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Cylinder Block Rebore - TM-5-4210-220-34_482
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TM-5-4210-220-34 Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Cylinder Block Rebore (cont)
TM 5-4210-220-34 3-8. ENGINE - Continued (23)  Install unfinished new undersize service cap on replaced saddle.  Tighten to 240 ft lb (325 Nm). (24)  Line bore the unfinished cap and insert to standard bore using similar three step procedure as used to bore saddle. Service Cap 4.712 in.  (119.68 mm) Set Tool First Cut +0.040 in.  (1.02 mm) 4.752 in.  (1.02 mm) Set Tool Second Cut +0.040 in.  (1.02 mm) 4.792 in.  (121.72 mm) Set Tool Third Cut +0.020 in.  (0.51 mm) Final Dimension 4.812 in./4.813 in.  (122.22/122.25 mm) (25)  Check finished bore with ’NO/GO’ test ring.  The ring should pass through the reworked saddle and cap with a slight drag. (26)  If   cylinder   block   is   line   bored   properly,   there   will   be   no   more   than   0.001   in.      (0.003   mm)   overhaul misalinement from one end of block to other, or 0.0005 in.  (0.013 mm) between adjacent bores. (27)  Thoroughly clean block. b. Cylinder Block Rebore NOTE Using machine shop technique. Machine  shop  repair  is  essential  when rear     main     saddle     is     damaged     and cannot   be   used   to   center   boring   tool J29005. (1) All  critical  dimensions  are  measured  from the   reamed   locating   holes.       These    are 0.937    0.938    in.        (23.80    23.83    mm)    in diameter and are located at each end of the left bank pan rail looking from rear of block. (2) Center line of the crankshaft is 4.999 5.001 in.  (126.97 127.03 mm) in from center line of  reamed  locating  holes  and  4.748  4.752 in.  (120.60 - 120.70  mm)  up  from  pan  rail surface. (3) Machine  the  main  bearing  saddle  bore  to 4.912 - 4.913 in.  (124.76 - 124.79 mm). (4)  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. 3-193

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