDIESEL 8.2L V8Article
pointed toward Text (p.
flywheel housing, and14) Forseal
slide overpacific la ca 92101© 1996 Mitchell International, All Rights Reserved.Tuesday, S
cyph8r
expander onto crankshaft.
3) Remove expander and mounting studs. Using Seal Installer
(J-29010-A) and handle, drive seal in until tool bottoms against
flywheel housing. Install flywheel.
Seal Installation (Flywheel Housing Removed)

1) Support inner face of housing in arbor press or on flat
surface. Position seal with lip pointed toward flywheel housing.
2) Coat lip of oil seal lightly with engine oil. Using Seal
Installer (J-29010-A) and handle, drive seal in until tool bottoms
against flywheel housing.
FLYWHEEL
Removal
1) Remove flywheel bolts and scuff plate. While holding
flywheel in position by hand, reinstall one bolt finger tight.
CAUTION: When removing or installing bolts, hold flywheel firmly

against crankshaft by hand to prevent it from slipping off
end of crankshaft. Flywheel is NOT doweled to crankshaft.
2) Install lifting tool to flywheel. See Fig. 13. Attach

hoist to lifting device. Remove remaining flywheel bolt. Remove
flywheel.
Fig. 13: Removing Flywheel

Installation
1) Apply International Compound No. 2 to threads and
underside of bolt head on all bolts. Install guide studs. Position
flywheel in housing with lifting device.
2) Install 2 flywheel bolts through scuff plate 180ø apart.
Snug bolts to hold flywheel and scuff plate to crankshaft. Remove
lifting device and guide studs. Install remaining bolts and run them
in snug.
3) Tighten flywheel bolts. Mount dial indicator on flywheel
housing and check runout of flywheel at clutch contact face. Maximum
runout is .0010" (.025 mm) total indicator reading per inch of radius.
FLYWHEEL HOUSING
Removal
1) Disconnect battery. Remove starter. With flywheel removed,
remove 6 oil pan-to-flywheel housing bolts and all flywheel housing-
to-block bolts. Note location of bolts.
2) Install aligning studs to guide housing until it clears DETROIT DIESEL 8.2L V8Article Text (p. 15)For cyph8r pacific la
from crankshaft. Remove housing. Remove crankshaft oil seal.
Installation
1) Install new crankshaft oil seal with Installer
(J-29010-A). Coat flywheel housing-to-block sealing surface with
sealant. Coat lip of crankshaft oil seal lightly with oil. Install
Expander (J-29009-A) to pilot oil seal.
2) With aligning studs attached to block, guide housing into
place up against cylinder block. Remove expander. Install all flywheel
housing bolts in their proper location, finger tight. Remove aligning
studs.
3) Tighten 4 long outer housing-to-block bolts 34-39 ft. lbs.
(46-53 N.m). Tighten remaining 9 bolts (inside bell housing)
43-49 ft. lbs. (58-66 N.m). Tighten 6 oil pan bolts. Install flywheel.
See FLYWHEEL installation procedure.
4) Thread dial indicator Base Post (J-9737-3) tightly into
one of tapped holes in flywheel. See Fig. 14. Assemble dial indicators
on base post.
Fig. 14: Checking Flywheel Housing Concentricity

5) Position dial indicators straight and square with flywheel

housing bell face and inside bore of bell. Tap front end of crankshaft
with soft hammer toward one end of block to ensure end play is in one
direction.
6) Adjust each dial indicator to read zero at 12 o'clock
position. Rotate crankshaft one full revolution, taking reading at 45ø
intervals (8 readings each for bore and bolting flange face).
7) Stop rotating crankshaft before recording each reading to
ensure accuracy. Maximum total indicator reading must not exceed .013"
(.33 mm) for each bore face.
8) If runout exceeds limits, remove housing and check for
dirt or foreign material between end plate, housing and new gasket.
Repeat installation procedure.
ENGINE COOLING
WATER PUMP
Removal DETROIT DIESEL 8.2L V8Article Text (p. 16)For cyph8r pacific la
1) Remove drive belts. Remove fan assembly and water pump
pulley. Drain cooling system.
2) Remove hoses from pump body. Remove pump body-to-engine
front cover bolts and detach pump.
Disassembly
1) Remove pulley hub using Puller (J-29190-A). See Fig. 15.
Fig. 15: Removing Pulley Hub From Bearing Shaft

