TM 9-6115-604-34
NAVFAC P-8-633-34
(16)
Remove the capscrews (44), lockwashers (45), front and rear crankcase breathers (46 and 47), and
gaskets (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 accordance
with 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 cleaning
operations. After determining that the cylinder block is repairable, perform complete cleaning and necessary
repair 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, for
inspection 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 or
turned bushings. Install a repair sleeve if any bore is over 0.002 inch (0.05 mm) out-of-round, or worn over
a 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 the
ledge for downward taper toward the center of the bore. Resurface the counterbore ledge if the
depth 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.
NOTE
On engines manufactured before July 1980, to engine number 33103621, the cylinder liners
press into the top counterbore (B, Figure 9-56). On engines manufactured after this, the liners
press into the secondary bore (C, Figure 9-56). Select the appropriate inspection and repair
procedures accordingly.
(b)
Check the secondary cylinder liner bore diameter (C, Figure 9-56). Install a sleeve if the bore
diameter 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 (see
Figure 9-57):
(a)
Place the gage flat on the top deck of the cylinder block with the bumper pins against the
counterbore inside diameter on cylinder blocks to engine number 33103621. On later engines, index
the 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 and
zero the indicator.
(e)
Release the pressure on the bumper pins, and reposition the gage in the same spot to check the
indicator adjustment. Re-zero the indicator if necessary.
(f)
Move the gage 180 degrees from the original setting position, hold the bumper pins firmly against the
counterbore 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
