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Cylinder Block Rebore - TM-5-4210-220-34_483
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TM-5-4210-220-34 Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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APPENDIX A REFERENCES - TM-5-4210-220-34_485
TM 5-4210-220-34 3-8. ENGINE - Continued 3-8.11 Cylinder Block - Continued (5)     Drill   four   1/8   in.      holes   in   saddle   1/4   in. deep  using  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. (6)     Use compressed air to clean drilled holes. (7)     Install   rivets,   being   careful   not   to   strike insert.      Rivets   are   used   only   for   locating insert; the bearing cap holds insert in place. File of any excess rivet material. (8)     Remove    hold    down    bolts    and    retaining plates.  File any excess material from insert to make flush with the saddle cap. (9)     Install unfinished new undersize service cap on  repaired  saddle.    Tighten  to  240  ft  lb (325 Nm). (10)  Line  bore  the  unfinished  cap  and  insert  to standard  bore  dimensions  of  4.812  4.813 in.  (122.22 - 122.25 mm). (11)  Check finished bore with ’NO/GO’ test ring. The ring should pass through the reworked saddle and cap with a slight drag. (12)  If cylinder block line is properly bored, there will  be  no  more  than  0.001  in.    (0.03  mm) overall misalinement from one end of block to other, or 0.0005 in.  (0.013 mm) between adjacent bores. (13)  Thoroughly clean block. 3-194

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