2) Using Water Pump Bearing Remover/Installer (J-29189),

press shaft/bearing assembly, seals and impeller out of pump body as
an assembly. See Fig. 16.Discard all water pump parts (even pulley
hub) except body.
DETROIT DIESEL 8.2L V8Article Text (p. 17)For cyph8r pacific la ca 92101© 1996 Mitchell International, All Rights Re
DETROIT DIESEL 8.2L V8Article Text (p. 18)For cyph8r pacific la ca 92101© 1996 Mitchell International, All Rights Reserved.Tuesday, S
Fig. 16: Removing & Installing Shaft/Bearing Assembly

Inspection
1) Examine pump body for cracks and excessive impeller
contact with body. Inspect bearing cavity for scores where outer
perimeter of water seal assembly seats and seals against bearing
cavity bore.
2) Measure bearing cavity inside bore diameter. Bore diameter
must be within 1.4970-1.4980" (38.036-38.054 mm) to provide sufficient
bearing press fit. Replace pump body if beyond diameter.
Reassembly
1) Press shaft/bearing assembly, with Water Pump Bearing
Remover/Installer (J-29189), into pump body until outer race of
bearing is flush with outer face of pump body. See Fig. 17.
Fig. 17: Water Pump Assembly
2) Supporting water pump shaft (impeller side) on arbor

press, press new pulley hub on shaft use Hub Remover/Installer
(J-29191).
3) Before installing seals, 3 water pump pulley hub
measurements are required with magnetic Base Dial Indicator (J-7872).
See Fig. 18 for water pump pulley hub Total Indicator Runout (TIR)
measurement locations.
* Location "A" = .0050" (.127 mm) maximum face TIR measured
outside of 4.0" (101.6 mm) diameter bolt hole circle.
* Location "B" = .0030" (.076 mm) maximum radial TIR
* Location "C" = .0020" (.051 mm) maximum radial TIR
DETROIT DIESEL 8.2L V8Article Text (p. 19)For cyph8r pacific la ca 92101© 1996 Mitchell International, All Rights Reserved.Tuesday, S
Fig. 18: Locating Water Pump Pulley Hub Measurements

4) When water pump pulley hub is found to be outside of

allowable limits, remove pulley hub (DO NOT REUSE) and inspect shaft.
5) If shaft is found to be okay, install new pulley hub and
repeat measurement procedure.
6) Press lip type oil seal (spring side positioned toward
impeller) into pump body bore, bottoming against outer race of
bearing, using Water Pump Bearing Remover/ Installer (J-29189).
7) Install water seal assembly into pump body bore. Ceramic
face of seal must not be contacted during installation.
8) Coat ceramic face side only of mating seal with an
ethylene glycol antifreeze and water mixture of 50/50.
9) Slide mating seal assembly over impeller end of shaft
bottoming against water seal assembly. Rubber (Black) portion of face
mating seal seats against impeller and ceramic side (White) seats on
water seal assembly.
10) Support shaft on pulley hub end and press impeller (using
its inner hub) on shaft with Puller (J-29190-A).
11) Check dimensions between impeller blades and body with
feeler gauge. Clearance is .001-.036" (.025-.91 mm).
12) Using straightedge, check to ensure impeller does not
protrude beyond pump body surface more than .018" (.47 mm) maximum
after assembly on surface "B". See Fig. 18.
13) Impeller may have to be repositioned inward or outward to
meet specifications.
Installation
Affix new seal ring to pump body. Mount pump on engine.
Tighten bolts. Install hoses. Install remaining components.
THERMOSTAT
Removal
Drain cooling system. Remove hose connections between water
pump and radiator. Loosen bolts and remove water outlet elbow from
water pump housing. Discard gasket. Remove thermostat.
Installation
To install, reverse removal procedure.
ENGINE OILING
A rotor-type pump draws oil from oil pan through screen and
delivers it to oil filter. See Fig. 19. From filter, oil flows to oil
cooler and then enters longitudinal oil gallery in cylinder block
where supply divides. Part of oil goes to camshaft bearings and up
through rocker assemblies. Remainder of oil goes through oil passages
in crankshaft to main bearings and connecting rod bearings.
DETROIT DIESEL 8.2L V8Article Text (p. 20)For cyph8r pacifi

