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REPAIR - TM-5-4210-220-34_481
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Cylinder Block Rebore - TM-5-4210-220-34_483
TM 5-4210-220-34 3-8. ENGINE - Continued 3-8.11 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 micrometer barrel. (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) Final Dimension 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. 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. (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 saddle cap. 3-192

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