3304 VEHICULAR ENGINES
TM 5-3805-263-14&P-2
SPECIFICATIONS
CYLINDER LINER
(1)
(2)
(3)
Bore in liner
( n e w ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.751 ± .001 in. (120.68 ± 0.03 mm)
Use again maximum bore when measured near upper end of the
wear surface of the cylinder liner . . . . . . . . . . 4.755 in. (120.78 mm)
Thickness of flange
on liner . . . . . . . . . . . . . . . .4048 ± .0008 in. (10.282 ± 0.020 mm)
Filler band.
Cylinder Liner Installation
Put liquid soap on bottom liner bore in block. on grooves in lower
liner, and on O-rings. Install O-rings on liner. Put filler band (3) in
engine oil for a moment and install on liner. Immediately Install liner
in cylinder block (before expansion of filler band).
CYLINDER LINER PROJECTION
1. Install gasket and spacer plate (2) with bolts (3) and two 1S379
Washers. Tighten bolts (3) evenly in four steps
lst step
. . . . . . . . . . . . . . . . . . . . . . . .
10 lb. ft. (14 N•m)
2nd step
. . . . . . . . . . . . . . . . . . . . . . . . .
25 lb. ft. (35 N•m)
3rd step . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 lb. ft. (70 N•m)
4th step . . . . . . . . . . . . . . . . . . . . . . . .
70 lb. ft. (95N•m)
2. Install tools as shown. Tighten bolts (4) evenly in four steps:
lst step
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5lb ft. (7 N•m)
2nd step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 lb ft. (20 N•m)
3rd step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 lb. ft. (35 N•m)
4th step . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 lb. ft. (70 N•M)
3. Measure cylinder liner projection with dial indicator (6) in lP2402
Gauge Body (8) as shown. Measure at four places around each
cylinder liner near the clamped area.
Cylinder liner projection measurement for any cylinder
liner must be . . . . . . . . . . . . . . . .0013 to .0069 in. (0.033 to 0.175 mm)
Maximum permissible difference between all
four measurements . . . . . . . . . . . . . . . . . .002 in. (0.05 mm)
Maximum permissible difference between average projection
of any two cylinder liners next to
each other . . . . . . . . . . . . . . . . . . .002 in. (0.05 mm)
Maximum permissible difference between average
projection of all cylinder liners under one
cylinder head . . . . . . . . . . . . . . . . . . . . .003 in. (0.08 mm)
NOTE: If liner projection is not correct, turn the liner to a new position
within the bore. If projection can not be corrected this way, move the
liner to a different bore
SHIM THICKNESS, COLOA CODE, AND PART NUMBER
.007 In.
.006 In.
.009 In.
.015 In.
.030 In.
(0.18 mm)
(0.20 mm)
(0.23 mm)
(0.38 m)
(0.76 mm)
BLACK
RED
GREEN
BROWN
BLUE
8S6045
8S6046
8S6047
6S6048
8S6049
4. Minimum permissible depth to machine counterbore to
adjust cylinder liner projection . . . . . . . . . . . . . 0 3 0 i n . ( 0 . 7 6 m m )
Maximum permissible depth to machine counterbore to
adjust cylinder liner projection . . . . . . . . . . . .
.045 in. (1.14 mm)
Install a .030 in. (0.76 mm) shim plus any added shims necessary
to get the correct cylinder liner projection.
NOTE: Be sure that the .030 in. (0.76 mm) shim is directly under the
cylinder liner flange.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Put liquid gasket on the top of the top shim and on the bottom
of the bottom shim before installing.
Crossbar (from 8B7548 Puller).
Spacer plate.
S1589 Bolt with two 1S379 Washers.
1D4595 Bolt.
3H465 Plate.
1P2403 Dial Indicator.
1P2394 Adapter Plate.
1P2402 Gauge Body.
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