CHAPTER : 3

SECTION : 3.2

Cylinder Block
3.2-1
3.2-2
SECTION : 3.2
Cylinder Block
CYLINDER BLOCK
INSPECTION
Before any parts are discarded or used again, a careful
inspection must be performed. The inspection should
include wearing surfaces and general over-all conditions.
Inspection and machining of the cylinder block must be
performed with oil pan rail on a flat surface to prevent
distortion. Do not leave bolted to engine stand.
USING DYE PENETRANTS TO LOCATE
FLAWS
Use dye penetrant for locating cracks, porosity, leaks,
etc. Clean suspected area with grease-removing cleaner.
Apply dye penetrant allowing time for it to dissolve or
enter into the defect (usually about fifteen minutes). Do
not “force” dry.
Remove all excess penetrant and apply develope so
defect will stand out. Cracks usually show up as a solid
or dotted line; however, caution must be observed as
this can be a non-damaging forging lap. Porosity usually
shows up as dots in local.
The cylinder block section consists of cylinder
block; cylinder liners; crankshaft; main and
connecting rod bearings, vibration damper;
connecting rods, pistons; rear cover, camshaft; gear
housing and gear cover.
CORROSION
Corrosion most frequently occurs on portions of block
nearest cylinder liner and is evidenced by pitting. Discard
block if area cannot be repaired by sleeving. See “Parts
Replacement and Repair”.
CAMSHAFT BUSHINGS
Use dial bore gauge to measure camshaft bushing inside
diameter, Fig. 3.2. Mark bushings for replacement if
worn larger than 2.1295 inch [54.098 mm] or chipped,
scored or scratched. If bushings have turned in block
bore, check block bore size and replace bushings. If
bore is larger than 2.555 inch [57.290 mm], sleeve bore
as described in “Parts Replacement and Repair”. Make
certain oil passages between bushings and block oil
holes are properly aligned. If replacement is necessary,
see “Parts Replacement and Repair”.
CYLINDER LINER COUNTERBORE
1. The top (head) surface of block should be checked
for flatness. Refinish block (see “Top Surface
Refinishing”) if damaged or distorted beyond 0.002
inch [0.05 mm] from true. Use a straight edge and
0.002 inch [0.05 mm] feeler gauge.

Fig. 3-2 : Measuring camsnaft bushing
2. Check upper liner counterbore and remove burrs,
dirt, etc. so liner will enter without distortion. If
counterbore diameter (A, Fig. 3-3) exceeds 6.5635
inch [ 166.713 mm ], or if counterbore depth [ B,
Fig. 3 - 3 ] exceeds 0.411 inch [ 10.44 mm ], mark
counterbore for sleeving.
Fig. 3-3 : Cylinder liner counterbore dimension.
3. The counterbore may be remachined to the limits
in Step 2. Remachine if any of the following
conditions are not met.
a. Depth counterbore must be equal within 0.001
inch [0.03 mm] when measured at four
equidistant points. Measure at edge of liner
bore (Fig. 3-4) with ST-547.
3.2-3
Fig. 3-4 : Checking counterbore depth.
b. Counterbore must not slope downward toward
the center of the bore.
c. Counterbore must not slope upward more than
0.0014 inch [0.036 mm] toward the center of
the bore.
d. Counterbore must be free of nicks, scratches,
and dents.
4. If counterbore does not require machining or
sleeving, or if it has been repaired, check liner for
proper protrusion by either of the methods
described in Steps 5 and 6 below.
Fig. 3-5 : Location of cylinder liner flange thickness.
3.2-4
Fig. 3-6 : Measuring cylinder liner flange.
5. The most accurate method of checking and
adjusting protrusion is as follows :
a. Install liner in block with the approximate
number of liner shims beneath the flange. Do
not use packing rings or crevice seals. Shims
are available in thicknesses of 0.007, 0.008,
0.009, 0.020, 0.031, and 0.062 inch [0.18,
0.020, 0.34, 0.51, 0.79, and 1.57 mm] Use
ST-1184 Cylinder Liner Hold-Down Tool. Tool
should be spaced so even load will be applied.
Torque to 50 ft-lb [68 N°m].
Note : Shims should not be used unless counterbore
has been resurfaced.
b. Use ST-547 Gauge Block and check liner
protrusion above the cylinder block at four
equidistant points outside the bead, Fig. 3-7.
Add or remove shims from beneath the liner
flange as needed to reach 0.004 to 0.006 inch
[0.10 to 0.15 mm] protrusion.
c. With liner installed, check for out-of round as
described under “Cylinder Liner Lower Bore”.
6. A second method may save time :
Fig. 3-7 : Checking cylinder liner protrusion.
a. Measure liner flange with micrometer. Do not
include bead on top of liner flange in taking
measurement. Fig. 3-5 and 3-6.
b. Measure block counterbore depth with dial
indicator depth gauge or ST-547 Gauge Block.
Always measure counterbore depth on ledge
at the edge of liner bore, Fig. 3-4.
c. Subtract counterbore depth from liner flange
thickness to determine amount of shims or
depth of counterbore cut that must be used to
provide 0.004 to 0.006 inch [0.10 to 0.15 mm]
liner protrusion.
d. Check as described in Step 5 above.
CYLINDER LINER LOWER BORE
1. Install a new cylinder liner in the block without
packing rings or crevice seal. Secure with ST-1184
and torque to 50 ft. Ib. [68 N°m].
2. Clearance between liner and block must not
exceed 0.008 inch [0.20 mm]. Liner contact with
block is permissible as long as it does not cause
liner out-of-round.
 3.2-5

3. Check liner bore for roundness, Figs. 3-9

and 3-10.

a. Check with precision dial bore gauge.

b. Micrometer readings to be taken as near points

at C, D, E, F, and G along axis A-A and B-B as
possible.

1) At point “C”,approximately 1 inch [25.4

mm] below top of liner, it is permissible to
have up to 0.003 inch [0.08 mm] out-of-
round.
Fig. 3-10 : Cylinder liner check points.

4. If clearances do not fall within limits, recheck after

counterboring. Limits do not apply with cylinder
counterboring. Limits do not apply with cylinder
head installed and tightened to operating torque if
clearance is not correct, Check lower block packing
ring bore inside diameter.

5. Lower liner bore concentricity should be checked

with ST-1252. If a piston seizure has occurred or
the cylinder block has been counterbored. Check
the counterbore to lower cylinder liner bore should
be concentric with 0.005 inch [0.13 mm] total
Fig. 3-9 : Checking cylinder liner out-of-round.
indicator reading.

2) At other points, each about 2 inches [50.8 CQUNTERBORE CONCENTRICITY

mm] lower than preceding depth, out-of-
round must not exceed 0.002 inch [0.05 Check the cylinder liner counterbore to lower bore
mm]. concentricity with ST-1252.

1. Place gauge flat on top deck of cylinder block with

bumper pins against counterbore inside diameter.
3.2-6

2. Raise or lower bar to position indicator in area of Table 1: Main Bearing Capscrew Torque -
lower bore to be checked. Ft-Lb [N°M]

Minimum Maximum
3. Holding gauge bumper pins firmly against
counterbore inside diameter, zero indicator. Step 1 Tighten to 200[271] 210[285]
Step 2 Advance to 410[556] 420[570]
4. Release pressure, reposition gauge to check
indicator reading. Rezero indicator if necessary. Step 3 Loosen
completely
5. Place gauge 180 degrees from original setting Step 4 Tighten to 200[271] 210[285]
position, hold bumper pins firmly against Step 5 Advance to 420[570] 460[624]
counterbore inside diameter, record indicator
reading. Breakway torque in direction of tightening must be 420
to 490 ft-lb [570 to 666 N°m].
6. Move gauge 90 degrees and repeat procedure.
Lower bore must be concentric within 0.005 inch 2. Gauge main bearing bores horizontally, vertically
[0.13 mm] total indicator reading. and diagonally with dial bore gauge, Fig. 3-11. Bore
must not exceed 6.0965 inch [154.851 mm].
Note : Total indicator reading is two (2) times actual
shift of bore. (Example : Indicator reading - 0.002 inch
[0.05 mm]. Actual shift from center of bore - 0.001 inch
[0.03 mm].

MAIN BEARING CAPS

Caps must have 0.002 to 0.004 inch [0.05 to 0.10 mm]

interference fit in block. Check if engine has experienced
bearing failure. Milled faces of cap must always rest on
mating portion of block to prevent distortion during
tightening.

Replacement caps are available as service parts. See

Fig. 3-11 : Checking main bearing bore.
“Parts Replacement and Repair”
ST-1177 Boring may also be used to check main bearing
MAIN BEARING BORE
bore alignment, see “Parts Replacement and Repair”. If
it is definitely determined that a main bearing cap has
1. Assemble main bearing caps to block in .operating
been distorted, mark block for reboring.
position. Tighten cap-screws as shown in Table 1.

WATER PASSAGES

1. Check all water passages to make sure they

are open and check for eroded water holes which
 3.2-7

may prevent proper seating of head gasket or
grommet retainers.
2. Water holes not eroded more than 1/16
inch [1.59 mm] from edge of hole can be sleeved.
See “Parts Replacement and repair”.
3. Check for erosion within 1/32 to 3/32 inch [0.79 to
2.38 mm] from liner counterbore. Block must clean
up before removing a maximum of 0.010 inch [0.25
mm] material. See “Top Surface Refinishing”.
TAPPET BORE
2. Using a suitable puller, pull shaft from block.
3. Place new shaft in block bore and drive shaft in
block until it seats on shoulder,
4. Install setscrew to secure idler shaft in block and
lockscrew in boss.
OIL CONTROL VALVE REPLACEMENT
The oil control valve in the front of cylinder block
maintains oil pressure at idle. Low oil pressure at idle
may indicate a weak or broken spring.

1. Measure tappet bores with a small bore gauge.
2. Tappet bores must not be out-of-round more
than 0.0015 inch [0.038 mm]. Valve tappet
bores must not exceed 1.190 inch [30.21 mm] and
injector tappet bores must not exceed 1.627 inch
[41.33 mm]. If these conditions are not met,
replace block.
PARTS REPLACEMENT AND REPAIR
1. Remove expansion plug (4, Fig. 3-13) from oil
control valve housing (1).
2. By-pass disc (2) spring (3) and plug (4) may be
replaced after block oil passages have been
cleaned. See Table 2 for spring specifications.
3. If housing must be pulled, a slide hammer with a
“L” shaped or hooked head may be used. Do not
allow hook to extend into block.

Up to this point we have discussed inspection

procedures. Now we will discuss some of the more
complex repair procedures and the use of necessary
Service Tools.

IDLER GEAR SHAFT

Replace idler shaft only if worn smaller than

1.9965 inch [50.711 mm] or damaged.

1. Remove outer lockscrew from left side of idler shaft

(shaft) boss and setscrew which secures shaft in
block. Lockscrew and setscrew are in the same
hole.
3.2-8

3. Cut piece of 2-1/2 inch [63.50 mm] outside

diameter (O.D.) seamless steel tubing with 1/8 inch
[3.17 mm] wall thickness to length of bore in block.
Chamfer O.D. of one end to facilitate installation.
Bore hole in tubing to align with oil hole in block.

