5_108.bk Page 126 Thursday, October 4, 2001 11:45 AM
REPAIR INSTRUCTIONS CUTTING THE COUNTERBORE
CLEANING AND INSPECTION
Refer to Figure 158.
The engine should have been thoroughly steam cleaned prior to component removal and the block should be relatively clean. If heavy accumulations of dirt and grease are still present, steam clean the block as thoroughly as possible before attempting to clean with solvents.
1. Fill the oil fill tube (7) with 30W nondetergent oil to maintain lubrication during use. 2. Back off the lower depth-set collar (16) two increments or less, and tighten the thumbscrew (6) securely. 3. Cut the counterbore by turning the T-handle clockwise while maintaining constant downward pressure on the tool. Stop the handle in a different position to avoid creating a ridge in the counterbore. 4. Continue backing off the lower depth-set collar, no more than two graduations per cut. Check the depth measurement between each adjustment. Plan to remove 0.001 inch (0.025 mm) on the final cut to meet the final predetermined counterbore depth. This ensures achieving a very fine machined finish. 5. Remove the tool from the cylinder bore. a.
Loosen the two cutter bit hold-down capscrews (9) and rotate the cutter bit adjusting screw (10) counterclockwise until the cutter bit is retracted into the cutter plate (13).
b.
Remove the four machine hold-down bolts (3) and special washers (4).
c.
Remove the tool from the cylinder bore.
6. Follow steps 1 through 5 for the remaining cylinders.
Cylinder Block Core Plug and Camshaft and Auxiliary Shaft Bushing Replacement SPECIAL TOOLS REQUIRED r
Camshaft Bushing Installation/Removal Kit J 37713
r
Camshaft Bushing Remover/Installer J 21428-01
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Counterbore Tool PT2210
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Counterbore Cutter Plate PT2210-3A
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Hex Key Wrench PT2210-14
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Universal Dial Depth Gauge PT5025
r
3-Inch Stylus Extension PT5025-11
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Cleaning solvent is flammable and toxic to the eyes, skin and respiratory tract. Skin and eye protection are required. Avoid repeated or prolonged contact. Use only in well-ventilated area.
Compressed air used for cleaning can create airborne particles that may enter the eyes or irritate the skin. Pressure must not exceed 30 psi (207 kPa). Eye protection is required. Use only with effective chip guarding and personal protective equipment (goggles/ shield, gloves, etc.).
Cleaning the cylinder block is important. While cleaning the cylinder block, carefully inspect the areas around the cup plugs and the coolant jacket. If cup plugs or pipe plugs show signs of leaking, they should be replaced. Cleaning the cylinder block is a good time to inspect it for cracks or other possible defects that may be reason for rejection. Refer to the Troubleshooting section for information on testing for leaks in the cylinder head and cylinder block. If damage is not found until after the engine is assembled, the engine must be disassembled and rebuilt again.
