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INSTALLATION (cont) - TM-5-4210-220-34_470
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TM-5-4210-220-34 Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Cylinder Block.
TM 5-4210-220-34 3-8. ENGINE - Continued (14)  Snug up all bolts.  Rap the caps sharply with a soft hammer to seat them correctly and torque all bolts, except rear cap, to 260 ft lb (350 Nm).  Be sure to start tightening in the sequence No.  2, No.  3, No.  1. (15)  Tighten rear cap bolts to 50 ft lb (68 Nm) and then strike both ends of crankshaft two or three times with a soft hammer to ensure correct seating of the rear cap in the block saddle. (16)  Retorque all bearing cap bolts to 260 ft lb (350 Nm) working in sequence No.  3, No.  2, No. 4, No.  1. (17)  Install stabilizers bolts (1) and washers (2) and tighten to 75 ft lb (100 Nm). (18)  Check the crankshaft rotates freely.  If not, remove and reinstall the crankshaft. (19)  Attach a dial indicator to the block so the plunger rests on the rear crankshaft flange.  Using a 12 in.  (30 mm) pry bar, wedge the crankshaft toward and away from  the  dial  indicator.    Total  end  play  should  be  between 0.004 - 0.011 in.  (0.010 - 0.28 mm). (20)  Excess  end  play  indicates  wrong  thrust  washers  installed,  insufficient  end  play  indicates  a  misalined  rear bearing or dirt or burr on the washer (4). (21)  Install the cylinder liner, piston and connecting rod as detailed in para.  3-8.9. (22)  Install the cylinder heads as detailed in para.  2-19.8. (23)  Install the flywheel housing (and gear train as required) as detailed in para.  3-8.6. (24)  Install the oil pump as detailed in para.  2-19.10. (25)  Install the oil pan as detailed in para.  2-19.11. (26)  Install other equipment removed as required and install engine in truck. 3-181

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