TM 5-3805-248-23-2
CYLINDER BLOCK REPAIR - CONTINUED
0342 00
INSPECTION - CONTINUED
22.
Use gage to determine amount of damage to top deck. If minor roughness is not more than 0.003 in. (0.0762 mm) deep,
proceed to step 23. If medium-course roughness or erosion is 0.004-0.006 in. (0.1016-0.1524 mm) deep, complete step
26. If serious erosion with pitting is more than 0.006 in. deep, proceed to step 29.
23.
Use a flat file to carefully file top deck area with minor roughness to a flat surface.
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when
drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT
direct compressed air against human skin. Failure to follow this warning may result in injury or death. Make
sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear
protective goggles or face shield.
24.
Use compressed air to thoroughly clean repaired top deck area.
25.
Use oiled emery cloth to lightly sand around top surface of bore and top of inside bore of top deck area. Proceed to step
28.
26.
Use flat file to carefully file top deck area with medium roughness to a flat surface.
27.
Use compressed air to thoroughly clean repaired top deck area.
CAUTION
Boring tool must be stopped immediately when adjusting nut bottoms against positive stop. This will avoid
tool chatter at end of cut. Failure to follow this procedure could result in damage to equipment.
NOTE
Steps 28 through 36 are the procedures for the repair of one cylinder liner counterbore. Repeat these
procedures for each of the six cylinder liners, if necessary.
The counterbore for a cylinder liner seal insert must be cut parallel to top deck within 0.001 in. (0.0254
mm).
28.
Use gage to set counterbore tool group for a depth of
HALF-BASE
0.060 in. (1.524 mm).
29.
Use counterbore tool group to repair top deck area
with serious erosion damage. Preliminary counterbore
SURFACE TO CLEAN
UP 100%
depth is 0.060+0.001 in. (1.524+0.0254 mm).
30.
Use a half-base micrometer or liner projection tool
group to measure depth of counterbore. If bore is not
deep enough, slightly raise adjusting nut on boring
tool and repeat step 29.
COUNTERBORE
MINOR SURFACE
EROSION PERMITTED
394-1115
0342 00-8