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Cylinder Block Bore Inspection
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TM-5-4210-220-34 Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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INSTALLATION - TM-5-4210-220-34_480
TM 5-4210-220-34 3-8. ENGINE - Continued g. Cylinder Block Deck Surface Inspection (1) Check head contact area of block for flatness with block straight edge and feeler gage. (2)  Block  should  not  vary  more  than  0.003  in. (0.008 mm) transversely or 0.006 in.  (0.15 mm) longitudinally. (3) Distance from centerline of crankshaft to top of   block/head   surface   must   be   between 16.184 in. and 16.189 in.  (411.07 - 411.20 mm).    If  block  is  not  within  specification,  it must be replaced. h. Cylinder Counterbore Inspection WARNING Death or serious injury could occur if compressed air is directed against the skin.  Do not use compressed air for cleaning or drying unless the pressure Is/has been reduced to 30 psi (2.11 kg/cm2) or less.  When working   with   compressed   air   always   use   chip   guards,   eye   protection   and   other   personal   protective equipment. (1) Thoroughly clean cylinder liner counterbores.  Blow area clean with compressed air. (2) Measure counterbore depth.  Counterbore depth must be 0.4755 0.4770 in.  (12.078 12.116 mm) or 0.4905 0.4920 in.  (12.459 12.497 mm) and must not vary more than 0.0015 in.  (0.038 mm) throughout the entire circumference.  There must not be over 0.0015 In.  (0.038 mm) difference between any two adjacent cylinder counterbores when measured along the cylinder longitudinal center line of the cylinder block. j. Block Bolt Hole Threads Inspection (1)     Inspect cylinder head and main bearing cap bolt holes.  If threads are damaged, use a tap to clean up the threads or Install a helicoil thread insert. (2)     An  insert  thread  repair  kit,  J29513,  is  available  for  installing  an  11/16  in.    -  11  helicoil  thread  insert  in  the cylinder head and main bearing cap retaining bolt holes of the cylinder block. INSTALLATION (1)     Install  all  oil  gallery  and  core  hole  plugs  removed  for  cleaning  procedure.    Use  pipe  sealant  (item  22, Appendix B) on all threads. (2)     Use  pipe  sealant  (item  22,  Appendix  B)  on  outer  diameter  of  any  cup  plugs  being  installed.    Always  use proper sized driver and pilot to fit cup plug.  2 1/2 in.  plugs use driver J8092 and adapter J24597; 1 5/8 in. plugs use driver J7079-02 and adapter J21850. (3)     Coat airbox bore plugs (2 1/2 - 16) with engine oil (item 17, Appendix B).  Tighten to 270 ft lb (336 Nm) using plug installer J23019. 3-189

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