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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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