j. Clamp the liner in place with a hold-down clamp,
gaps in a staggered array and star the top of the piston
straight into the ring compressor.
and measure the distance from the top of the liner flange
q. Remove individual cylinder liners and place the
to the top of the block with a dial indicator. The top of the
piston and rod assembly on the liner with the numbers on
flange should be 0.0465 to 0.050 inch below the top of
the rod and cap aligned with the matchmark on the liner.
the block. There should not be more than 0.0015 inch
difference between any two adjacent liners when
measured along the cylinder longitudinal center line. If
The numbers on the side of the connecting rods
the above limits are not met, install the liner in another
and caps identify the rod with the cap and
bore and recheck, or replace the liner.
indicate the cylinder in which they are to be
k. Matchmark the liner and the block with chalk or
used. If a new connecting rod is to be installed,
paint so the liner may be reinstalled in the same posi-tion
the same identification number must be stamped
in the same bore. Place the matchmark on the engine
on the new connecting rod.
serial number side of the block. Remove hold-down
r. Push the piston and rod assembly into the liner
l. Install bushings (18) in piston (19), and ream the
until the piston is out of the ring compressor. Remove
bushings. The inside diameter of the bushings must be
the rod cap and ring compressor. Push the piston into
1.3775 to 1.3780 inches. Insert the cylinder into the liner
the liner until the compression rings pass the liner ports.
and measure the piston-to-liner clearance with a feeler
s. Install seal ring(25) into the cylinder block. Apply
gauge, at four places around the circumference of the
hydrogenated vegetable oil or a permanent anti-freeze
piston. Clearance should be 0.0031 to 0.0068 for new
solution to the inner surface of the seal ring. Rotate the
parts, or a maximum of 0.010 inch for used parts. Mark
crankshaft until the connecting rod journal of the cylinder
the piston and remove it from the liner.
being worked on is at the bottom of its travel. Lubricate
m. Insert one piston ring at a time far enough down
the journal with clean engine oil.
the cylinder liner to be within the normal operating area of
t. Install the upper bearing shell (4) (the one with a
the ring. Use a piston to push the ring down to be sure it
short groove at each parting line), in the connecting rod.
is parallel with the top of the liner. Measure the ring gap
Lubricate the shell with clean engine oil.
with a feeler gauge. Gap should be 0.020-0.046 inch for
u. Install the assembled piston, connecting rod, and
chrome rings and 0.020-0.036 inch for cast iron rings.
liner into the top of the block so that the identification
n. Press spray nozzle (21) into the top of the
number on the rod faces the serial number side of the
connecting rod (22) until it bottoms in the counterbore.
engine. Also, align the match marks on the liner with
Install bushings (20) into the connecting rod, with the joint
those on the block. Insert the assembly until the
located at the top of the connecting rod.
connecting rod mates with the crankshaft journal.
connecting rod bushings to 1.3760 to 1.3765 inches.
v. Place the lower bearing shell (4) in the
o. Lubricate piston pin (17) and bushings (18) and
connecting rod cap (3). Lubricate the bearing shell with
(20) and assemble the piston and connecting rod. In-
clean engine oil. Install bearing cap (3) and secure with
stall new pin retainers (16). Place the piston and con-
rod bolts (2) and nuts (1). Tighten the nuts to 40 to 45 ft-
lb (54-1 N. m).
necting rod upside down on the work bench. Fill the in-
side of the piston with clean fuel oil to a level above the
w. Check the connecting rod side clearance.
piston bosses. Dry the outside of the piston and allow it
Clearance should be 0.006 to 0.012 with new parts.
to set for approximately fifteen mintues. If fuel oil leaks
x. Refer to chapter 4 and install the cylinder head,
around the retainers, install new retainers.
lower front cover, flywheel and flywheel housing, oil inlet
p. Install piston rings (15) on pistons (19). Apply
pipe and screen, and oil pan. Replenish coolant and
clean engine oil to the piston, rings, and the inside of an
lubrication oil. Refer to chapter 2 and install the engine in
appropriate ring compressor. Position the piston ring
Section IX. REPAIR OF CYLINDER BLOCK
4-41. Removal and Disassembly
a. Refer to chapter 2 and remove the engine from
The cast iron cylinder block is a one-piece casting which
forms the main structural part of the engine. Transverse
b. Refer to chapter 3 and remove engine
webs provide rigidity and strength and assure alignment
of the block bores and bearings under load.
accessories and associated assemblies from the engine.
c. Refer to figure 4-19 and remove bolts (1), lock