Fig. 19: 8.2L Engine Oiling System
OIL PUMP
Removal
Remove front cover assembly. See ENGINE FRONT COVER. Loosen
and remove oil pump cover bolt and cover. Remove outer rotor cover.
Remove inner rotor and hub.
Inspection
1) Inspect lobes and faces of pump rotors and pump bushing in
cylinder block for scratches or burrs. Measure clearance between inner
and outer rotors at each lobe. Clearance is .0015-.006" (.04-.15 mm).
2) Inspect teeth on outer rotor gear for chipped or worn
teeth. Replace both gears, if necessary, even when one gear is chipped
or worn.
Installation
1) Lubricate oil pump outer rotor with engine oilFor
DETROIT DIESEL 8.2L V8Article Text (p. 21) andcyph8r place pacific la ca 92101© 1996 Mitchell International, All Rights Reserved.Tuesday, S
in cylinder block. Lubricate oil pump inner rotor with engine oil and
place in hub.
2) Install inner rotor and hub with smaller diameter end of
hub into outer rotor. Seat small diameter in bolt hole counterbore.
Install cover and bolt over pump and tighten bolt. Rotate gear 7 full
turns to ensure freeness of pump after installation.
3) Check gear backlash with dial indicator. See
OIL PUMP GEAR BACKLASH table. Install front cover assembly. See
ENGINE FRONT COVER.
OIL PUMP GEAR BACKLASH

Application In. (mm)
New .......................................... .001-.006 (.025-.152)

Used ................................................... .009 (.228)
OIL COOLER
Removal
1) Remove plug at bottom of oil cooler cover to drain cooling
system. Remove any accessories or other equipment necessary to provide
access to cooler.
2) Disconnect hoses from both ends of oil cooler cover.
Matchmark end of oil cooler cover, cooler core and adapter so they can
be reinstalled in same position. Remove bolts which attach cover and
core to filter adapter.
Inspection
1) Inspect housing and cover for cracks or damage. Use
adapters to plug openings on oil cooler. See Fig. 20.
Fig. 20: Preparing Oil Cooler For Pressure Test

2) Place oil cooler into heated water (180øF or 82øC) tank

and apply 75-150 psi (5.27-10.54 kg/cm2) to oil cooler. Inspect for
leaks.
Installation
To install, reverse removal procedure with new gaskets and
seals. Ensure cooler is installed in its original position. Check for
leaks.
OIL PRESSURE
Normal oil pressure is 35-50 psi (2.4-3.5 kg/cm2) at

3,000 RPM.
OIL & FILTER CHANGE INTERVALS

Application Intervals
Highway Truck, Buses &

Pickup & Delivery
Oil Change .................................... Every 6,000 Miles
Oil Filter .................................... Every 6,000 Miles
Stand-By Engine DETROIT DIESEL 8.2L
Oil Change ............................ Every 150 Hrs. Or One Yr.
Oil Filter ............................ Every 150 Hrs. Or One Yr.
OIL CAPACITIES
Normal oil capacity is 10 Qts. (9.5L).
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Cam Follower Guide ................................... 17-20 (23-27)

Camshaft Gear ........................................ 43-49 (58-66)
Connecting Rod Caps .................................. 59-70 (80-95)
Crankshaft Pulley Bolt ........................... 246-283 (334-384)
Cylinder Head Bolts
(14 mm) ............................................ (1) 145 (196)
(15 mm) ............................................ (2) 110 (150)
Flywheel Bolts ...................................... 64-67 (87-100)
Flywheel Housing Bolts ......................................... (3)
Front Cover Bolts .................................... 22-25 (30-34)
Injector Clamp ......................................... 7-9 (10-12)
Injector Control Tube Assembly ....................... 22-25 (30-34)
Main Bearing Caps ................................ 103-118 (140-160)
Oil Pump Cover Bolts ................................. 43-49 (58-66)
Pulley/Damper Assembly ........................... 246-283 (334-384)
Rocker Arm Bracket ................................... 34-39 (46-53)
Rocker Cover Bolts ................................... 17-20 (23-27)
Valley Cover Bolts ................................... 17-20 (23-27)
Water Pump Bolts
M10 x 70 mm ........................................ 34-39 (46-53)
M8 x 20 mm ......................................... 22-25 (30-34)
(1) - Tighten about 1/2 turn at a time.

