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REMOVAL - TM-5-4210-220-34_473
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TM-5-4210-220-34 Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Cylinder Block Cleaning and Inspection
TM 5-4210-220-34 3-8. ENGINE - Continued 3-8.11 Cylinder Block - Continued INSPECTION a. Cylinder Block Pressure Test In Truck NOTE This procedure is to be used as a quick test to determine if the cylinder heads or cylinder block has been damaged. (1)     Remove rocker covers, para.  2-19.3, and oil pan, para.  2-19.11. (2)     Check/fill  water  jacket  with  mixture  of  water  and  antifreeze,  (item  2,  Appendix  B),  containing  at  least  one gallon of antifreeze.  The antifreeze will penetrate small  cracks  and  its  color  can  be  used  in  detecting  leak location. (3)     Apply 14 psi (100 kPa) via radiator fill neck.  Maintain pressure for two hours if required, to allow mixture time to work it’s way through any cracks that may be present. (4)     Examine exterior of block, interior cylinder bores, air box, oil passages and crankcase area for presence of coolant mixture and repair/replace components as required. b. Block End Plates Inspection (1)     Remove gaskets from both front and rear end plates. (2)     Inspect front and rear end plates for nicks or scratches.  Check plates for warpage.  Replace plates if warped or scored too deep to seal with new gasket. (3)     Inspect plug nuts for cracks or damaged threads.  Replace plug nuts, or end plate as required. (4)     When installing new plug nuts, support end plate on a solid flat surface to avoid destroying the plate.  Press nut in end plate until head on the nut seats on end plate. (5)     Thoroughly clean gasket material from block ends. c. Main Bearing Journal Bore Inspection (1)     Check the bore diameters original position.  No.  1 or front main bearing cap is also stamped on the face of the pan mounting flange of the cylinder block. (2)     Lubricate main bearing bolt threads and bolt head contact areas with a small quantity of anitseize compound (item  4,  Appendix  B).    Tighten  to  240  ft  lb  (325  Nm)  when  making  this  check,    do  not  install  main  bearing stabilizers. (3)     Specified bore diameter is 4.813 - 4.812 in.  (122.22 - 122.25 mm).  If all four bores do not fall within these limits, the cylinder block must be repaired or replaced.  For repair, refer to REPAIR following. 3-184

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