bores either fore or aft of one being
(c) Cut piece of 2-1/2 inch (63.50 mm) OD
seamless steel tubing with 1/8 inch
(3.17 mm) wall to length of bore in
block. Chamfer one end to facilitate
(d) Measure OD of tubing.
(e) Perform boring operation. Bore must be
smaller than tubing OD to provide press
(f) Remove boring bar and carefully clean
block to remove all shavings.
(g) Apply a thin coat of Permatex to tubing
OD and block bore ID to prevent galling
during installation and to provide a
tighter press fit.
(h) Install tubing with short mandrel to
prevent collapsing. Mandrel must have
shoulder on drive end.
(i) Pin sleeve with 1/16 inch-27NPTF x 1
inch pipe plug or soft steel pipe plug
through side wall of block or through
camshaft bushing bore. Stake plug.
(j) Reinstall boring bar and bore sleeve to
2.2535/2.2545 inch (57.239/57.264 mm)
ID. Remove bar and clean all shavings
(k) Install bushings.
(4) Tappet Guide Screw Holes. Tappet guide
screw threads may be repaired using heli-
(5) Main Bearing Cap Sidebolt
This procedure cannot be followed in
(a) Drill out stripped or damaged threads
with a 53/64 inch drill (0.83 mm) to
1.000 to 1.150 inch (25.40 to 29.21 mm)
(b) Countersink 0.885 to 0.895 inch (22.48
to 22.73 mm) diameter by 86-degree
(c) Tap hole with 7/8-14 UNF-2B tap to
0.800 to 0.900 inch (20.32 to 22.86 mm)
(d) Install heli-coil insert.
(e) Screw in insert finger tight; locking
tangs will automatically stop insert.
For proper engagement, visually check
insert flush or below surface of cap.
(g) Secure in position by driving heli-coil
insert down flush with cap surface by
(6) Top Surface Refinishing.
If necessary, a cylinder block may be
salvaged by removing a maximum of
0.010 inch (0.25 mm) of material from the
(a) Use either a milling machine or large
surface grinder; locate block on main
(b) Remove dowels from head mounting
surface and make light cuts of 0.001 to
0.003 inch (0.03 to 0.08 mm) deep,