Section I. GENERAL MAINTENANCE INSTRUCTIONS 3-1. OVERVIEW
TM 9-2815-225-34&P 3-34. ENGINE BLOCK REPAIR (Contd)
3-91
c. Inspection and Repair (Contd)
15. Fourteen washers (17) Inspect carefully for any cracks Discard if any evidence or or indication of cracks. indication of cracks exist.
16. Six self-locking screws (8) Inspect threads for damage. Discard if damaged.
and twelve captive washer screws (11)
NOTE
Ensure engine block is checked on a flat surface to prevent distortion. Do not inspect engine block on maintenance stand.
17. Engine block (14) Inspect for the following:
a. Check for wear or damage. Discard if damage is beyond repair.
b. Check for cracks. Clean area to be checked with
SD-3 solvent. Use crack detection kit (3375432) to find cracks.
c. Check for corrosion. Check for corrosion on engine block (14) near cylinder sleeves (2). Discard if counterbore area cannot be cleaned or repaired.
d. Check for flatness. Check with straightedge and feel-er gauge. If milling is required and 0.01-0.02 in. (0.25-0.51 mm) of metal is removed from top of engine block (14), use oversize gasket (3036126) to maintain cor-rect distance between cylinder head and engine block (14).
e. Inspect all threads. Repair with suitable thread chas-er. Use solid bushing-type thread insert for damaged cylinder head screw threads, and Heli-Coil insert for damaged main bearing screw threads.
f. Check for wear or damage in Replace if damaged or worn.
area of six head-to-block pins (6).
g. Check for wear or damage in Replace if damaged or worn.
area of six cam follower pins (15).
TM 9-2815-225-34&P
3-34. ENGINE BLOCK REPAIR (Contd)3-93
c. Inspection and Repair (Contd)
18. Bearing cap (19), Install on engine block (14) and Ensure bearing caps (19), (20),
three bearing caps (20) and tighten as follows: and (21) are in their correct
(21), fourteen washers (17), location and position.
and screws (18)
a. Tighten fourteen screws (18) to 85 lb-ft (115 N•m) in sequence shown. Then tighten each screw (18) to 250-260 lb-ft (339-353 N•rn).
b. Loosen fourteen screws (18) three to five threads or a
minimum of three complete turns.
c. Repeat step 18a.
19. Bores of installed bearing Install bore alignment checking Use bore alignment checking bar caps (19), (20), and (21) of bar. Measure bore diameter of (ST-1157). For greater accuracy, engine block (14) each at three different locations. place engine block (14) on end
before measuring bore diameter.
Minimum bore is 4.7485 in.
(120.6119 mm); maximum is 4.7505 in. (120.6627 mm). Discard if maximum is exceeded.
CAUTION
Never use reamer in place of a check bar. Damage to cylinder block will result.
20. Bore alignment of installed a. Install suitable bore alignment Bore alignment checking bar bearing caps (19), (20), and checking bar. Inspect for burrs (ST-1157) should turn freely.
(21) of engine block (14) or slight binding. Remove burrs with emery cloth.
If a slight bind exists, perform step b.
b. If necessary, remove 0.0002- If alignment cannot be obtained, 0.003 in. (0.0051-0.076 mm) of refer to step 21 and ream bore stock from bottom milled surface of installed bearing caps (19), of the main bearing caps which (20), and (21).
are out of alignment. Remove stock by lapping or surface grinding.
TM 9-2815-225-34&P
3-34. ENGINE BLOCK REPAIR (Contd)3-95
c. Inspection and Repair (Contd)
•• Omit this step if replacement caps are being used.NOTE
•• Reaming of bearing cap bore requires bearing caps be installed and tightened to specifications.
21. Bearing cap bore of engine Use suitable reamer; ream as
block (14) follows:
a. Position reamer bar on engine block (14) so rear of bar is piloted in two good bearing cap bores.
b. Lubricate reamer with OE/HDO 10 lubricating oil.
c. Use hand driver to turn reamer.
d. Run reamer through all seven bearing cap bores without backing up or reversing.
e. Check bearing cap bore with Clean block thoroughly after
checking bar and measure reaming.
diameter with dial indicator.
22. No. 7 bearing sleeve (22), Inspect for the following:
four camshaft bushings (23), a. Chips, scoring, or scratches. Replace if scratched, scored, or
and two camshaft bushings chipped. Proceed to step 23 for
(24) removal.
b. Spun or turned within bore of If camshaft bushings have turned,
engine block (14). oil passages will not be aligned.
Remove and discard any camshaft bushing that has spun or turned.
Proceed to step 23 for removal.
c. Using inside micrometer Refer to Appendix F for wear or dial bore gauge, measure limits. Mark each camshaft
each inside diameter. bushing for replacement if
not within wear limits. Proceed to step 23 for removal.
