b. Refer to figure 14-38. Disassemble cylinder
0.7 to 0.062 inch. Cylinder liner must be held down
block as follows:
(1) With a suitable liner puller and liner bridge or
0.8 .c. All old gasket material must be scraped from the
equivalent, remove liners (17), shims (18), seals (19)
block. Use care to avoid damaging seal surface.
and preformed packing (20 and 21). Discard preformed
d. Inspect the cylinder block on a fiat surface to
packing and crevice seals.
prevent distortion, do not leave on engine stand. The
cylinder block shall be checked as follows:
Do not pull liners (17) with liner puller plate
(1) Inspect block for cracks, porosity, and leaks
on or near extended portion of liner.
using the dye penetrant method.
(2) Proceed to paragraph 14-86 and thoroughly
(a) Clean suspected defective area with
inspect cylinder block. If after a complete inspection of
kerosene or other grease-removing cleaner.
block the existing block is to be reused, proceed to step
(b) Apply dye penetrant and wait 15 minutes.
Do not "force" dry.
(3) With a suitable camshaft hushing driver kit,
(c) Remove all excess penetrant and apply
or equivalent, remove bushings (22 and 23).
developer so defects will stand out; cracks will show up
(4) If damaged, remove dowels (24, 25, 26, 27, 28,
as a solid or dotted line; caution must be observed as
29, 30 and 31).
this can be a non-damaging forging lap. Porosity will
be indicated by dots in local areas, the wider the area
(6) If data plate is damaged, remove screws (34)
spreads, the larger the defect.
and plate (35) from cylinder block (36).
(2) Check block for corrosion. Corrosion
normally occurs on portions of block nearest cylinder
14-36. Cleaning, Inspection
liners and is evidenced by pitting. If area cannot be
a. Clean all metal parts with cleaning solvent
cleaned, or is distorted and cannot be repaired, discard
Federal Standard P-D-680, or equivalent. Thoroughly
dry with compressed air.
(3) Check upper liner counterbore diameter, at
& Steam clean all disassembled parts (except those
four equidistant points (1, fig. 14-39). Inside diameter
that might be damaged by steam or moisture) with a
shall be no greater than 6.5015 inches. Depth (2) shall
steam jet. Dry thoroughly with compressed air.
be less than 0.413 inch and shall not vary more than
(1) Check liner protrusion above milled surface of
0.001 inch at any one cylinder. Recondition as de-
block. An installed liner must protrude 0.0 03-.0065
scribed in paragraph 14-37.
inch. To check protrusion without installing liner, per-
(a) Check liner protrusion above the cylinder
form the following:
block at four equidistant points outside the bead. Add
or remove shims from beneath the liner flange as
flange. Do not include bead on top of liner flange.
needed to reach 0.00-0.0065-inch protrusion.
Measurement should be 0.35;,-.356 inch.
(b) Check liner bore roundness at several points
(b) Check counterbore depth at four or more
within range of piston travel. Liner shall not be out-of-
locations. Ledge must not be cupped more than 0.0007
round more than 0.002 inch in the packing ring area or
inch. Depth must not vary more than 0.001 inch
more than 0.003 inch in the top one inch.
throughout counterb,re circumference. If these re-
(4) Inspect camshaft bushing. Replace if
quirements are not met, counterbore ledge must be
chipped, scored or scratched. Check inside diameter
reworked per paragraph 14-37.
with inside micrometer. Inside diameter shall be no
(c) Calculate depth of cut that will permit using
greater than 2.502 inches. Check bore size if bushings
a standard size shim to provide the required liner
have turned in block bore. Bore shall be 2.6865--2.6875
protrusion. Normally a 0.007---.009-inch cut will be
inches. Check to make sure all oil passages between
adequate to recondition counterbore.
bushings and block are properly aligned.
(5) Check cylinder liner bore as follows:
If material to be removed will result in a
(a) Install a new cylinder liner in block without
counterl)ore depth exceeding 0.413 inch, block
preformed packing or crevice sell.
should not be reused
(b) Clearance between liner and block should be
(d) Check for variations in protrusion under
0.002-0.006 inch. Liner may contact block as long as
each cylinder head. Variation shall not exceed 0.002
contact does not cause liner to be out-of-round. Limits
inch under head nor can it exceed 0.001 inch at any one
do not apply with cylinder head installed and tightened
to operating torque. If clearance is not correct, check
(2) The most accurate method of checking liner
lower block packing ring bore inside diameter. Lower
protrusion is as follows:
bore inside diameter shall be 6.107 --.109 inches.
(a) Install liner in block with proper number of
(6) Inspect main bearing caps. Caps must fit in
shims beneath the flange. Shims are available from
block with no perceptible clearance or "shake." Milled
0.007 to 0.062 inch. Cylinder liner must be held down