4. Measure O.D. of tubing.

5. Perform boring operation. Bore must be 0.002 to

0.005 inch [0.05 to 0.13 mm] smaller than tubing
O.D. to provide press fit.

6. Remove boring bar and carefully clean block to

remove all shavings.
Fig. 3-13 : Oil control valve
7. Apply a thin coat of Permatex to tubing O.D. and
Table 2 : Oil Control Valve Spring Specifications - block bore to prevent galling during installation and
Inch [mm] to provide a tighter press fit.
Working Force at Working
Free Length Length Length (Lb.[N]) 8. Install tubing with short mandrel to prevent
collapsing. Oil holes in tubing must align with oil
1.520 to 1.680 0.800 10.1 to 12.3 hole in block. Mandrel must have shoulder on drive
[38.61 to 42.67] [20.32] [44.9 to 57.2] end.

4. Align scribe mark on body with scribe mark on
block and drive valve housing into block. Body must
be flush to 0.020 inch [0.51 mm] below block face.
5. Check hole alignment. If correct, install by-pass
disc and spring. Coat expansion plug with sealant
with ST7 1053 Plug Driver. Plug should be flush
with body.
9. Pin sleeve with 1/16 inch-27 NPTF x 1 inch
Salsbury pipe plug or soft steel pipe plug through
side wall of block or through camshaft bushing bore.
Stake plug.
10. Reinstall boring bar and bore sleeve to 2.2535 to
2.2545 inch [57.239 to 57.264 mm] I.D. Remove
bar and clean all shavings from block.

SLEEVE CAMSHAFT BUSHING BORE IN BLOCK 11. Install bushings.

1. If camshaft bushing bore in block is damaged, first CAMSHAFT BUSHING REPLACEMENT

determine the cause of damage and correct it.
Bore may then be repaired by installing sleeve.
2. Pilot boring bar in two good camshaft bushing
bores either in front of or behind one being repaired.
1. Begin at front of block. Drive bushings from front
four camshaft bushings bores with ST-1228. Eight
bushings will be removed from each bank.
2. Drive new bushings into place in reverse order.
Rearmost bushing in number four bore must be

installed first. Bushings should be nearly flush and
must not protrude from bores. Split in bushing must
locate toward top of block.
3. From rear of block, drive out remaining old
bushings.
4. Again, drive new bushings in reverse order.
Split must face top of block.
5. Inspect new bushings to make sure oil hole in
block is not covered.
MAIN BEARING CAP SIDEBOLT HOLE REPAIR
Note : This procedure cannot be followed unless holes
are centered. Off center holes create thin walls which
weaken main bearing caps.
1. Drill out stripped or damaged threads with 53/64
inch drill to 1.000 to 1.150 inch [25.40 to 29.21
mm] deep.
2. Countersink 0.885 to 0.895 inch [22.48 to 22.73
mm] diameter by 86 degrees included angle.
3. Tap hole with 7/8-14 UNC-2B tap to 0.800 to 0.900
inch [20.32 to 22.86 mm] deep.
4. Install “Keensert” insert Cummins Part No. 203299.
a. Screw in insert figner tight, “Kees” (locking
tangs) will automatically stop insert at proper
depth.
b. Visually check insert for proper engagement.
It must be flush or below surface of cap.
3.2-9
c. Secure in position by driving “Kees” down flush
with cap surface by lightly tapping on tool.
5. Inspect cap to insure no nicks or burrs are on any
machined surface. Correct as necessary.
MAIN BEARING CAP REPLACEMENT
Replacement main bearing caps (except No. 7 cap)
require only boring 0.015 inch [0.38 mm] excess material
from bore. Other dimensions are the same as finished
main bearing cap (caps). No. 7 replacement cap does
not have cap-to-block dowel holes and must be machined
to cylinder block (block) width. Replacement caps provide
the correct 0.004 to 0.007 inch [0.10 to 0.18 mm]
interference fit in block.
1. If the cap is No. 7
a. Machine thrust faces of cap so that holes
center over threaded hole and so that cap
which is the same as block thrust surface
width.
b. Remove locating dowels from block Locate cap
so thrust faces of cap and block are flush. Use
Prusssian Blue on block surface to locate
dowel holes in cap.
c. Remove cap, drill dowel holes, reinstall cap,
ream dowel holes, to the smallest permissible
oversize install dowels in block.
2. Install all caps on block and ream bore with
ST-1177.
3.2-10
MAIN BEARING BORE CHECKING AND MACHINING
ST-1177 Main Bearing Boring Tool is designed to perform
both the boring and checking functions. Before boring
operation, allow tool and block to stabilize to room
temperatue.
ASSEMBLY TO BLOCK
1. Remove two undamaged main bearing caps,
preferably one from each end of block or as far
apart as possible.
2. Insert proper centering rings in two (2) bores and
tap top of centering ring with plastic hammer to
seat.
3. Reinstall main bearing caps and torque to required
specifications following steps in Table 1.
Note : If centering ring must be installed n journals which
have had caps replaced )y semi-finistied caps, limit torque
to 10 t-lb [14 N°m].
4. Oil centering ring bores and boring bar, install boring
bar (ST-1177-16, Fig. 3-14) through centering rings
rotating slowly. Bar should spin free. Slide bar out
one end until appropriate checking ring can be
installed on bar. Oil outside diameter of checking
ring.
5. Using light finger pressure against checking ring
on both sides of bar, push checking ring through
each bore. Bar must be turned during this check.
a. Check bore for burrs if checking ring will not
pass through bore.
b. A 0.005 inch [0.08 mm] feeler gauge (not over
J? inch [12.70 mm] wide) can be used in
detecting irregularities in the bore.
c. Attempt to insert feeler gauge between bore
and slip ring. Run gauge completely around slip
ring on each side of bore. Evaluate as follows :
1) Gauge does not enter at any point, bar
rotates freely-standard bore.
2) Gauge enters on one side and not on
opposite-slight misalignment. No problem
if bar rotates freely.
3) Gauge loose-oversize bore.
4) Gauge enters on front and not on rear of
bore-tapered bore.
6. Mark bores to be salvaged.
ASSEMBLING MICROMETER TOOL BIT
SETTING GAUGE AND TOOL BIT
1. Place micrometer base shaft (ST-1177-46) through
bore of micrometer bracket (ST-1177-45) and thread
into micrometer base (ST-1177-44). Tighten
securely.
2. Tighten the socket head screw (ST-1177-29) in the
micrometer bracket until the bracket is tight on the
micrometer base shaft; micrometer hole in
micrometer bracket must be in alignment with cutting
tool hole in micrometer base shaft.
3. Install centering ring (ST-1177-42) over micrometer
base shaft and micrometer, ST-1177-5111.
a. Adjust micrometer thimble to value stamped
on centering ring.
b. Hold micrometer spindle against centering ring
and tighten socket head screw in micrometer
bracket. Check to see that micrometer spindle
turns free.
4. Remove centering ring and install appropriate cutter
holder over micrometer shaft.
5. Align tool bit hole in cutter holder with hole through
micrometer base shaft and tighten cutter holder
socket head screws. Scribed lines are used on the
base shaft and cutter holder for this purpose. Keep
even gaps between two (2) halves of cutter holder.
6. Insert appropriate cutting bit in tool holder.
Tool must be short enough so it does not extend
into the bore of the tool holder. When adjusting
micrometer or tool cutter, be careful to just contact
tool to prevent damage.
 3.2-11

Fig. 3-14 : Exploded view of ST-1177 boring tool.

Note: 3375053 Thrust Bearing Surface Cutter is also used with this tool.

Ref. Part Description Ref. Part Description

No. No. No. No.

1 ST 1177-1 Cutting Tool (5/8 long) 27 ST 1177-27 Swivel Joint

2 ST 1177-2 Cutting Tool (7/8 long) 28 ST 1177-28 Cutter Holder (Large)
3 ST 1177-3 Cutting Tool (1 1/4 long) 31 ST 1177-31 Drive Adapter
4 ST 1177-4 Cutting Tool (1 1/2 long) 33 ST 1177-33 Torsion Bar
5 ST 1177-5 Cutting Tool (2 long) 34 ST 1177-34 Torsion Bar Bracket
6 ST 1177-6 Capscrew (10-24x5/8) 36 ST 1177-36 Centering Ring (3.753 dia.)
7 ST 1177-7 Swivel Pad Screw (1/4-20x1/2) 37 ST 1177-37 Centering Ring (4.063 dia.)
8 ST 1177-8 Cutter Holder (Small) 38 ST 1177-38 Centering Ring (4.125 dia.)
9 ST 1177-9 Checking Ring (3.751 dia.) 39 ST 1177-39 Centering Ring (4.750 dia.)
11 ST 1177-11 Checking Ring (4.061 dia.) 41 ST 1177-41 Centering Ring (5.345 dia.)
12 ST 1177-12 Checking Ring (4.1227 dia.) 42 ST 1177-42 Centering Ring (6.096 dia.)
13 ST 1177-13 Checking Ring (4.7472 dia.) 51 ST 1177-51 Alien Wrench (5/32)
14 ST 1177-14 Checking Ring (5.3422 dia.) 52 ST 1177-52 Alien Wrench
15 ST 1177-15 Checking Ring (6.0932 dia.) (3/16) ST 1177-53 Tool Box
16 ST 1177-16 Bar ( 2in.x 56 in.) 54 ST 1177-54 Centering Ring (5.846 dia.)
17 ST 1177-17 Bore Feed Ass'y 55 ST 1177-55 Checking Ring (5.843 dia.)
18 ST 1177-18 Bore Bar Bridge ST 1177-56 Bridge Bearing Pin
21 ST 1177-21 Bridge Bearing ST 1177-5111 Micrometer Assembly
22 ST 1177-22 Bearing Bar 43 ST 1177-43 Micrometer

7. With cutter key (ST-i 177-49) adjust tool bit against 8. Back off micrometer and remove cutter holder from
micrometer spindle and tighten tool bit retaining micrometer base shaft.
screw in cutter holder, back off micrometer and
check tool bit setting. CUTTING MAIN BEARING BORES

Note : Do not tighten micrometer spindle against tool 1. Install bore feed assembly (ST-1177-17) in one
bit point or carbide may be chipped. Do not sweep end of boring bar and tighten socket head screw,
micrometer spindle across carbide cutter; for it will chip ST-1177-32.
cutting edge.
3.2-12

2. Install torsion bar (ST-1177-33), threaded end first, 10. With swivel joint on boring bar adapter, bore the
through bore feed assembly (ST-1177-17), start journal. Keep boring bar well lubricated during all
threads into end hole of torsion bracket (ST-1177- boring operations.
34). The flats on bar can be used to secure if to
bracket. Caution : Do not use drill rated less than 10 amperes
or over 450 rpm.
3. Locate tapped hole in end of block and secure
torsion bracket to block with a suitable capscrew 11. To cut next journal:
and washer.
a. Remove cutter holder from boring bar.

