TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
bores either fore or aft of one being
repaired.
(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
installation.
(d) Measure OD of tubing.
(e) Perform boring operation. Bore must be
0.002/0.005
inch
(0.05/0.13
mm)
smaller than tubing OD to provide press
fit.
(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
from block.
(k) Install bushings.
(4) Tappet Guide Screw Holes. Tappet guide
screw threads may be repaired using heli-
coil inserts.
(5) Main Bearing Cap Sidebolt
Hole Repair.
NOTE
This procedure cannot be followed in
off-centered
holes
due
to
thin-wall
construction.
(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)
deep.
(b) Countersink 0.885 to 0.895 inch (22.48
to 22.73 mm) diameter by 86-degree
angle.
(c) Tap hole with 7/8-14 UNF-2B tap to
0.800 to 0.900 inch (20.32 to 22.86 mm)
deep.
(d) Install heli-coil insert.
(e) Screw in insert finger tight; locking
tangs will automatically stop insert.
(f)
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
lightly tapping.
(6) Top Surface Refinishing.
NOTE
If necessary, a cylinder block may be
salvaged by removing a maximum of
0.010 inch (0.25 mm) of material from the
top surface.
(a) Use either a milling machine or large
surface grinder; locate block on main
bearing pads.
(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,
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