TM 9-6115-604-34
NAVFAC P-8-633-34
(8)
If a main bearing cap or caps are defective, install and line bore a new cap or caps using main bearing
bore kit 337,5059 with main bearing bore tools ST-11 77.
(9)
Refinish a damaged thrust bearing surface at the rear of the cylinder block using thrust surface cutter
3375053 with main bearing bore tool ST-11 77.
(10)
Water holes that have not eroded more than 0.0625 inch (1.59 mm) from the edge of the hole can be
sleeved. Sleeve an eroded water hole as follows:
(a)
Fabricate a sleeve from copper tubing with an inside diameter that will restore the eroded hole to its
original diameter. Cut the tubing for the sleeve approximately 0.5 inch (13 mm) long and measure
the outside diameter with micrometer caliper.
(b)
Using ST-1 010, bore and ream the eroded hole 0.002 to 0.005 inch (0.05 to 0.13 mm) smaller than
the sleeve.
(c)
Coat the sleeve with sealant MIL-S-45180, and install it in the reamed hole using a bushing driver
and hammer.
(d)
Being careful not to damage the gasket surface, file the sleeve flush with the surface using a flat mill
file.
(11)
Refinish a damaged cylinder block head gasket surface as follows:
(a)
Install the bore bar, centering rings and checking rings from main bearing bore kit3375059. Slide the
checking ring to the center of one cylinder bore, and measure the distance from the checking ring to
the cylinder block head surface (Figure 9-58). Make several checks on both banks to determine
taper, and to serve as a basis for set-up in the resurfacing machine. Up to 0.010 inch (0.25 mm)
may be removed from the surface, provided a minimum height of 15.171 inch (385.34 mm) will
remain after machining. Remove 3375059 checking fixtures.
(b)
Remove sufficient material to restore the surface and remove taper using a milling machine or
surface grinder. The machine surface shall be finished to 125 microinch (3.18 micrometer) RMS.
An equal amount of material shall be removed from the top surfaces of both cylinder banks.
(c)
Recheck the block height in accordance with step (a), above. The block height shall not be less than
15.171 inch (385.34 mm) and shall not vary more than 0.002 inch (0.05 mm) over the length of the
block
(d)
Resurface the counterbore to obtain the proper liner protrusion by removing the same amount of
material from the counterbore ledge that was removed from the top surface (see steps (4) and (5),
above).
d. Assemble and Install.
(1)
Install the nameplate (57, Figure 9-24) on the side of the cylinder block (58), and secure with screws (56).
(2)
Install 15 expansion plugs (54) and four expansion plugs (55) in the cylinder block (58) in accordance with
paragraph 2-10.
(3)
Install 12 oil restrictor expansion plugs (53) in the cylinder block in accordance with paragraph 2-1 0.
NOTE
Tighten all pipe plugs in accordance with Table 1-2.
(4)
Wrap the threads of 20 pipe plugs (52) with anti-seize tape, MIL-T-27730, and install in the sides of the
cylinder block (58).
(5)
Wrap the threads of four pipe plugs (51) with anti-seize tape, MIL-T-27730, and install in the rear of the
cylinder block (58).
(6)
Wrap the threads of 20 pipe plugs (50) with anti-seize tape, MIL-T-27730, and install in the top and sides of
the cylinder block (58).
(7)
Wrap the threads of four coolant drain cocks (49) with anti-seize tape, MIL-T-27730, and install in the
cylinder block (58).
(8)
Using new gaskets (48), install the front and rear crankcase breathers (47 and 46) using lockwashers (45)
and capscrews (44). Tighten the capscrews to 20 to 30 pound-feet (27 to 41 newton-meters).
(9)
Install the dowels (43) in the front, rear, and head surface of the cylinder block (58) if removed.
(10)
Install the lifting brackets (42) using washers (41) and capscrews (40). Tighten the capscrews to 190 to
200 pound-feet (258 to 271 newton-meters).
9-103