4. Pull out on plastic knob of feed assembly until pin b. Pull out on plastic knob on feed assembly and
is free of slot and turn one-fourth turn, then pull turn one-fourth turn.
complete feed assembly back all the way to the c. Push in on feed shaft (the knob) until it stops
knob and tighten wing setscrew in feed assembly against feed assembly.
to secure on torsion bar.
d. Turn plastic knob one-fourth turn, until pin
seats in slot.
Note : Later models of ST-1177 have a feed engagement
lever on the side of the bore feed assembly (ST-1177- e. Repeat Steps 9 and 10.
17) in place of the plastic engagement knob. Position
lever to “open” to adjust feed assembly, position lever to 12. Clean block and check size of bore with a dial bore
“close” to engage feed mechanism. gauge and alignment with checking ring.

5. Install square head set bolt in second threaded

hole of torsion bracket end and tighten snug against
block to stabilize torsion assembly.
6. Turn plastic knob on drive assembly onefourth turn
until pin seats in groove.
7. Install adapter (ST-1177-31) in other end of boring
bar with the i inch square drive out. Lock with socket
head set-screw.
8. Lock swivel joint (ST-1177-27) in a inch drill chuck.
These instructions assume use of a right hand
rotation drill.
9. Install tool bit holder on boring bar, next to journal
to be cut. When operating, boring bar will feed
toward feed assembly. Make sure tool cutting edge
is turned in direction of drill rotation.
USE OF THE BRIDGES
The bridges and bearings are intended for additional
support of boring bar and are designed to compensate
for any distortion of block oil pan surface. It is not
necessary to use bridges if centering rings are located
equally apart.
1. Assemble bearing bar (ST-1177-22) on bearing
bridge (ST-1177-21) with hexagon head capscrew
(ST-1177-23) finger tight.
2. Slide bearing over boring bar at point where
support is needed. Allow room for cutter holder, if
next to journal being cut.
3. Lower line bore bridge (ST-1177-18) over bearing
bar and secure to oil par rails.

4. Tighten socket head screw (ST-1177-25) in bearing
until bearing is snug on boring bar; do not restrict
bar from turning.
5. Tighten hexagon head capscrew (ST-1177-25) in
bearing bar and socket head capscrew (ST-1177-
19) in bridge.
6. Turn boring bar to see that it is free.
SLEEVING ERODED WATER HOLES
The cylinder block surface around the water holes must
be free of any erosion, pits, scratches or blemishes which
are more than 0.003 inch [0.08 mm] deep in the area 1/
16 to 5/32 inch [1.59 to 3.97 mm] from edge of water
holes. Repair as follows :
1. Insert hold-down adapter of ST-1010 into cylinder
head capscrew hole.
2. Position tool on top surface of cylinder block with
reamer guide hole over water hole to be repaired.
3. Inser t tool hold-down capscrew into holder
assembly and tighten finger tight.
4. Insert locating pin into eroded hole and tighten
hold-down capscrew to 50 ft-lb [68 N°m].
5. To set depth of 0.5625 inch [14 mm] reamer
assembly, insert assembly in guide. Place gauge
block between holder assembly and reamer
adjustable stop collar. Insert 0.005 inch [0.13 mm
feeler gauge between bushing and adjustable
collar; tighten setscrew.
Caution : Take care not to use too large a reamer; avoid
getting head gasket grommet over cylinder liner flange.
3.2-13
6. Attach drive adapter to half-inch drill check and place
grooved end of drive adapter into reamer assembly.
7. Ream out eroded water hole until collar bottoms
against tool.
8. Remove drill, reamer assembly, holder assembly
and hold-down adapter.
9. Drive bushing into reamed hole with driver.
Bushing should protrude about 0.003 to 0.005 inch
[0.08 to 0.13 mm].
10. If block is to be resurfaced, see “Top Surface
Refinishing”. If not to be resurfaced, file bushing
flush with surface using a wide, flat mill file.
a. Be careful not to damage surface when filing
sleeves.
b. Thoroughly clean block water passages to
remove all cutting and filings.
11. If proper bushing is not available, heavy-wall copper
tubing may be used. Tubing must provide 0.002 to
0.005 inch [0.05 to 0.13 mm] press fit. Overall
length should be approximately 1/2 inch [12.7 mm];
inside diameter must be 7/16 inch [11.13 mm] to
allow proper water flow through cylinder head.
3.2-14
TOP SURFACE REFINISHING
If necessary, a cylinder block may be salvaged by
removing a maximum of 0.010 inch [0.25 mm] of material
from the top surface.
1. Use either a milling machine or large surface
grinder; locate block on main bearing pads.
2. Remove dowels from cylinder head mounting
surface and make light cuts of 0.001 to 0.003 inch
[0.03 to 0.08 mm] deep, removing only enough
material to make block usable.
3. Check distance from centerline of main bearing
bore to top of block. (Fig. 3-15). Distance
after finishing must not be less than 18.994 inch
[482.45 mm].
Fig. 3-15 : Location to check cylinder block height.
4. An alternate method of measuring block height is
a. Remove block from milling machine or surface
grinder.
b. Install main bearing caps, tighten as described
in Table 1, Page 3-4.
c. Using clean engine lubricating oil, coat outside
surface of ST-1177-15 Checking Ring. Insert
checking ring into main bearing bore
(checking ring must pass through bore freely).
d. Allow checking ring to protrude approximately
half way from main bearing bore, measure
distance from top surface of block “to checking
ring. Distance must not be less than 16.948
inch [430.48 mm] after finishing.
e. Repeat Steps c and d for each main bearing.
5. Finish surfaces to 125 A.A.
6. Resurface counterbore to obtain proper liner
protrusion. Check cylinder liner to block contact in
crevice seal area.
MACHINING LOWER BORE
ENTRY CHAMFER
If the lower bore or the lower bore entry chamfer is
beyond the tolerances, pitted, or eroded, one of the
following operations may be performed to salvage the
cylinder block. If the erosion has occurred only on the
entry chamfer and not in the packing ring sealing area,
the chamfer may be “built-up” by the use of a plastic
steel compound such as Devcon Plastic Steel, Type “A”.
The manufacturer’s directions should be followed for this
salvage procedure. Check the chamfer depth after this
operation and resurface the chamfer if beyond
acceptable tolerance.
LOWER LINER PACKING RING BORE REPAIR
It is very important that dimensions given be duplicated.
Depth arid diameter dimensions must be held within
tolerances given so cylinder liner packing rings and
crevice seals will seal properly.
INSTALLATION OF BRASS SLEEVE USING BORING
BAR
The O.D. of 163401 Brass Sleeve is approximately
0.012 inch [0.30 mm] larger than recommended bore.
This press fit is sufficient interference to hold sleeve in
place.

Caution : The following instructions do not apply when
ST-1287 or cast iron sleeve Part No. 195778 is to be
used.
1. Bore cylinder block as shown in Fig. 3-16 and to
dimensions as follows:
a. Bottom of block bore (11) is 6.361 to 6.363
inch [161.57 to 161.62 mm] diameter, to block
deck (1) is 8.565 to 8.585 inch [217.55 to
218.06 mm].
Fig. 3-16 : Sleeve and block boring dimensions.
b. The 20 degrees chamfer (5) in block is 0.010
to 0.020 inch [0.25 to 0.51 mm].
2. Clean all chips from block.
3. Mix sealer of three parts glycerine to one part
litharge to a smooth paste.
4. Wipe bore with a clean cloth and apply sealer.
5. Sleeve is larger than top bore. Place O.D. of sleeve
against top of bench and press out-of-round just
enough to push through bore.
6. Turn sleeve in cylinder bore so O.D. chamfer is
down.
7. Provide a driver which closely pilots sleeve and
with clearance flats on outside diameter.
3.2-15
8. Index driver so flats will allow it to pass through top
bore and place driver on sleeve.
9. Turn so driver is on bottom and press sleeve over
driver by using a wooden hammer handle or
equivalent. This is slightly difficult due to limited
space.
10. Coat O.D. of sleeve with sealer.
11. Position sleeve in chamfered edge of bore.
12. Place driver extension in driver; make sure sleeve
is centered in bore and tap lightly on extension to
seat driver in sleeve and start sleeve into bore.
13. Drive sleeve into bore of block with a heavy
hammer or hydraulic ram until it bottoms in the
bore.
14. Should driver stick in sleeve due to interference, a
cylinder liner puller can be used to pull driver.
15. Bore sleeve inside diameter as shown in Fig. 3-16
and to dimensions as follows :
a. Bottom of sleeve (8) 20 degrees chamfer to
(2) block deck is 7.314 to 7.326 inch [185.78
to 186.08 mm].
b. Top of sleeve 20 degrees chamfer to (3) block
deck is 7.265 to 7.285 inch [184.53 to 185.04
mm].
c. Bottom of sleeve (7) 0.040 to 0.060 inch [1.02
to 1.52 mm] radius to block (4) deck is 7.187
inch [182.55 mm] maximum.
d. Top of sleeve (7) radius is 0.040 to 0.060 inch
[1.02 to 1.52 mm] (6) diameter 6.250 to 6.260
inch [158.75 to 159.00 mm].
e. Sleeve (9) bore diameter is 6.124 to 6.125 inch
[155.55 to 155.60 mm] to a (10) depth of 8.850
to 8.875 inch [224.79 to 225.42 mm].
3.2-16

16. Remove boring bar from bore. Use fine emery cloth Table 3 : Lower Bore Sleeve and Boring Data
to break sharp corners in entrance of bore so
rubber packing rings will not be damaged when Repair Boring Diameter in Block
cylinder liners are installed. Sleeve
Part No. Inch [mm]
17. Clean bore thoroughly to remove all emery dust
and boring chips. Blow dry with compressed air ST-1287-41 6.250/6.251 [158.755/158.775]
and coat machined surfaces with engine lubricating ST-1287-42 6.300/6.301 [160.020/160.045]
oil. 195778 6.361/6.363 [161.569/161.620]

18. After boring and sleeve installation check alignment
as described under “Counterbore Concentrictly”.
INSTALLATION OF CAST IRON SLEEVE USING
ST-1287 BORING TOOL
1. Cylinder to be bored should be in vertical position.
2. Clean cylinder block surface to remove gasket
material, dirt burrs, etc. The cylinder block surface
must be clean and smooth.
c. Back off micrometer and readjust as required.
4. Select proper centering ring. Remove o-ring and
install centering ring onto tool with taper towards
cutter, Fig. 3-17. Install o-ring into groove to prevent
centering ring from coming off tool, Figs. 3-18 and
3-19.
5. Place tool bit in tool holder until it bottoms against
drive shaft.

3. Preset tool bit with micrometer set block.

a. Check the micrometer with the “Standard”

included with the tool. The micrometer should
read five (5) inch [127 mm] when measuring
the “Standard”. If calibration is off, loosen the
socket head cap-screw and move the
micrometer in or out as required. When the
micrometer reads five (5) inch [127 mm] tighten
the socket head capscrew.

b. Place the tool bit in the set block. Loosen

the set screw in the tool bit. Depress plunger
as required to be in general range. Preset
the micrometer to the proper value. See
Table 3. Loosen setscrew allowing plunger to
contact micrometer. Tighten setscrew securely.
 3.2-17

a. Loosen the round drive engagement knob on

top of the tool (2). Push the splined drive shaft
(3) down until the tool bit touches the preset
depth collar on the gauge^ rod.

b. Slide the depth set coller (4) on the splined

drive shaft down the drive shaft until it bottoms
out on the top of the tool. Tighten the setscrew.
This allows the drive shaft to cut to the proper
depth as adjusted on the gauge rod.