TM 9-2815-225-34&P
3-34. ENGINE BLOCK REPAIR (Contd)3-97
c. Inspection and Repair (Contd)
23. No. 7 bearing sleeve (22), Remove from engine block (14). Use camshaft bushing driver kit
four camshaft bushings (23), (3376633). Discard after removal.
or two camshaft bushings (24)
NOTE
Before installation of bearing sleeve and camshaft bushing(s), inspect camshaft bushing bore of cylinder block.
24. Camshaft bushing bore in Inspect for the following: Refer to Appendix F for wear
engine block (14) limits.
a. Check for burrs or nicks. Remove with medium-grit emery cloth.
b. Check for concentricity of Use suitable measuring device.
camshaft bushing bore.
c. Open and clean oil passages. Clean with suitable brush.
25. No. 7 bearing sleeve (22), Install on camshaft bushing four camshaft bushings (23), bore of engine block (14) as or two camshaft bushings follows:
(24)
a. Ensure oil passages are open in camshaft bushing bore.
b. Ensure there are no burrs in camshaft bushing bore of engine block (14).
c. Install with oil holes aligned Use camshaft bushing driver kit to holes in camshaft bushing (3376633). Apply a light coat of
bores. OE/HDO 10 lubricating oil to
inside diameter of No. 7 bearing sleeve (22), camshaft bushing (23) or (24) after installation.
d. The alignment notch on No. 7 bearing sleeve (22) must align with oil drain opening in No. 7 camshaft bushing bore.
TM 9-2815-225-34&P
3-34. ENGINE BLOCK REPAIR (Contd)3-99
c. Inspection and Repair (Contd)
26. Cylinder liner counterbore Inspect for the following:
of engine block (14)
a. Check for dirty or rough edges. Remove trapped dirt and clean rough edges.
b. Check inside diameter and Counterbore diameter must be depth at four equally spaced measured in liner press fit area positions. Refer to Appendix F for 0.100 in. (2.54 mm) maximum
wear limits. below deck. Repair and shim
cylinder liner counterbore if the following conditions are not met.
Refer to step 27 for counterbore repair.
a. Difference in measurement around circumference must not exceed 0.001 in. (0.0254 mm).
b. Ledge must be parallel with top of engine block (14) to within 0.0014 in. (0.0356 mm).
NOTE
When checking cylinder liner protrusion, ensure shim(s) and cylinder sleeve correspond to cylinder being inspected as tagged during removal.
c. Check cylinder sleeve (2) Installing cylinder sleeve (2) protrusion. Measure depth of is not necessary. Cylinder sleeve cylinder sleeve counterbore of shims (31), (32), (33), (34), (35), and engine block (14) and outside (36) are available in the following flange of cylinder sleeve (2) for thicknesses: 0.007, 0.008, 0.009, corresponding cylinder. Subtract 0.020, 0.031, and 0.062 in.
difference to determine amount of shims and/or depth of counter-bore cut.
NOTE
Cylinder head surface of engine block must be flat and without damage or distortion. Use a straightedge and a 0.002-in. feeler gauge to check cylinder head surface.
TM 9-2815-225-34&P
3-34. ENGINE BLOCK REPAIR (Contd)3-101
c. Inspection and Repair (Contd)
NOTE
The cylinder sleeve counterbore must be altered or repaired if:
a. Material has been milled from top surface of cylinder block.
b. Ledge of counterbore is not flat or even.
c. Protrusion of cylinder liner is not correct.
d. Cracks extend more than halfway out from radius.
27. Cylinder sleeve counterbore Repair as follows:
of engine block (14)
a. Position adapter plate on Use engine block counterbore tool cylinder sleeve counterbore. (3375455). Check counterbore tool
bit before boring operation. A cor-rectly ground tool bit will leave counterbore surface completely flat or cupped to a 30-degree angle. The cup is preferred with a 0.005-0.015-in. (0.127-0.381-mm) radius as shown in cylinder sleeve counterbore cross section.
b. Tighten top and bottom locating pins by turning in screws.
c. Set tool adjustable sleeve so blade just contacts bottom of counterbore ledge.
TM 9-2815-225-34&P
3-34. ENGINE BLOCK REPAIR (Contd)3-103
c. Inspection and Repair (Contd) 27. Cylinder sleeve counterbore
of engine block (14) (Contd)
CAUTION
•• Never turn counterbore tool counterclockwise. Doing so will damage cutter blade.
