TM 9-6115-604-34NAVFAC P-8-633-34(16)Remove the capscrews (44), lockwashers (45), front and rear crankcase breathers (46 and 47), andgaskets (48). Discard the gaskets.(17)Remove the four coolant drain cocks (49) from the cylinder block (58).(18)Remove 20 pipe plugs (50) from the top and sides of the cylinder block (58).(19)Remove four pipe plugs (51) from the rear of the cylinder block (58).(20)Remove 20 pipe plugs (52) from the sides of the cylinder block (58).(21)Using a sharp punch to penetrate and pry out the plugs, remove the 12 oil restrictor expansion plugs (53)at the cylinder head surface of the cylinder block (58).(22)Remove 15 expansion plugs (54), and four expansion plugs (55) from the cylinder block (58) in accordancewith step (21), above.(23)Remove the screws (56) and nameplate (57) from the side of the cylinder block (58).b.Inspect. Perform a complete cylinder block inspection before carrying out repairs or extensive cleaningoperations. After determining that the cylinder block is repairable, perform complete cleaning and necessaryrepair operations in accordance with step c, below. Inspect the cylinder block as follows:(1)Visually inspect cylinder block (58) in accordance with paragraph 9-30.(2)Use magnetic particle inspection in accordance with MIL-1-6868, or dye penetrant, MIL-1-25135, forinspection in accordance with MIL-1-6866 at areas of suspected cracks or porosity.(3)Check the camshaft bore diameters for wear and out-of-round that may have been caused by loose orturned bushings. Install a repair sleeve if any bore is over 0.002 inch (0.05 mm) out-of-round, or worn overa diameter of 3.1895 inch (81.013 mm).(4)Remove burrs, dirt, and scale from the cylinder liner counterbore, and check the counterbore as follows:(a)Using 3376220, check the counterbore depth at 90 degrees intervals (A, Figure 9-56), and check theledge for downward taper toward the center of the bore. Resurface the counterbore ledge if thedepth varies over 0.001 inch (0.03 mm), or the ledge tapers downward toward the bore center.Install a counterbore sleeve if the depth of the counterbore is beyond the limit in Table 1-4.NOTEOn engines manufactured before July 1980, to engine number 33103621, the cylinder linerspress into the top counterbore (B, Figure 9-56). On engines manufactured after this, the linerspress into the secondary bore (C, Figure 9-56). Select the appropriate inspection and repairprocedures accordingly.(b)Check the secondary cylinder liner bore diameter (C, Figure 9-56). Install a sleeve if the borediameter is over 7.157 inches (181.79 mm).(5)Check the cylinder block lower liner bore concentricity using concentricity gage ST-1 252 as follows (seeFigure 9-57):(a)Place the gage flat on the top deck of the cylinder block with the bumper pins against thecounterbore inside diameter on cylinder blocks to engine number 33103621. On later engines, indexthe bumper pins on the secondary bore.(b)Check the counterbore diameter in the top 0.400 inch (10.16 mm) of the bore (B, Figure 9-56).Install a counterbore sleeve it bore diameter is over 7.4935 inches (190.335 mm).(c)Raise or lower the bar to position the indicator in the lower bore.(d)Hold the gage bumper pins firmly against the counterbore or secondary bore inside diameter andzero the indicator.(e)Release the pressure on the bumper pins, and reposition the gage in the same spot to check theindicator adjustment. Re-zero the indicator if necessary.(f)Move the gage 180 degrees from the original setting position, hold the bumper pins firmly against thecounterbore or secondary bore inside diameter, and record the indicator reading.(g)Move the gage 90 degrees and record the indicator reading.(h)Replace the cylinder block if the lower liner bore is not concentric within 0.005 inch (0.13 mm) TIR.9-99
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