Note : Gauge rod is not marked for 195778 Sleeve. This

sleeve is approximately 0.100 inch [2.54 mm] shorter
Fig. 3-17 Installing centering ring.
than ST- 1287 -41 and 42. If 195778 Sleeve is used,
adjust stop collar as required to avoid boring too deep.

8. Remove gauge rod.

9. Pull upward on round knob to raise boring bar all

the way up.

10. Remove all nicks or burrs from counterbore in

block. Clean thoroughly. Deck must be flat and free
from rough area that would cause machine
misalignment with lower bore.

11. Install tool in counterbore, lower unit into

Fig. 3-18 Installing o-ring into groove. counterbore with tapered centering ring engaging
counterbore.

12. Secure base plate to block with cap-screws and

spacers. Tighten securely to approximately 50 ft-
lb [68 N°M].

13. Push downward on round knob slowly until tool bit

touches lower bore area. Raise up boring bar
approximately 1 inch [25.4 mm].

14. Tighten round knob; this engages the automatic

feed mechanism. Rotate shaft by hand to be sure
it rotates freely.

Fig. 3-19 Centering ring and o-ring installed. 15. Install flexible coupling drive in a heavy duty drill.
Recommend drill size is 1/2 to 3/4 inch, 10 amperes
or more, 450 RPM.
3.2-18

16. Place drill and flex coupling on drive shaft. Bore sleeve is positioned, sleeve driver should rotate
until stop collar “bottoms out”. (A noticeable change freely for removal; remove tool.
in drill speed will be observed).
9. Wipe clean excess Loctite compound from around
17. Loosen round knob, pull drive shaft all the way up. sleeve entrance.
Tighten knob.
SLEEVE CHAMFERING TOOL
18. Remove boring bar.
ST-1318 Chamfer Tool provides a crevice seal entry
Caution : Do not allow tool bit holder to strike block chamfer. This tool must be used when ST-1287-39, 40,
during removal. 41 or 42 sleeve is used. The chamfer tool will “blend in”
the entry chamfer of sleeve to the block.
19. Inspect bore, measure bore. Clean thoroughly and
remove rough edges with emery cloth. 1. Select the proper cutter plate for the block.

INSTALL REPAIR SLEEVE INTO
CYLINDER BLOCK
1. Thoroughly clean bore area with compressed air;
wipe clean.
2. Clean the block bore and outside diameter of the
sleeve with Loctite Primer. Apply narrow band of
Loctite bushing Mount, or equivalent completely
around the sleeve outside diameter.
3. Set repair sleeve on top of counter-bore.
2. Place chamfer tool bit in position in cutter plate.
Cutter should be positioned with lower edge of tool
bit angle recessed slightly below the pilot diameter.
Tighten clamping screws.
Note : Two chamfer tool bits are included. The 15 degree
angle tool is used for all engines except the V-903.
3. Place locating plate on main shaft.
4. Place cutter plate (3) on main shaft (2). Install
flatwasher (4) and nut (5). Tighten nut.

4. Push sleeve through upper bore. 5. Place tool in block.

5. Install proper sleeve drive into sleeve. (Inside 6. Holding the T-handle, loosen the socket head
diameter chamfer of sleeve must be positioned capscrew on the adjusting collar and lower the
upward toward top deck.) cutting plate until the cutter makes contact with
the upper part of the repair sleeve to be chamfered.
6. Install upper locator over drive handle and into
counterbore. 7. Turning the T-handle clockwise and pushing down
gently, cut the chamfer to the desired depth. When
7. Tap gently on driver handle to position sleeve in
the desired depth is reached, tighten the socket
bore.
head capscrew on the adjusting collar. This
establishes the depth for cutting the remaining
8. With suitable hammer (preferred rawhide mallet)
chamfers.
drive sleeve into place. When sleeve is positioned,
 3.2-19

Ref. Part Description

No. No.

1 ST 1318-23 Cutter (All except V903)

1 ST 1318-24 Cutter (V903)
2 ST 1318-14 Cutter Plate (NTS 1/2)
2 ST 1318-15 Cutter Plate (V6,V8, 5 1/2)
2 ST 1318-16 Cutter Plate (V903)
2 ST 1318-17 Cutter Plate(NH 51/8)
2 ST 1318-18 Cutter Plate (V378, V504, V555)
3 3377343 Guide Plate (NT .020 O.S.)
3 3822914 Guide Plate (NT .040 O.S.)

Fig. 3-20 : ST-1318 chamfer tool.

8. Turn the socket head capscrew in the top collar
clockwise into the notch on the lower collar until a
g inch [6.4 mm] gap is between the two collars.
9. Place the chamfer tool into the next bore to be
chamfered.
10. Gradually turn the setscrew counterclockwise and
continue turning T-handle until the two collars meet.
This is the previously set desired chamfer depth.
3. Position unit in cylinder block bore by lowering tool
holder in counterbore to “centre” tool. Secure adapter
plate to block with cylinder head capscrews (or other
suitable capscrews) and spacers or washers as
required.
4. Rotate boring bar clockwise to see that it is centered
and rotates freely. If not, reposition plate. Correct
positioning prevents cutting counter-bore inside
diameter oversize.

11. Continue this procedure on the remaining sleeves
to be chamfered.
CYLINDER LINER COUNTERBORE
Resurface cylinder liner (liner) counterbore if block has
been resurfaced, if ledge is uneven, or where liner
protrusion is incorrect. ST-1255 is used for this operation.
1. Select proper cutter plate. Preset tool bit by using
0.010 to 0.015 inch [0.25 to 0.38 mm] feeler stock
wrapped around area of tool bit slot. Push tool bit
out to touch feeler stock. Tighten in position, then
recheck.
2. Install tool holder to bearing bar. Tighten securely.
5. Back off adjusting collars to lower tool holder to
counterbore ledge. Turn bar clockwise with even
downward pressure and continue to back off
adjusting collar until predetermined depth is
reached. Each mark on collars represents 0.001
inch [0.02 mm]. At this point, adjust top screw. This
will allow all counterbores to be cut the same depth
throughout the block as required.
CYLINDER HEAD CAPSCREW THREAD SALVAGE
If cylinder head capscrew threads in the cylinder block
are stripped or thread area is cracked slightly, block may
be repaired by using a special (solid bushing-type) thread
insert and appropriate tools to insure alignment and
3.2-20

location. Special thread insert, ST-1272-15, is threaded 2. Details 3, 4 and 14 are not available for service
internally and externally and also features a counterbore replacement, use local standard hardware source.
on one end same as cap-screw hole in teh block. Internal
threads in the block. Operations may be performed “in GENERAL INSTRUCTIONS
frame” with minimum effort on part of mechanic using 1. Assemble reamer guide bar (2) to base plate (1).
ST-1272. Secure base plate to block with capscrews and
spacers included.
1. Base Plate
2. Place tapered locator stem (5) through guide bar
2. Reamer Guide
into hole to be salvaged. Tighten capscrew (3)
3. Capscrew (standard 5/8-18x3) securing guide bar to base plate.
4. Flatwasher (standard 5/8 I.D.)
3. Remove tapered locator. Use a 23/32 size drill to
5. Locator
remove excess stock before reaming. Install special
6. Reamer-Special
reamer (6) in pilot bushing.
7. Tap-Special
8. Flex Drive Adapter 4. Install flex-drive (8) into heavy duty 1/2 or 5/8 inch
9. Stop Collar electric drill, 10 amperes or more, 450 RPM.
10. Nut - Special 5. Ream hole until reamer “bottoms out “ Remove
11. Chip Remover reamer and remove shaving with special cup
12. Loctite Retaining Compound remover (11).
13. Loctite Primer (Grade T) 6. Reinstall reamer (6) to insure reamer “bottoms out”
14. (2) Spacers (standard 4 inches long) in bore.
15. (10) Threaded Inserts
7. Remove reamer. Install special tap in pilot bushing.
Tap will set on top of block. Place thread insert
between pilot bar and stop collar on tap. Adjust stop
collar to test on top of insert and secure collar.
8. Using electric drill and swivel, tap hole until stop
collar is 1/8 to 1/4 inch [3.18 to 6.35 mm] from
“bottoming out” on pilot bar.

9. Remove tap (7), clean all shavings from hole,

Fig. 4-31. Reinstall tap to 1/8 to 1/4 inch [3.18 to
6.35 mm] from bottom. Tap remainder of depth with
tap handle or suitable wrench until stop collar (9)
bottoms out.

Fig. 3-21 : ST-1272 repair kit.

1. To order additional thread inserts, detail 15 contains

ten thread inserts. If 20 inserts are desired order
two detail 15 thread inserts, etc.
 3.2-21

10. Remove tap and tool. Thoroughly clean hole. 3. Lower tool holder into bore by pulling up on orifice
retractor knob (ST-1168-14) while pushing down on
11. Install special nut on standard head capscrew. depth coliar, ST-1168-12.

12. Install thread insert on cylinder head capscrew 4. Tool holder lower diameter is used to centrer
against special nut. machine in counterbore inside diameter. Push tool
holder lower locating diameter into counterbore and
13. Clean external threads of insert with Loctite Primer tighten four (4) mounting capscrews alternately to
T Cleaner to remove all foreign material. Allow to 25 to 35 ft-lb [34 to 48 N°m] torque.
dry.
5. Retract tool holder by pulling up on orifice retractor
knob, ST-1168-14.
14. Apply light coat of Loctite Sealer to external threads
and install in block until insert is flush with block
6. Loosen setscrew (ST-1168-23) in back end of tool
top surface. bit and push adjustable set pin (ST-1168-21) all
the way in Lock setscrew.
15. Hold head bolt and back off nut 1/4 turn.
Remove bolt from insert. 7. Adjust micrometer (ST-1168-25) to 6.750 inch
[171.45 mm].
16. If required, file off any excess stock so insert is
flush with block. 8. Place tool bit (ST-1168-19) in tool bit gauge and
hold firmly against stop and hardened pad (ST-1168-
BLOCK COUNTERBORE SALVAGE
27). Loosen setscrew and allow adjustable set pin
St-1168 Cylinder Liner Counterbore Salvage Tool is used to come out against micrometer spindle. Lock
to enlarge damaged counter-bores for the installation of setscrew.
Part No. 202226 Salvage Sleeve or bores that have been
reworked to maximum depth. 9. As a further check, back off thimble on micrometer
and recheck tool bit length again.
ASSEMBLY OF TOOL
1. Assemble and secure adapter plate (ST-1168-28, 10. Insert tool bit into tool holder and tighten lockscrew
Fig.4-33) to main body. (ST-1168-20). Tool bit must be held all the way in
against tool holder.
2. Assemble tool holder (ST-1168-39) on shaft of main
body (1168) and secure with nut (ST-1168-33) and 11. Turn tool holder until too bit recess is at large
washer, ST-1168-34.
opening in (ST-1168-28) Adapter Plate.