•• Do not remove more than a total of 0.062 in. (1.575 mm) of material when counterbor-ing. Inside diameter of ledge should never be less than outside diameter of cylinder sleeve. A ledge that drops toward center of cylinder may cause cylinder sleeve to break during installation.
d. Turn counterbore tool clockwise with even pressure.
e. Use a series of light cuts to Do not remove more than clean up entire circumference 0.004 in. (0.102 mm) material
of seat. per cut.
f. Check seat to determine if additional cuts are required.
g. Chamfer edge of counterbore Use shims to compensate for ledge 45° after counterboring. metal removed and to restore Do not chamfer deeper than cylinder sleeve (2) protrusion to 0.013-0.024 in. (0.330-0.610 mm). 0.003-0.006 in. (0.076-0.152 mm).
Use as few shims as possible.
Where possible, use one thick shim in place of two or more thin-ner shims.
h. Remove counterboring tool.
28. Six cam follower Inspect for wear or damage. Replace if worn or damaged.
pins (15) Force may be required to remove
cam follower pins (15). They are a press fit. Install using a brass hammer.
29. Six head-to-block Inspect for wear or damage. Replace if worn or damaged.
pins (6) Force may be required to remove
head-to-block pins (6). They are a press fit. Install using a brass hammer.
d. Assembly
NOTE
•• Assembly steps 30 through 34 will to be completed prior to mounting engine block on maintenance stand.
TM 9-2815-225-34&P
3-34. ENGINE BLOCK REPAIR (Contd)3-105
d. Assembly (Contd)
32. Four plugs (26) Install on engine block (14). Balance of plugs are on opposite
side of block. Tighten to 15 lb-ft (20 N•m).
33. Five plugs (30) Install on engine block (14). Tighten plugs (30) to 35 lb-ft
(48 N•m). One is shown; four are on opposite side of block.
34. Plug (27) and washer (28) Install on engine block (14). Tighten plug (27) to 70 lb-ft (95 N•m). When step 34 is completed, mount engine block (14) on suitable maintenance stand.
CAUTION
•• Prior to installation, engine block counterbore must be free of sharp edges that would cut or damage cylinder sleeve preformed packings.
•• If engine block counterbore and cylinder sleeve flange are not clean and free from oil prior to installation, improper sealing or protrusion may result.
NOTE
Before final installation of cylinder sleeves, ensure protrusion of each cylinder sleeve is correct. Refer to step 26 for checking protrusion.
35. Cylinder sleeve shims (31) Install on cylinder sleeve (2) as Amount of shims required was
through (36) required. determined during inspection.
36. New gasket (3), new black Install on cylinder sleeve (2). Install new gasket (3) with
preformed packing (4), chamfer down in top groove, new
and new red preformed black preformed packing (4) on
packing (5) center groove, and new red
pre-formed packing (5) on bottom groove. Repeat this step for remaining cylinder sleeves (2).
TM 9-2815-225-34&P
3-34. ENGINE BLOCK REPAIR (Contd)3-107
d. Assembly (Contd)
CAUTION
•• Do not lubricate preformed packing until ready to install assembled cylinder sleeve.
Preformed packing will increase in size once in contact with OE/HDO 10 lubricating oil for more than 10 minutes.
•• Prior to installing a cylinder sleeve, apply a bead of inner sealer on counterbore of cylinder sleeve flange. Do not use an excessive amount of sealer. Excessive amounts can cause problems in cooling system.
•• Do not permit lubricating oil once applied to preformed packing to come in contact with liner sealant. Oil will prevent sealant from adhering to liner flange and counterbore contact surface.
NOTE
Diameter of applied sealer bead must be at least 3/64 in. (1.2 mm) and not more than 1/16 in.
(1.6 mm) wide. Cylinder sleeve must be installed within five minutes after sealer has been applied.
37. Six cylinder sleeve Install on engine block (14) as Lubricate black preformed
assemblies (1) follows: packing (4), red preformed
pack-ing (5), and gasket (3) with OE/HDO 10 lubricating oil. Install assembled cylinder sleeves (2) within 10 minutes.
a. Place cylinder sleeve (2) on bore of engine block (14) by hand.
b. Push downward with one Ensure preformed packings (4)
quick stroke. and (5), and gasket (3) do not
move from groove.
c. Using cylinder sleeve driver Use sleeve driver (ST-1229).
and a mallet, drive flange against counterbore edge.
d. Install two cylinder sleeve Tighten clamps to 50 lb-ft (68 N•m).
clamps (37) on engine block (14) Use cylinder sleeve clamps and cylinder sleeve (2), and check (ST-1154) (37) for securing protru-sion after installation. cylinder sleeve assembly (1) on
cylinder sleeve bore. Use gauge block (3376220) (38) to check pro-trusion. The amount of protrusion must not exceed 0.003-0.006 in.
(0.076-0.152 mm).
e. Check inside diameter for Bore must not be out-of-round out-of-round condition. Measure more than 0.003 in. (0.076 mm) in at several points within range top 1 in. (25.4 mm) area of piston
of piston travel. travel and not more than 0.002 in.
