ARMY TM 9-6115-464-34
AIR FORCE TO 35C2-3-445-2
NAVY NAVFAC P-8-624-34
(13) Do not remove plug (15) from cylinder block (16) unless replacement is necessary.
b. Cleaning, Inspection, and Repair.
Clean sludge and dirt deposits from cylinder block with dry cleaning solvent. If necessary, block
should be steam cleaned.
Clean all oil and water passages.
Scrape carbon deposits from top of block.
Remove gasket remains from all mating surfaces.
Perform magnetic particle inspection of cylinder block in accordance with MIL-I-6868.
Inspect cylinder bores for scores and scratches. Minor scratches and scores may be removed by
honing. If necessary, cylinder bores maybe rebored to accept up to 0.060 inch oversized pistons.
Check cylinder bores for excessive wear. Diameter shall be 3.7490 to 3.7510 inches.
Inspect cylinder bores for out-of-roundness. Each cylinder shall not be out-of-round by more than
Check cylinder bore taper. Taper shall be 0.0005 inch maximum.
Non conformity to dimension specified in steps (7) through (9) above requires that cylinders be bored
to accept oversized pistons.
Temporarily install main bearing caps and check main bearing bore diameter. Diameter shall be
3.0665 to 3.0670 inches.
Check camshaft bearing bore diameter. Diameter shall be 2.1870 to 2.1880 inches.
Visually inspect main bearing and camshaft bearing bore diameters for nicks and scratches. Remove
nicks and scratches with oil-soaked abrasive paper.
Check oil pump bore diameter. Diameter shall be 2.0000 to 2.0005 inches.
Inspect oil pump bore for nicks and scratches. Remove minor nicks and scratches by polishing with
Inspect for broken or damaged studs. If any studs are broken too short to allow removal, center
punch, drill, and use an easy out.
Inspect all gasket surfaces for nicks, burrs, and scratches. Remove nicks, burrs, and scratches with
oil-soaked abrasive paper.
Use a straight edge and check the block lengthwise, across each end and between cylinder bores for
warping. Warpage shall not exceed 0.0003 inch. Remove studs and guide pins and mill to a
maximum of 0.0005 inch top of block to correct a slight warpage. If cylinder block is warped
sufficiently that milling would radically affect engine performance, replace block.
Check all internal threads for crossing, stripping, and peening. Clean or repair minor thread damage.
Repair extensively damaged threads by reaming, tapping and installing inserts.
c. Assembly and Installation.
(1) Prior to installation, mask all openings. Treat and paint.
(2) If removed, position cylinder block (16), and install plug (15).
(3) If removed, install guide pin (14), and studs (13, 12,11, 10).
(4) If removed, install guide pin (9) and studs(8).
(5) If removed, install guide pin (7) and studs (6 and 5).