MACHINING THE BLOCK

12. Place a 0.004 inch [0.10 mm] feeler gauge between
1. Remove cutting tool from (ST-1168-39) Holding block and tool bit and lower tool bit onto feeler gauge
Plate. by pulling up on retractor knob while pushing down
on set collar.
2. Place boring machine on cylinder block above bore
to be cut and hand start mounting capscrews.
13. Loosen set collar setscrew and back off collar
Capscrew spacers (ST-1168-29 or 40) must be on
counterclockwise until salvage sleeve can be
capscrews.
placed between collar and, boring machine main
body as a depth indicator. Tighten setscrew in set
collar. Remove feeler gauge.
3.2-22

Fig. 3-22 : ST-1168 boring tool

Ref. Part Description Ref. Part Description

No. No. No. No.

1 ST 1177-27 Universal Drive 22 ST 1168-45 Guide Plate V903

2 ST 1168-37 Bushing Driver Handle 18 ST 1168-51 Cutter Plate Key
3 ST 1168-46 Long Bushing Driver Shaft 23 3376782 Cutter Plate Assembly
4 ST 1168-47 Short Bushing Driver Shaft 24 3376784 Depth Spacer Block
5 3823718 Retaining Compound 20 3823674 Cutter Assembly
6 3824715 Primer T 18 ST 1168-51 Cutter Plate Key
7 ST 1168-28 Base Plate 25 3376187 Cutter Ass'y (.068/.073R)
8 ST 1168-29 Stud Adapter (1 in. x 2 1/4) 26 3375443 Cutter Ass'y (.057/.067R)
9 3376552 Micrometer Block Assembly 27 3375822 Cutter Ass'y (.008/.012R)
10 ST 1168-52 Setting Standard 28 3375823 Depth Spacer Block
11 ST 1168-40 Stud Adapter (3/4 x 2 3/4) 29 3375824 Depth Spacer Block
12 3375826 Micrometer Block Assembly 30 3375831 Depth Spacer Block
13 3375827 Base Plate 31 3376189 Depth Spacer Block
14 3375828 Setting Standard 32 3824054 Cutter Plate Ass'y
15 3375829 Stud Adapter 33 3376219 Cutter Ass'y (1/4 Offset)
16 ST 1168-36 Bushing Driver 34 3376223 Bushing Driver
17 ST 1168-44 Guide Plate 35 3376224 Guide Plate
18 ST 1168-51 Cutter Plate Key 36 3376226 Sleeve Driver Shaft
19 ST 1168-97 Cutter Plate Assembly 37 3376365 Cutter Holder Plate
20 3823674 Cutter Assembly 32 3824054 Cutter Plate Assembly
16 ST 1168-36 Bushing Driver 18 ST 1168-51 Cutter Key
21 ST 1168-43 Guide Plate N855, V28 23 3376782 Cutter Plate Ass'y
24 3376784 Depth Spacer Block

Note : This spaces the set collar to cut a depth 0.004
inch [0.10 mm] less than total height of salvage sleeve
to be used.
14. Place 1/2 inch drive Universal joint (ST-1168-48) in
a 1/2 or 3/4 inch heavy duty (10 amperes or more)
hand drill.
Caution : Do not use drill rated less than 10 amperes
or over 450 rpm.
15. With drill on half inch drive of boring tool
(ST-1168-3), bore hole until drill freewheels. About
half way down during cut, tool bit begins cutting out
old counterbore ledge, operator should have a firm
grip on drill to be prepared for increased load on
drill from added metal being cut. Stop immediately
when drill freewheels.
16. Retract tool holder by pulling up on retractor knob.
Remove tool bit form tool holder. Remove boring
tool. Clean away all shavings and deburr above with
emery cloth.
 3.2-23

INSTALLING SALVAGE SLEEVE CRANKSHAFT

1. Clean bore thoroughly with a non-petroleum base
solvent or cleaner.
2. Coat outside of sleeve lightly with a suitable sealant
and drive sleeve into bore with driver until it bottoms
(see ST-1168-36 through 46). A solid sound can
be heard when sleeve bottoms.
3. The sleeve will protrude above the top block by
0.004 inch [0.10 mm] and must be filed even with
the top of block. Remove all burrs with emery cloth.
Crankshafts are steel forgings with accurately machined
and hardened main and connecting rod journals. Each
shaft is balanced for proper weight distribution to insure
even forces during rotation. For complete crankshaft
inspection and reconditioning information, see Bulletin
No. 3379092.
CLEANING
1. All plugs must be removed and the crankshaft
steam cleaned.

4. The salvage sleeve is designed to be 0.005 to 2. Clean the crankshaft oil holes with a stiff-bristle
0.010 inch [0.13 to 0.25 mm] above required brush that does not shatter. If necessary, follow
counterbore depth. Check depth and cut to a depth with cleaning solvent and air. If a steel bristle brush
of from 0.350 to 0.351 inch [8.89 to 8.91 mm], is used, follow with air and magnet.

CYLINDER LINERS

Cummins cylinder liners (liners) form combustion

chamber walls and are in direct contact with coolant for
efficient cooling. Coolant is sealed in cylinder block
(block) by accurately machined surfaces at liner flange
and by packing rings and crevice seal at lower end of
liner.

INSPECTION

1. Check for cracks in cylinder liners just under top

flange, at bottom If liner, or above top seal ring
groove as follows: Fig. 3-23 : Blind oil drilling in crankshaft.

a Magnetic Method, Note : Apply special attention in cleaning of “blind” holes,

b. Dye Penetrants. these act as dirt collectors.

2. Discard any liner with excessive corrosion or 3. Use a small magnet which can be inserted into
erosion and pits 1/16 inch [1.6 mm] deep or more, the oil holes to remove metallic material.
or if dents, pitting or fretting on underside of liner
4. Visual inspection of all drillings must be made to
flange cannot be removed by lapping.
assure removal of all dirt.
3. Check worn liners with dial bore gauge. Replace
if worn larger than 5.505 inch [139.83 mm].
3.2-24

DISASSEMBLY AND INSPECTION Table 4 : Crankshaft Journal Specifications -

Inch [mm]
Note : Remove and replace crankshaft gear only if
Connecting Rod Main Bearing
chipped, cracked, broken or worn. 3375840 Crankshaft
Gear Puller Set may be used for this operation. Under Maxi- Mini- Maxi- Mini-
size mum mum mum mum
1. Attach a circular-type puller behind the crankshaft
gear. Stan- 3.750 3.7485 5.750 5.7485
dard [95.25] [95.212] [146.05] [146.012]
0.010 3.740 3.7385 5.740 5.7385
2. Apply 75 to 100 ft-lb [102 to 136 N°m] on puller 94.99] [94.957] [145.79] [145.758]
screw. 0.020 3.730 0.7285 5.730 5.7285
[94.74] [94.704] [145.54] [145.504]
3. Heat gear with heating torch - not a cutting torch - 0.030 3.720 3.7185 5.720 5.7185
to 400°F [205°C]. The gear will expand, making it [94.49] [94.45] [145.29] [145.250]
0.040 3.710 3.7085 5.710 5.7085
easier to pull . Remove gear key. [94.23] [94.196] [145.03] [144.996]

4. Inspect crankshaft-for scratches, nicks, cracks and

obvious wear pattern and measure crankshaft Note : Main bearing shells and connecting rod bearing
journals with micrometers. See Fig. 3-31 and shells are available in 0.010, 0.020, 0.030 and 0.040
Table 4. inch and thrust rings in 0.010 and 0.020 extra thickness
over standard size.

6. Carefully examine crankshaft thrust flange at No.

7 main bearing. If surfaces are scored or scratched,
Crankshaft thrust surfaces should be re-ground
and oversize thrust rings installed.

7. Reground crankshafts or those used with

undersize rod and main bearings and/or oversized
thrust rings should be marked so correct bearing
shells and thrust rings can be installed in proper
position, Figs. 3-32 and 3-33.

8. The marking for undersize rod and main bearings

Fig. 3-24 : Measuring crankshaft connecting rod journal, should be on front counterweight, oversize thrust
ring size on rear counterweight. Both thrust ring
5. Check crankshaft for out-of-round condition.
size and ring location must be included in stamping
Crankshafts should be re-ground if main bearing
as shown in Fig. 3-33. For example : Front-Std.
or crankpin journals are worn out-of-round more
and rear - 0.010 inch assembly.
than 0.002 inch [0.05 mm] or if worn smaller than
minimum dimensions given in Table 4.

Fig. 3-25 : Undersize main and connecting rod markings
9. Install crankshaft gear, if removed.
Fig. 3-26 : Oversize thrust bearing marking
Note : Check parts catalog for correct gear part number.
a. Install key in shaft.
b. Heat gear in preheated oven at 400°F [204°C]
for minimum of one hour.
c. Lubricate flange with high pressure grease and
drive gear onto shaft with piece of tubing.
BEARINGS
Main and connecting rod bearings (or sheels) are two-
piece units. Upper main bearing shells contain oil holes
3.2-25
for lubrication. Connecting rod bearings shells both
contain oil holes for lubrication and are interchangeable.
Thrust rings are used at No. 7 main bearing.
INSPECT BEARING SHEELS
1. Gauge shell with ball point micrometer (Fig. 3-38)
dial indicator thickness gauge, or comparater.
Discard shells that are chipped, flaked or scored.
Discard bearing shells worn thinner than
dimensions given in Table 5.
Fig. 3.27 : Measuring bearing shell.
2. Total worn maximum oil clearance should not vary
more than 0.002 inch [0.05 mm] between adjacent
main bearings. Maximum main bearing oil
clearance should not exceed 0.010 inch [0.25 mm]
and maximum rod bearing oil clearances should
not exceed 0.0085 inch [0.216 mm].
Note : Under no circumstances scrape bearing shells,
nor should they be lapped or filed to increase oil
clearances. A properly fitted bearing will appear dull gray
after a reasonable period of service, indicating it is
running on an oil film. Bright spots indicate metal-to-
metal contact and black spots indicate excessive
clearance.
3.2-26

CRANKSHAFT THRUST RINGS CLEANING

The best measurement of wear on crankshaft thrust rings Rubber dampers should be cleaned in household
and thrust flange is the crankshaft and clearance check. detergent.

1. With thrust bearings installed, place dial indicator Table 5 : Bearing Shell Thickness -
Inch [mm]
as shown. Move crankshaft to rear of engine.
Connecting Rod Main
2. Zero indicator and move crankshaft forward. Undersize Minimum Minimum
Reading must not exceed 0.018 inch [0.46 mm] if
clearance is excessive, crankshaft may need Standard 0.1232 0.1692
[3.129] [4.298]
reconditioning. See Manual Bulletin No. 3379092,
0.010 0.1282 0.1742
Crankshaft Reconditioning. [3.256] [4.425]
0.020 0.1332 0.1792
3. Oversize thrust rings are available; be sure to use [3.383] [4.552]
same size (thickness) hglfring on both upper and 0.030 0.1382 0.1842
[3.510] [4.679]
lower por tions. Stamp crankshaft rear
0.040 0.1432 0.1892
counterweight indicating size used if other than [3.637] [4.806]
standard.