(0.051 mm) in area of gasket (3).
TM 9-2815-225-34&P
3-34. ENGINE BLOCK REPAIR (Contd)3-109
d. Assembly (Contd)
38. Cap (25) Install on rear of engine block (14). Use suitable plug driver and pipe sealant around outside diameter of cap (25).
39. Fourteen screws (18), Install loosely on engine block (14). Bearing caps will be removed at
washers (17), No. 7 bearing assembly during crankshaft
cap (19), No. 2, 4, and 6 installation.
bearing caps (20), and No. 1, 3, and 5 bearing caps (21)
FOLLOW-ON TASKS: • Install engine crankshaft and main bearings (para. 3-68).
• Install pistons, connecting rods, and bearings (para. 3-69).
• Install camshaft and cam followers (para. 3-70).
• Install cylinder head assemblies and pushrods (para. 3-71).
• Install injector assemblies (para. 3-82).
• Perform injection timing (para. 3-72).
• Install accessory drive housing assembly (para. 3-73).
• Install oil pump (para. 3-74).
• Install front gear cover (para. 3-75).
• Install accessory drive pulley (para. 3-76).
• Install air compressor (para. 3-77).
• Install fuel pump (para. 3-78).
• Install vibration damper and crankshaft pulley (para. 3-79).
• Install flexplate or flywheel, flywheel housing, and rear cover (para. 3-80).
• Install oil pan (para. 3-81).
• Install and adjust valve crossheads (para. 3-83).
• Install rocker arm housing assemblies (para. 3-84).
• Adjust injectors and valves (para. 3-85).
• Install engine retarders (para. 3-86).
• Install air aftercooler (para. 3-87).
• Remove engine from maintenance stand (para. 3-88).
• Install starter motor and solenoid (TM 9-2320-273-20 or TM 9-2320-283-20).
• Install bracket, alternator, and belts (TM 9-2320-273-20 or TM 9-2320-283-20).
• Install engine on vehicle (TM 9-2320-273-34 or TM 9-2320-283-34).
TM 9-2815-225-34&P
3-34. ENGINE BLOCK REPAIR (Contd)3-111
a. Disassembly c. Inspection and Repair
b. Cleaning d. Assembly and Testing
INITIAL SETUP:
APPLICABLE MODELS MATERIALS/PARTS
All Solvent, SD-3 (Appendix C, Item 30)
Cloth, crocus (Appendix C, Item 4)
SPECIAL TOOLS Oil, cutting (Appendix C, Item 18)
Head holding fixture (15434) ST-583 Compound, Prussian blue (Appendix C, Item 9) Valve spring compressor (15434) ST-448 Oil, lubricating, OE/HDO 30 (Appendix C, Item 21) Fuel passage cleaning brush (15434) ST-876 Sealant, cup plug (Appendix C, Item 25)
Valve seat extractor (15434) ST-1279 Liquid thread sealant (Appendix C, Item 27) Valve seat insert tool (15434) ST-257 Forty-eight valve collets (15434) 127554 Valve seat insert cutter (15434) ST-662 Four O-ring seals (15434) 131026
Valve guide arbor (15434) ST-663 Six 3/4-in. expansion plugs (15434) 213394 Valve seat insert staking tool (15434) ST-1124 1-in. expansion plug (15434) 213395
Valve seat insert staking tool driver (15434) Two 1-1/4 in. expansion plugs (15434) 216524
ST-1122 Injector assembly (15434) 3030445
Dowel pin extractor (15434) ST-1134 Injector clamp (15434) 3028171
Crosshead guide spacer (15434) ST-633 Two injector clamp screws (15434) 3028279 Valve guide driver (15434) 3375282 Six injector preformed packings (15434) 3007759 Gauge block (15434) 3376220
Injector sleeve puller (15434) ST-1244 PERSONNEL REQUIRED
Bead cutting tool (15434) ST-788 Automotive repairman MOS 63H
Injector seat cutting tool (15434) ST-824
Injector sleeve driver (15434) ST-1227 TROUBLESHOOTING REFERENCES
Injector sleeve holding tool (15434) ST-1179 Para. 2-8 Injector sleeve expander (15434) ST-880
Injector seat cutter (15434) ST-884 EQUIPMENT CONDITION
Valve spring tester (15434) 3375182 Cylinder head assembly removed (para. 3-24).
Expansion plug driver (3/4-in.) (15434)
3375190 REFERENCES (TM)
Expansion plug driver (1-in.) (15434) 3375191 None Expansion plug driver (1-1/4 in.) (15434)
3375192 SPECIAL ENVIRONMENTAL CONDITIONS
Valve vacuum tester (15434) ST-1257-A Work area clean and away from blowing dirt and dust