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INSTALLATION - TM-5-4210-220-34_480
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TM-5-4210-220-34 Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Cylinder Block Rebore - TM-5-4210-220-34_482
TM 5-4210-220-34 3-8. ENGINE - Continued (14)  With bearing in place, tighten rear end plate 5/8 in.  bolts to 110 ft lb (149 Nm) and 3/8 in.  bolts to 35 ft lb (47 Nm). (15)  Remove camshaft bearing. (16)  Trim off any excess gasket material in oil pan gasket mounting area. (17)  If required, rebuild engine. REPAIR a. Cylinder Block Rebore NOTE Use J29005 shop line boring tool, or for machine shop rebore, refer to b.  following. Block removed from truck and stripped as detailed in REMOVAL preceding. (1)     In  order  to  rework  cylinder  block  with  damaged  saddles  caused  by  a  spun  main  bearing  using  line  borer J29005, t here must be two undamaged main bearings saddles, one of which must be the rear main saddle. (2)     If rear main saddle is damaged, block must be machine shop line bored; see b.  following. (3)     Remove all main bearing caps.  Clean rework area. (4)     The two undamaged saddles act as an alinement saddle for centering rings of line borer J29005. (5)     In  a  block  that  has  front  and  rear  saddles  that  can  be  used  as  the  alinement  saddles,  boring  tool  will  only have  to  be  installed  and  set  once  to  enable  repair  work  to  be  done  to  either  number  2,  3,  or  both  main bearing saddles. (6)     Where the two alinement saddles are next to each other, the closest to the rear saddle is repaired first. (7)     Set centering rings into the alinement saddles.  Install main bearing caps and capscrews, but do not tighten. Lubricate centering ring holes with oil (item 17, Appendix B).  Slide boring bar through centering rings.  Bar must rotate freely. (8)     Tighten main bearing capscrews to 230 ft lb (312 Nm).  Centering rings should be held stationary and bar free to rotate. (9)     Install main bearing capscrews fingertight into all remaining saddles to prevent chips from entering bolt holes. (10)  Fasten torsion bar and hydraulic feed unit on either end of cylinder block.  Index the flat on the feed rod into boring bar.  Snug set screw. (11)  Zero the micrometer with the test block.  Micrometer is 0.005 in.  (0.13 mm) per revolution. 3-191

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