Note : Allowable amount of wear on thrust ring depends Caution : Use of solvent or degreasing compounds will
upon wear of crankshaft surfaces. Installed in a cylinder cause deterioration of rubber.
block, crankshaft end clearance must not exceed 0.018
inch [0.46 mm] at rebuild Fig. 3-28. INSPECTION

1. Inspect damper for cracks. Inspect rubber member

for deterioration that will impair its effectiveness.

a. If the cavity depth (1, Fig. 3-29) exceeds 1/8

inch [3.18 mm] all the way around, the damper
must be considered failed.

b. If the cavity depth (2) exceeds 3/8 inch [9.5

mm] all the way around the damper, the
damper must be considered failed.

2. Check for alignment of index marks on damper

hub and inertia member. If out of alignment more
Fig. 3-28 : Checking crankshaft end clearance. than 1/16 inch [1.59 mm], discard damper.

VIBRATION DAMPERS Note : Paint should be removed to complete Steps 3 and

4.
V-1710 engines use rubber member dampers which are
tuned to the engine’s natural system frequency. These 3. Vibration dampers that become damaged “wobble”
are made of metal units separated by rubber compound during operation, indicating loss of effectiveness.
material.

Fig. 3-29 : Rubber cavity depth of vibration damper.
Check for damper wobble on inner ledge of inertia
(outer) member. Wobble must not exceed 0.009
inch [0.23 mm] per inch [25.4 mm] of radius.
4. Measure eccentricity on outer ledge of inertia
member, it should not exceed 0.006 inch [0.15 mm]
per inch [25.4 mm] of damper radius.
Fig. 3.30 : Vibration damper alignment mark
3.2-27
REPAIR
Dampers are not subject to field repair. If inspection
shows them to be defective, install a new damper.
VIBRATION DAMPER MOUNTING ADAPTER
1. Check damper mounting capscrew hole threads
in crankshaft.
2. Maximum eccentricity of the mounting adapter,
measured on the outside diameter of the pilot, must
not exceed 0.004 inch [0.10 mm] total indicator
reading.
3. Wobble of the flange, measured at 2-3/4 inch
[69.85 mm] radius, must not exceed 0.003 inch
[0.08 mm].
4 The above readings are to be taken after assembly
on the engine.
Caution : Crankshaft must be kept to front or rear
thrust limit while wobble is checked.
CONNECTING RODS
INSPECTION
1. Magnaflux all connecting rods, caps and bolts;
discard if cracks are detected.
Note : Be sure rod and cap are kept mated at all times.
a. Check rods for cracks with 1800 ampere
current AC equipment or 1500 ampere current
DC or rectified AC equipment longitudinally
between plates.
b. Check rods for cracks with 3000 to 3400
ampere-turns with AC equipment or 2600 to
2800 ampere-turns with DC or rectified AC
equipment in a coil. Pay particular attention to
shaded critical areas.
Note : Ampere-turns is defined as the amperage flowing
through the coil, multiplied by the number of turns in the
coil. Most coils contain four (4) turns and therefore only
3.2-28
Fig. 3.31 Connecting rod specifications
700 amperes need to be applied with DC equipment, or
850 amperes with AC equipment.
c. Apply one and one-half percent wet solution
while current is on. Make visual inspection after
each application of current.
2. Assemble cap to rod and alternately tighten nuts
to operating tension as described in Table 6.
3. Check crankpin bore with a dial bore gauge.
Correct size is important to provide correct bearing
crush. Inside diameter after rod cap is removed
and reinstalled is 4.0018 to 4.0028 inch [101.646
to 101.671 mm] except within 30 degrees of parting
line. Within 30 degrees of parting line, maximum
dimension may increase to 4.0033 inch [101.684
mm].
4. Check piston pin bushing diameter with ST-205
Plug Gauge of with dial bore indicator. Replace
Bushing if worn larger Than 2.0025 inch [50.863
mm].
5. Use ST-561 Checking Fixture and Locating Mandrel
to check rod alignment.
Fig. 3.32 Checking connecting rod piston pin bushing
Note : Difference in reading should not exceed 0.015
inch [0.38 mm].
6. Check connecting rod bolts, bolt holes and bolt
pads.
a. The bolt head must rest squarely on milled
surfaces of rod.
b. If connecting rod bolts have been tightened
excessively, they may be permanently
stretched in which case they must be
discarded. Discard bolt if smallest diameter is
less than 0.540 inch [13.72 mm].
c. Check bolt pilot O.D. Discard bolt if pilot is
smaller than 0.6245 inch [15.862 mm],
d. Discard all bolts and nuts that have distorted
threads.
e. Check bolt hole diameter. If diameter exceeds
0.6249 inch [15.872 mm], discard rod.
f. Check bolt pad radius. See Restore Fillet.
CALIBRATE CHECKING FIXTURE FOR ROD SIZE
1. Select a new rod that has been checked for
correct absolute center to center length,
 3.2-29

12 inch [304.80 mm] between centers. (Production 6. Move dial holder so dials indicate on piston pin.
rods may vary from 11.998 to 12 inch [304.75 to
304.80 mm]). 7. Zero dial indicators.

2. Assemble cap to rod. Select fit bolts for a light press
fit (5 lb [22 N] minimum) in the rod. Lubricate
threads of bolts and nuts with engine lubricating
oil and tighten as specified in Table 6.
3. Insert piston pin mandrel, furnished in ST-563
Mandrel Set, in piston-pin bore.
4. Insert and tighten (“snug” only) expanding arbor
ST-758 in crankpin bore. Locating pin must be down
in cap on center line or rod.
Table 6: Connecting Rod Torquing Procedure -
Ft-lb [N°m]
Minimum Maximum
8. Lift rod, arbor and pin assembly from fixture; turn
horizontally 180 degrees; set back in fixture.
9. Readjust dial indicators to read halfway between
second readings and zero. Fixture is now
calibrated.
CHECK ROD ALIGNMENT
Measurements read directly from dial indicator indicate
comparative length and misalignment of bores.
Measurements apply with or without bushing installed.
1. Assemble mandrels in rod to be checked. Be sure
pin in mandrel is down and locked in position in
center line of rod.

Step 1 Tighten to 70[95] 80[108] 2. Set rod in calibrated fixture.

Step 2 Advance to 140[190] 150[203]
Step 3 Loosen completely 3. Record readings from right and left dial indicators
to determine length and bend.
Step 4 Tighten to 70[95] 80[108]

Step 5 Advance to 140[190] 150[203] a. To determine length, add right and left indicator
reading (noting plus and minus readings) and
Breakaway torque 140 [190] 180[244]
divide by two (2). This gives the amount shorter
5. Set rod in fixture, Fig. 3-34. or longer than the master

b. To determine bend, subtract the smaller

reading from the larger (again noting plus and
minus readings).

4. Length must be no longer than the master rod and

not more than 0.002 inch [0.05 mm] shorter. Bend
must not exceed 0.004 inch [0.10 mm] without
bushing or 0.0015 inch [0.038 m-n] with bushing
installed.

5. Measure rod twist with a feeler gauge between

piston pin and dial holding plate, Fig. 3-35.

Fig. 3-33 : Checking rod bore alignment.

3.2-30
Connecting rod twist when rod does not contain
piston pin bushing must not exceed 0.020 inch
[0.51 mm]. Twist must not exceed 0.010 inch [0.25
mm] with bushing in place and bored to size.
CHECK CENTERLINE OF ROD
1. Attach a Starrett No. 193 indicator so it will contact
the side milled surface of piston pin end or rod.
Fig. 3-34 : Checking rod twist.
2. Slide crankshaft end of connecting rod sideways
to contact ST-561 on same side as indicator gauge.
See Step 1.
3. Zero indicator gauge on milled surface.
4. Turn rod 180 degrees and repeat Steps 2 and 3.
Difference in reading must not exceed 0.015 inch
[0.38 mm].
REPAIR OPERATIONS
RESIZE CRANKPIN BORE
Resize only if crankpin bore is outside limits
given previously in “Inspection”.
1. Remove old piston pin bushing with ST-870 or ST-
1242 Mandrel and Block. Install cap and tighten
nuts to prescribed torque. See Table 6.
2. Recheck rod length on ST-561 Checking Fixture.
If rod length is 11.991 inch [304.57 mm] or less,
rod cannot be resized and must be discarded.
Note : Rod must measure 12.000 inch [304.80 mm] in
length to remove 0.009 inch [0.23 mm] from mating
surfaces of cap and rod face.
a. Parts rrust be clamped securely during
operation to insure proper contact of entire
mating surfaces and proper alignment of bores
for rod - bolts when asembled. Bolt holes must
remain perpendicular to machined mating
faces.
b. Use surface plate and lopping compound to lap
rod and cup mating surfaces. After grinding and
lapping, “blue” surfaces; seating or flatness
patteren must show a minimum 75 percent
contact. Still-blued area must not be in area
outside bolt centerline (area farthest from bore
centerline); this area should indicate 100
percent seating,.
Fig. 3-35 : Areas of flatness.
c. Place mating rod and cap surfaces together
and check closely for evidence of out-of-flat.
3. The rod cap must be reassembled to rod and
tightened to operating tension. See Table 6.

Note : When placing rod in boring machine, place
numbered side of rod in if spacer bars are not used.
Install rod with numbered side out if spacer bars are
used,
4. Line bore or grind crankpin bore to 4.0020 to 4.0025
inch [101.651 to 101.664 mm], A fixture is required
to maintain alignment of bores.
Note : The above mentioned measurement is boring
diemension before rod and cap separation. After rod
and cap separation and rod cap is retorqued to rod,
dimensions must be 4.0018 to 4.0028 inch [101.645 to
101.671 mm] in an area beyond 30 degrees on either
side of parting line, Fig. 4-47. Dimensions within 30
degrees of parting line must be 4.0018 to 4.0033 inch
[101.645 to 101.684 mm].
Fig. 3-36 : Connecting rod bore check points
5. Check alignment on ST-561. See “Check Rod
Alignment”.
Note : ST-294 Boring Machine is not a-ble for this job.
Use ST-526, a mi.nng machine or cylinder grinder with
a precision fixture. Finished surface must be 75
microinch A.A. or better to insure proper contact with
connecting rod bearing shells.
6. Install and bore new heavy-wall piston pin bushing
as described under “Replace Piston Pin Bushing”.
Bore piston pin bushing off center to restore rod
3.2-31
to original 11.998 to 12.00 inch [304.75 to
304.80 mm] length.
RESTORE FILLET
1. A dimension of 0.080 to 0.090 incn [2.03 to 2.29
mm] (1, Fig. 4-48) fillet radius must be present at
all corners where rod is milled for bolt head.
Fig. 3-37 : Connecting rod radius specifications.
2. Remove nicks and dents which are less than 1/16
inch [1.59 mm] deep by grinding or filing with a
half-round file. Radius must be 1/2 inch [12.70 mm]
or more. Blend radii at ends of cut. Scrap rod if
dents are deeper than 1/16 inch [1.59 mm] (3),
Fig. 4-42.
CHAMFER PISTON PIN BORE
1. ST-861 Chamfering Tool is used to chamfer piston
pin bushing bore, if not chamfered.
2. Install proper bushing tool detail by use of flat-head
screw.
3. Set the guide screw holder in position, There are
three notches so guide screw will follow face of
bore.
4. Adjust tool bit until point just clears guide
screw and tighten in piston with two set screw.
3.2-32

5. Install unit into bore. REPLACE PISTON PIN BUSHING

6. Adjust the guide screw (up or down) until tool bit
just engages bore.
Note : A slight pressure is required against guide screw.
To obtain this pressure, tighten set screw in end of holder
against guide screw.
1. To install standard size bushings in rods; use ST-
1242 or Detail 2 of ST-870, assemble Detail 5
sleeve piston pin bushing and Detail 6 guide sleeve.
Caution : If one piece bushing is being used, be sure
to line up oil hole in bushing and rod.

