Cylinder Block and Cylinder Sleeves

(4) Rotate the crankshaft to gain access for the

installation of a cylinder sleeve puller.

(5) Install the puller tool to remove the sleeve

from the top of the cylinder block.

(6) Remove the oil gallery plugs at the front

and rear of the engine.

(7) Remove the oil pressure regulating valve.

Refer to paragraph 3-7.

b. Cleaning and Inspection.

(1) Clean the oil passages in the cylinder block

throughly, Effective cleaning of these passages can

be accomplished only with the use of high steam

pressure. Mix a solvent in the water to dissolve

sludge and foreign material that has collected.

(2) To clean the cylinder block water jackets,

apply high pressure steam and water through all

block openings. Turn the block in various positions

while this is being done so that loose scale will be

washed nut. After oil and water passages have been

cleaned, flush the passages with clean water under

pressure. This will remove all traces of solvent and

foreign material.

Figure 3-20. Temporary locating dowel.

(3) Remove all carbon, dirt, and oil from the

cylinder sleeves and the machined recess in the bore

(b) Install the replacement cap (8, fig.3-18)

in the cylinder block. Replace the cylinder sleeves if

on the temporary dowels. Make certain the bearing

they are scored or worn beyond the allowable

tang slot is on the same side as the bearing tang slot

limits. Slightly scuffed cylinder sleeves, if not worn,

in the cylinder block. The cap has 17/64 inch

may sometimes be made usable by polishing or

drilled dowel holes.

lapping to remove surface irregularities.

(c) Install the lockwashers (7) and main

bearing capscrews (6) and tighten to a torque of

Note. When measuring the cylinder sleeves with an

110 to 120 ft lbs. After the capscrews are correctly

inside micrometer, first measure in a position parallel to the

tightened. remove the two temporary dowels.

crankshaft and then at right angles to the crankshaft. These

measurements should be taken at several locations within the

(d) Use the two 17 / 64 inch holes in the

area of piston ring travel.

bearing cap as a drill locating jig. Enlarge the 1/4

inch holes in the cylinder block to 17 / 64 inch

(4) Check the cylinder sleeves for roundness

by means of a cylinder diameter checking gage.

using a drill. Hand ream these holes to 0.2808-

Allovvable out-of-round when installed is 0.001

0.2816 inch to a minimum depth of inch.

inch. Using an inside micrometer, measure the

(e) Install oversize dowels (0.2801-

cylinder sleeve for taper and wear. The specified

0.280h inch diameter) with knurled ends fitting

inside diameter of a new cylinder sleeve is 3.4379-

tight in the rap.

3.4385 inches. The cylinder sleeve should be round

(f) The cylinder block is now ready for

to 0.00 10 inch and have no more than 0.007 inch

machining of the bearing caps. This is a machine

shop job. Correct size of the main bearing bore is

taper. Cylinder sleeves that do not meet these

2.6913-2.6820 inches. It is necessary to strictly

requirements must be replaced.

adhere to this dimension to obtain a correct fit of

(5) If the cylinder sleeves are within the

allowable wear limits and are to be used again,

the main bearings.

there may he a slight ring travel ridge near the top

(g) Complete the installation as instructed in

of the sleeve which should be removed with a ridge

(1), above.

reamer.

3-18. Cylinder Block and Cylinder Sleeves

c. Reassembly and Installation.

(1) Install the oil gallery plugs at the front and

a. Removal and Disassembly.

rear of the engine.

(1) Remove the engine from the truck. Refer

(2) Install the oil pressure regulating valve.

to paragraph 2-7.

Refer to paragraph 3-7.

(2) Remove the cylinder head assembly. Refer

(3) Thoroughly clean the cylinder sleeve and

to paragraph 3-12.

the bore in the cylinder block. Be sure the bottom

(3) Remove the pistons and connecting rods.

surface of the flange on the cylinder sleeve and

Refer paragraph 3-16.

3-23