(2) - Tighten bolt additional 1/4 turn.
(3) - See FLYWHEEL HOUSING..
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Specification
1981-92 8.2L (500 Cu. In.)

Non-Turbo
Fuel System ........................... Continuous Fuel Injection
HP@RPM ............................................. (1) 130@2800
(2) 145@2800
Torque Ft. Lbs.@RPM ................................ (1) 315@1200
(2) 330@1200
Compression Ratio ........................................ 18.3:1
Bore ............................................. 4.25" (108 mm)
Stroke ........................................... 4.41" (112 mm)
Turbo
DETROIT DIESEL 8.2L V8Article Text (p. 23)For cyph8r pacific la ca 92101© 1996 Mitchell International, All Rights
Fuel System ........................... Continuous Fuel Injection
HP@RPM ............................................. (3) 165@2800
(3) 160@2800
(4) 205@2800
Torque Ft. Lbs.@RPM ................................ (3) 375@1400
(2) 375@1400
(2) 442@1700
Compression Ratio ........................................ 16.9:1
Bore ............................................. 4.25" (108 mm)
Stroke ........................................... 4.41" (112 mm)
(1) - With 4A40 Injectors.

(2) - With 4B45 injectors.
(3) - With 4A53 injectors.
(4) - With 4C65 injectors.
VALVES
500 Cu. In.

Intake
Head Diameter ............................................... N/A
Face Angle .................................................. 30ø
Seat Angle .................................................. 31ø
Seat Width .................................................. N/A
Stem Diameter ............................................... N/A
Stem Clearance .............................................. N/A
Valve Lift .................................................. N/A
Exhaust
Head Diameter ............................................... N/A
Face Angle .................................................. 45ø
Seat Angle .................................................. 46ø
Seat Width .................................................. N/A
Stem Diameter ............................................... N/A
Valve Lift .................................................. N/A
PISTONS, PINS, RINGS

500 Cu. In.

Pistons Clearance ............................. .001" (03 mm) Max.
Pins
Piston Fit ................................. (1) .0027" (.068 mm)
Rod Fit ..................................... (2) .0038" (.98 mm)
Rings
Ring No. 1
End Gap ................................ .010-.020" (.25-.50 mm)
Valve Lift ..................... (3) .0027-.0055" (.068-.139 mm)
Ring No. 2
End Gap ................................ .010-.020" (.25-.50 mm)
Valve Lift ...................... (3) .002-.0035" (.050-.088 mm)
Ring DETROIT
No. 3 DIESEL 8.2L V8Article Text (p. 24)For cyph8r pacific la ca 92101© 1996 Mitchell International, All Rights Reserved.Tu
End Gap ................................ .010-.020" (.25-.50 mm)
Valve Lift ...................... (3) .002-.0033" (.050-.083 mm)
(1) - Piston and piston pin maximum clearance.

(2) - Connecting rod and piston pin maximum clearance.
(3) - Ring-to-groove side clearance.
CRANKSHAFT MAIN & CONNECTING ROD BEARINGS

500 Cu. In.

Standard Size
Main Bearings
Journal Diameter ............. 3.9360-3.9370" (99.975-100.00 mm)
Clearance ................................. .005" (.127 mm) Max.
Thrust Bearing ........................................... No. 4
Crankshaft End Play .................... .007-.015" (.19-.38 mm)
Connecting Rod Bearings
Journal Diameter .............. 2.7549-2.7559" (69.975-70.00 mm)
Clearance ................................. .006" (.150 mm) Max.
Side Play .............................. .008-.010" (.20-.25 mm)
Undersize .010" (.254 mm)
Main Bearings
Clearance ................................. .005" (.127 mm) Max.
Thrust Bearing ........................................... No. 4
Crankshaft End Play .................... .007-.015" (.19-.38 mm)
Connecting Rod Bearings
Clearance ................................. .006" (.150 mm) Max.
Side Play .............................. .008-.010" (.20-.25 mm)
CAMSHAFT
500 Cu. In.