7. Insert drive ratchet and turn tool one complete turn 2. Mount connecting rod in ST-526 Tobin-Arp Boring
to clean up edge of bore. Machine.

8. Loosen guide screw and again turn tool one or 3. Assemble the mandrel with all components listed
more complete turns to give a clean cut. in Step 1 into the connecting rod bushing bore.

Note : Repeat until a uniform chamfer of 0.040 to 0.060 4. Line up mark on Detail 5 with middle of boss on
inch [1.02 to 1.52 mm] depth is reached. rod.

9. Remove tool from bore, turn rod over and chamfer 5. Using an arbor press, push bushing into bore until
other side of bore. Detail 5 contacts side of rod pin boss.

10. With both sides chamfered, remove tool. 6. Remove assembly and place rod on Detail 7 block
so installed bushing half is down.
11. Use emery cloth to remove any sharp edges which
may have been left on chamfer.

12. Wash rod which is redy for bushing installation.


7. Using same tools less Detail 6 guide sleeve, press
second half-bushing in the rod flush with rod
surface.
8. To Install thick-walled bushings in rods which have
been resized at crankpin end, install in same
manner as Step 1, except use smaller inside
diameter Details 3, 9 and 10 instead of Details 2,
5 and 6.
BORE ROD PISTON PIN BUSHING
1. Fill lubricating holes with soap to keep out shavings.
2. Mount connecting rod in ST-526 Tobin-Arp Boring
Machine, Fig. 3-50.
Note : Lower mandrel should have only the two horizontal
blades in place to properly locate the side position of
the piston pin end of rod.
3. See instruction booklet furnished with ST-526 for
operating procedure.
4. Bore bushings to 2.001 to 2.0015 inch [50.825 to
50.838 mm] I.D. (1, Fig. 3-39). (Remove rod from
ST-526 and check size with ST-205 Plug Gauge.)
5. Remove Sharp edges with a scraper.
6. Remove shavings and soap, wash in mineral spirits
and dry with compressed air.
7. Check all dimensions on rebushed and rebored
rods on ST-561. Checking Fixture as previously
described.
PISTON AND PISTON RINGS
PISTON RINGS
New rings should be checked in cylinder liner in which
they are to be used to make sure the gaps are correct.
3.2-33
1. Insert each ring in mating cylinder liner. Position
with head of piston so it is seated squarely in right
travel area of liner.
2. Measure ring gap with a feeler gauge. Gap should
fall within limits given in Table 7. See Fig. 3-47.
Fig. 3-38 : Measuring piston ring gap in liner
3. Never file or stone chrome-plated rings.
4. Check current parts catalogs to assure use of
proper ring/piston combination. Chrome-plated top
and intermediate compression rings must be
installed in proper piston ring grooves.
PISTONS
CLEANING AND INSEPCTION
Remove and discard inserts from teflon pad type pistons.
Pad should be replaced at each rebuild. Do not reuse
button type pistons.
1. Clean pistons in a solvent cleaning bath that
will not attack aluminimum.
Caution : Piston skirts are coated with a plating that
may blister if overheated. We recommend that water
boiling point not be exceeded.
3.2-34

Table 7 : Piston Ring Gap - Inches [mm]

Part No. Maximum* Minimum

147670 0.033 0.023

[0.84] [0.58]
132880 0.029 0.019
[0.74] [0.48]
214730 0.029 0.019
[0.74] [0.48]
218732 0.025 0.010
[0.64] [0.25]

* Add 0.003 inch [0.08 mm] for each 0.001 inch Fig. 3-39 : Piston check points

[0.03 mm] wear on used cylinder liners inside

diameter.
2. After cleaning, check top and second ring grooves
with ST-560 Ring Groove Wear Gauge.
3. Shoulders of gauge must not touch ring groove
lands if piston is to be reused. If shoulders touch,
discard piston.
4. If ST-560 is not available, check wear with segment
of a new ring and a feeler gauge.
a. Hold ring in groove, flush with land and insert
0.006 inch [0.15 mm] feeler gauge.
b. If gauge enters groove without fore ing or
disengaging ring, wear is excessive and piston
should not be reused.
7. Check piston pin outside diameter with micrometer.
Pins should not be reused if out-of-round more
than 0.001 inch [0.03 mm] or worn smaller than
1.9978 inch [50.744 mm]. Do not re-bore piston
and use oversize piston pin.
PISTON-TO-CONNECTING ROD ASSEMBLY
1. Pistons are machined to a very close weight
tolerance. Therefore, as long as the same part
number piston is used throughout the engine,
piston balancing is unnecessary.
2. Be sure rod and cap are stamped with cylinder
number from which removed before disassembly
to prevent mixing parts.
3. Ipstall one piston pin snap ring in piston pin bore.

5. Measure piston skirt diameter with micrometer at
right angle to piston pin bore (A, Fig. 3-39) for
barrel-ground pistons. Measure at 70°F [21 °C]
Replace pistons if worn smaller than 5.483 inch
[139.27 mm].
6. Piston pin bore check at 70°F [21 °C] should
be between 1.9985 inch [50.762 mm] and 2.000
inch [50.800 mm]. Add 0.0005 inch [0.013 mm]
per 10°F [6°C] upto 90°F [32°C].
4. Heat aluminium pistons in boiling water or in an
oven at or below 210°F [97°C] for approximately
15 minutes. Install pin through piston and
connecting rod pin bore before piston cools. At
70°F [21 °C] the pin fit is 0.005 inch [0.013 mm]
press fit to 0.002 inch [0.056 mm] slip fit. This
prevents pin assembly unless piston is heated.
Secure pin with second snap ring in groove at
opposite end of pin bore.

Caution : Never drive piston pin in pistons. Driving
may cause distortion of piston, causing piston
seizure in cylinder liner.
REAR COVER
The rear cover is a unit subject to replacement of seals
only. Damaged housings require replacement by a new
assembly or installation of a thread insert for stripped
threads; these are the only items of repair.
A dual lip rear oil seal is available for use in place of two
single lip oil seals used in “Wet Type” clutch applications.
CAMSHAFT INSPECTION
Check camshaft bearing journals with micrometers. Fig.
3-49. Replace camshaft if journals are worn smaller than
2.120 inch [53.85 mm] or if scuffed or scored.
Fig. 3-40 : Measuring camshaft journal.
Replace camshafts that have scuffed, scored, pitted, or
craked injector or valve lobes. Check by magnetic
inspection for possible cracks. Cummins India Limited
does not recommended regrinding of camshaft lobes.
3.2-35
Following inspection, install 1/8 inch socket head pipe
plug in the gear end of camshaft. Torque to 15ft-lb [20
N°m].
GEAR
1. Remove gear if chipped, cracked or visibly worn
or if thrust bearing must be replaced. Gear is press-
fit on camshaft.
2. Place camshaft in a press between V-blocks. Heat
gear with heating torch to. 300° to 400°F [148° to
204°C] if to be discarded.
Caution : Never support gear on outer surfaces.
Always support hub area with V-blocks or equivalent
spacers.
3. Press camshaft from gear and remove key.
4. Heat camshaft gear in an oven preheated to 400°F
[204°C] for a minimum of one (1) hour.
5. Note type of key used. Refer to Table 8 and 9 fro
key offset when changing keys, camshafts, or
gears.
Note : Camshaft key part number is stamped on key for
identification purpose.
6. Coat camshaft gear hub area with high pressure
lubricant.
7. Place camshaft in press. Install new thrust washer
and insert new key in camshaft. Press on camshaft
gear while hot. Smooth side of thrust washer must
be toward engine block.
Note : Always check timing when a new camshaft or
gear is installed in an engine.
3.2-36

GEAR HOUSING GEAR COVER ACCESSORY DRIVE BUSHING

1. Inspect for cracks, breaks or burrs. 1. Inspect bushing for wear. Install new bushing if worn
larger than dimensions given to Table 10. Shaft to
Repair as necessary. bushing clearance must be 0.002 to 0.0075 inch
[0.05 to 0.191 mm]. Be sure oil oil hole is indexed,.
2. Replace studs if threads are damaged.
2. Undersize inside diameter bushings are available
3. Inspect threads and repair with thread inserts if
for use where air compressor crankshaft or fuel
damaged.
pump drive is worn or ground undersize. See
Table 10. Shaft to bushing clearance should be
4. If dowels are damaged, replace or bore out for
maintained between 0.002 to 0.0075 inch [0.05 to
next oversize.
0.191 mm].
5. Remove pipe plugs, clean oil passages, and
Inspection
replace pipe plugs.

1. If not previously removed, remove all oil seals.

 3.2-37

Table 8: Injector Timing Specifications

Engine *Key Arrow Crank Angle Piston Push Tube

Model Part No. Direction Degrees Travel Travel ln.[mm]
Inches [mm] Nominal Fast Slow

VTA-1710-, MG, 200707 To Front 19 deg. -0.2032 -0.0525 -0.050 -0.055

GS, GC, BTC [-5.161] [-1.333] [-1.27] [-1.40]

* These keys are normally used to get the required timing; however, due to stack-ups it may be necessary to use
another key.

Table 9: Camshaft Key Tabulation

Key Amount of Offset Change in Push Tube Travel Angle of

Part No. Inch [mm] Inch [mm] Offset

200707 0.0115 [0.2921] 0.0037 [0.0939] 0° 38'

200712 0.0075 [0.1905] 0.0024 [0.0609] 0° 23'
200713 0.0185 [0.4699] 0.0061 [0.1549] 1° 2'
200722 0.0060 [0.1524] 0.0019 [0.0482] 0° 20'
200723 0.0255 [0.6477] 0.0084 [0.2133] 1° 26'
202600 0.0390 [0.9906] 0.0128 [0.3251] 2° 29'
208746 0.0310 [0.7874] 0.0102 [0.2590] 0° 59'
3012307 0.051 [1.2954] 0.0168 [0.4267] 3° 14'

Arrow toward front- Advances Timing

Arrow toward rear- Retards Timing
On L.H.rotation engines reverse arrow for same timing effect.

