ENGINE - Continued
Cylinder Block - Continued
(12) Remove the test block and install the cutting tool holder on the micrometer test fixture. Use alien wrench to
set cutting tool (4) for first cut of 0.040 in. (0.016 mm). The point of the cutting tool should be in the center of
(13) Install cutting tool on the boring bar. Do not overtighten alien screws. The tool feeds away from the operator
and rotates clockwise as viewed by the operator.
(14) When installing the cutter, be use the sharp portion of the bit is in the cutting position. Lubricate bar with
engine oil (item 17, Appendix B).
(15) Using 1/2 in. drill with operating speed of 300 400 rpm, attached to universal adapter, move hydraulic feed
unit lever to the closed position.
(16) Line bore the damaged saddle in three steps.
Standard block saddle bore
4.812 in. (122.22 mm)
Set Tool For First Cut
+0.040 in. (1.02 mm)
4.852 in. (123.24 mm)
Set Tool For Second Cut
+0.040 in. (1.02 mm)
4.892 in. (124.26 mm)
Set Tool For Third Cut
+0.020 in. (0.51 mm)
4.912.4.913 (124.76/124.79 mm)
(17) Remove boring bar and clean reworked saddle.
(18) Install and aline the insert with the hold down bolts and plates. Use plate with step on the side of the Insert
opposite the tang. Tighten hold down bolts to 20 ft lb (27 Nm). Check insert for alinement.
(19) Drill four 1/8 in. holes in saddle, 1/4 in. deep, using the predrilled holes in insert as a guide.
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
(20) Use compressed air to clean drilled holes.
(21) Install rivets. Be careful not to strike insert. Rivets are used only for locating insert; the bearing cap holds
insert In place. File off any excess rivet material.
(22) Remove hold down bolts and retaining plates. File any excess material from insert to make flush with the