Journal Diameter ............... 2.5618-2.5646" (65.069-65.140 mm)
Clearance ............................ .0031-.0099" (.078-.251 mm)
Lobe Lift .................................................... N/A
END OF ARTICLE
DETROIT DIESEL 8.2L V8Article Text (p. 25)For cyph8r pacific la ca 92101© 1996 Mitchell International, All Rights Reser

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DETROIT DIESEL 8.

The engine model and serial numbers are located on a metal

EXHAUST & INTAKE MANIFOLDS

CYLINDER HEAD (REPLACEMENT)

NOTE: Because of various accessory equipment available, only

CYLINDER HEAD FLATNESS LIMITS

Longitudinal ........................................... .006 (.152)

NOTE: Cylinder head welding is not recommended. If cylinder head is

NOTE: All 8.2L engines produced after October, 1985 (Serial

3) Install head bolts finger tight. Tighten bolts, about

DETROIT DIESEL 8.2L V8Article Text (p. 2)For cyph8r p

4) Install fuel injectors. Install valve and injector push

I-E-I-E-I-E-I-E (Left bank, front-to-rear).

VALVE CLEARANCE ADJUSTMENT

CAUTION: Ensure injectors are in no-fuel position before rotating

1) Rotate crankshaft in right-hand direction until piston is

VALVE CLEARANCE SPECIFICATIONS

Hot ..................... .011 (.28) .................. .012 (.31)

(1) - 100øF (38øC) or less.

CYLINDER HEAD (OVERHAUL)

Removal (Cylinder Head Removed)

Fig. 2: Exploded View Of Valve Assemblies

Removal (Valve Springs) (Cylinder Head On Engine)

Installation (Valves & Springs)

Removal & Installation

VALVE SPRING HEIGHT

Use Spring Tester (J-22738-02) to check spring load. Replace

ROCKER ARM ASSEMBLY

NOTE: Injector rocker arm is slightly different from valve rocker

2) If worn, surface may be faced up to maximum of .010"

2) Remove spring from center group of 3 cam followers. Remove

NOTE: If change in injector timing or valve clearance occurs during

CAM FOLLOWER LIMITS

Cam Follower-To-Cylinder Block .......................... .004 (.10)

3) Examine camshaft lobes for scoring, pitting or flat spots.

CAMSHAFT & TIMING GEARS

ENGINE FRONT COVER

Fig. 4: Installing Oil Pan Seal

FRONT COVER SEAL

Removal (Cover On Engine)

Installation (Cover On Engine)

Removal (Front Cover Removed)

GEAR BACKLASH LIMIT

New .......................................... .003-.007 (.076-.177)

PISTONS, PINS & RINGS

PISTON & ROD ASSEMBLY

2) Install each piston and rod assembly in its respective

FITTING & INSTALLING RINGS

1) Pistons have 3 rings (2 compression rings and 1 oil ring).

Fig. 9: Locating Ring For Turbo & Non-Turbo Engines

2) Second ring used in both type engines uses rectangular

DETROIT DIESEL 8.2L V8Article Text (p. 11)For cyph8r

4) Measure ring gap with feeler gauge. If gap on compression

Fig. 11: Measuring Piston Ring Side Clearance

CRANKSHAFT & ROD BEARINGS

1) Remove one main bearing cap at a time with lower bearing

MAIN BEARING THICKNESS LIMITS

Standard ......... .1250-.1255 (3.175-3.188) ......... .124 (3.15)

CONNECTING ROD BEARINGS

1) Remove one connecting rod bearing cap. Check clearance

CONNECTING ROD BEARING THICKNESS LIMITS

Standard ......... .0950-.0955 (2.413-2.416) ...... .0933 (2.370)

THRUST BEARING ALIGNMENT