Table 10 : Accessory Drive Bushing Dimensions - Inch [mm]

Undersize Part No. Minimum Maximum

Standard 132770 1.565 1.569

[39.75] [39.853]

0.010 132771 1.555 1.559

[39.50] [39.599]

0.020 132772 1.545 1.549

[39.24] [39.345]
3.2-38

Fig. 3-41 : Fuel pump/accessory drive bushing location.

Fig. 3-42 : Auxiliary/generator drive bushing location.

 3.2-39

2. Check bushings, remove and discard if rough or The following service tools or tools of equal quality are
worn. considered necessary or desirable to repair and/or
rebuild the cylinder block as outlined in this manual.
3. Check trunnion and/or bushing for wear. Replaceable
bushing is available to “rebuild” outside diameter of SERVICE TOOLS REQUIRED
trunnion which was not originally equpped with
Service
bushing.
Tool
Number Tool Name
PARTS REPLACEMENT AND REPAIR

ST-1177 Boring Tool (Main Bearing

1. Press new bushing or bearings into cover as
Bore)
required.
ST-1252 Concentricity Gauge
ST-1228 Camshaft Bushing Drive Kit
2. If gear trunnion on cover is to be bushed; machine
3375116 Boring Machine
gear case trunnion to 6.247 to 6.250 inch [158.67
to 158.75 mm] outer diameter, Fig. 3-56. DESIRABLE SERVICE TOOLS

ST-205 Plug Gauge

ST-547 Gauge Block
ST-561 Checking Fixture (Connecting
Rod)
ST-563 Locating Mandrel Set (Conne
cting Rod)
ST-758 Locating Mandrel Set (Conne
cting Rod)
ST-598 Bushing Mandrel (Gear Cover)
ST-861 Chamfering Tool (Connecting
Rod)
ST-899 Connecting Rod Ring Gauge
ST-1116 or Puller (Main Bearing Cap)
ST-1178
ST-1171 Bushing Mandrel (Accessory
Fig. 3-43 : Gear case cover and trunnion. Drive)
ST-1184 Cylinder Liner Hold Down
CAMSHAFT SUPPORT Tool
ST-1189 Tappet Guide Screw Salvage
CLEANING AND INSPECTION Kit
ST-1272 Salvage Tool
1. Clean support in a solvent not harmful to aluminum. 3375840 Gear Puller
ST-1318 Lower Bore Chamfer Tool
2. Be sure oil drain holes are open.
STANDARD TOOLS — OBTAIN LOCALLY
3. Discard support if inside diameter is worn larger
than 1.757 inch [44.653 mm] at any location or if Dial Bore Indicators
cracked or chipped. 1/2 Inch Electric Drill
Micrometers
3.2-40

4-42

Specifications and Usable Parts Limits-lnch[mm]

Measurement Usable Limit New Minimum New Maximum

4 Cylinder Block

-1 Camshaft Bore 2.2555 2.2535 2.2545

[57.290] [57.239] [57.264]

-2 Camshaft Bushing I. D. Installed 2.1295 2.1245 2.1283

[54.089] [53.962] [54.059]

-3 Cylinder Liner Counterbore Diameter 6.5615 6.5635

[166.662] [166.713]

-4 Cylinder Liner Counterbore Depth 0.411 0.350 0.352

[10.44] [8.89] [8.94]

-6 Cylinder Block Lower Liner Bore 6.124 6.126

[155.55] [155.60]

-7 Liner-To-Block Diametrical Clearance

.1 Lower Bore 0.002 0.006
[0.05] [0.15]

-8 Cylinder Liner
.1 I.D. 5.505 5.4995 5.5010
[139.83] [139.69] [139.73]
.2 Press Fit O.D.
.1 Flange 6.564 6.566
[166.73] [166.78]

.3 Flange Thickness 0.355 0.356

[9.02] [9.04]

.4 Installed Out-Of-Round
.1 Press Fit Area 0.003
[0.08]

.2 Packing Ring Area 0.002

[0.05]

-9 Cylinder Liner Protrusion 0.004 0.006

[0.10] [0.15]

.1 Liner Protrusion Variation under Same Head [0.001]

[0.03]

-10 Main Bearing Bore 6.0965 6.095 6.096

[154.851] [154.81] [154.84]
 3.2-41

Measurement Usable Limit New Minimum New Maximum

4 Cylinder Block (Cont’d.)

-11 Main Bearing Cap Interference Fit 0.002 0.004

[0.05] [0.10]

-13 Block Height

.1 From Top of Alignment Bar 15.9457 15.9565 15.958

[405.021] [405.295] [405.33]

.2 From Main Bearing Bore Centerline 18.994 19.004 19.006

[482.45] [492.70] [482.75]

.3 Variance End-To-End Maximum 0.002

[0.05]

.4 Flatness Maximum 0.004

[0.10]

.5 Waviness Maximum [0.0007]

[0.018]

-14 Tappet Bores in Block

.1 Injector 1.627 1.6245 1.6265

[41.33] [41.262] [41.313]

.2 Valve 1.1895 1.187 1.189

[30.213] [30.15] [30.20]

-15 Idler Shaft Bore in Block 1.7485 1.7505

[44.44] [44.46]

-16 Idler Shaft Pilot Diameter 1.7520 1.7525

[44.501] [44.514]

-17 Idler Shaft Diameter 1.997 1.9975 1.998

[50.72] [50.797] [50.75]

-13 Bearings

.1 Main Thickness 0.1692 0.1705 0.1712

[4.298] [4.331] [4.348]

.2 Connecting Rod Thickness 0.1232 0.1245 0.125

[3.129] [3.162] [3.175]

-19 Bearing Journal Clearance

.1 Main 0.010 0.0026 0.006

[0.25] [0.066] [0.152]

.2 Connecting Rod 0.0085 0.0018 0.0053

[0.216] [0.046] [0.135]
3.2-42

Measurement Usable Limit New Minimum New Maximum

4 Cylinder Block (Cont’d.)

-20 Crankshaft Thrust Ring Thickness

.1 Standard 0.245 0.247

[0.22] [6.27]

.2 0.010 Oversize 0.255 0.257

[6.48] [6.53]

.3 0.020 Oversize 0.265 0.267

[6.73] [6.78]

-21 Crankshaft End Clearance 0.018 0.006 0.013

[0.46] [0.15] [0.33]

-22 Crankshaft

.2 Main Bearing Journal 5.7465 5.7485 5.750

[145.961] [146.012] [146.05]

.2 Connecting Rod Journal 3.747 3.7485 3.750

[95.17] [95.212] [95.25]

.3 Main and Rod Journal Out-Of-Round 0.002

[0.05]

.4 Gear Area

.1 Front 3.812 3.813

[96.82] [96.85]

.5 Seal Area

.1 Front 3.750 3.751

[95.25] [95.28]

.2 Rear 7.248 7.250

[184.10] [184.15]

-23 Vibration Damper

.1 Alignment Mark 1/16 1/16

[1.6] [1.6]

.2 Eccentricity 0.030 0.030

[0.76] [0.76]

.3 Wobble 0.055 0.055

[1.40] [1.40]
 3.2-43

Measurement Usable Limit New Minimum New Maximum

4 Cylinder Block (Cont’d.)

-24 Conecting Rods

.1 Crankpin Bore 4.0018 4.0028

[101.646] [101.671]

.2 Out-of-Round 0.00.1
[0.03]

.3 Piston Pin Bushing I.D. Installed 2.0025 2.001 2.0015

[50.864] [50.83] [50.838]

.4 Rod Length Center-To-Center 11.998 12.000

[304.749] [304.800]

.5 Rod Bore Alignment

.1 Without Bushing 0.008

[0.20]

.2 With Bushing 0.004

[0.10]

.6 Rod Twist

.1 Without Bushing 0.020

[0.51]

.2 With Bushing 0.010

[0.25]

.7 Rod Bolt

.1 Smallest O.D. 0.540

[13.72]

.2 Pilot O.D. 0.6245 0.6247 0.6252

[15.862] [15.867] [15.880]

.3 Press Fit in Rod 5 Ibs. 5 Ibs.

[22 N] [22 N]

.8 Rod -Bolt Hole

.1 Pilot I.D.Rod 0.6249 0.6243 0.6248

[15.872] [15.857] [15.870]

.2 Pilot I.D. Cap 0.6249 0.6243 0.6248

[15.872] [15.857] [15.870]

.9 Side Clearance

.1 Rod-To-Rod-To-Crankshaft 0.008 0.022

[0.21] [0.56]
3.2-44

Measurement Usable Limit New Minimum New Maximum

4 Cylinder Block (Cont’d.)

-25 Piston and Piston Rings

.1 Piston Skirt Diameter

.1 214770, 214710 5.480 5.4830 5.4840

[139.19] [139.268] [139.294]

.2 175760, 195250, 199619, 3003175, 5.483 5.4870 5.4880

3003176 [139.268] [139.370] [139.395]

.3 Piston Pin Bore 2.000 1.9985 1.9989

[50.80] [50.762] [50.772]

.4 Piston Pin Diameter 1.9978 1.9988 1.999

[50.744] [50.770] [50.77]
.5 Piston Ring Gap

.1 Top (147670) 0.023 0.033

[0.58] [0.84]

.2 Intermediates (214730, 132880) 0.019 0.029

[0.48] [0.74]

.3 Oil (218732) 0.010 0.025

[0.25] [0.64]

6. Padded Piston Pad-To-Pad Diameter 5.0445 5.0470

(between flats) [128.130] [128.194]

.7 Pad Thickness 0.223 0.225

[5.66] [5.72]

-26 Camshaft

.1 Journal Diameter 2.120 2.122 2.123

[53.85] [53.90] [53.92]

.2 Thrust Plate Thickness 0.093 0.098

[2.36] [2.49]

.3 End Clearance 0.010 0.015

[0.25] [0.38]

.4 O.D. At Front Support 1.745 1.747 1.748

[44.32] [44.37] [44.40]

.5 Outboard Bearing Support

.1 I.D. 1.757 1.751 1.754

[44.63] [44.48] [44.55]

.2 O.D. 2.616 2.618

[66.45] [66.50]
 3.2-45

Measurement Usable Limit New Minimum New Maximum

4 Cylinder Block (Cont’d.)

-27 Gear Cover

.1 Accessory Drive Bushing I.D.

.1 Standard 1.5705 1.565 1.569

[39.891] [39.751] [39.853]

.2 0.010 Undersize 1.5605 1.555 1.559

[39.637] [39.497] [39.599]

.3 0.020 Undersize 1.5505 1.545 1.549

[39.383] [39.243] [39.345]

.2 Generator Drive Bushing I.D. 1.3205 1.316 1.319

[33.541] [33.426] [33.503]

-28 Gear Cover

.1 Seal Bore I.D. 8.123 8.127

[206.32] [206.43]

-29 Gear Train

.1 End Clearance

.1 Idler Gear 0.020 0.001 0.016

[0.51] [0.03] [0.41]

.2 Gear-To-Gear-Backlash 0.010 0.006 0.010

[0.25] [0.15] [0.25]