TRUCK SERVICE MANUAL
The following service tools or tools of equal quality are
considered necessary to repair and or rebuild the cylinder
block as outlined in this section.
Before any parts are discarded or used again a careful
Service Tools (Or Equivalent) Required
inspection must be performed. The inspection should include
wearing surfaces and general over-all conditions.
Note: Inspection of cylinder block must be performed on a flat
surface to prevent distortion, do not leave on engine stand.
Counterboring Tool (Water Hole)
Using Dye Penetrants To Locate Flaws
Counterboring Tool (Cylinder Liner)
Use dye penetrate method for locating cracks, porosity, leaks,
etc. Clean suspected defective area with kerosene or other
Lower Bore Chamfer Kit
Apply dye penetrate allowing time for it to dissolve or enter into
Counterbore Salvage Tool
the defect (usually about fifteen minutes); do not "force" dry.
Boring Tool (Main Bearing Bore)
Remove all excess penetrant and apply developer so defect
Camshaft Bushing Drive Kit
will stand out; cracks usually show up as a solid or dotted line;
Cylinder Liner Bore Salvage Tool
however, caution must be observed as this can be a non-
damaging forging lap. Porosity usually shows up as dots in
Head Capscrew Thread Salvage
local areas. The wider the area spreads, the larger the defect.
Desirable (Or Equivalent) Service Tools
Corrosion most frequently occurs on portions of block nearest
Plug Gauge (Connecting Rod)
cylinder liners and is evidenced by pitting. Discard block if
area cannot be cleaned, or if area is distorted and cannot be
Ring Groove Gauge
repaired by sleeving as outlined under "Parts Replacement
Checking Fixture (Connecting Rod)
and Repair" following.
Locating Mandrel (Connecting Rod)
Bushing Mandrel (Gear Cover)
Chamfering Tool (Connecting Rod)
Ring Gauge (Connecting Rod)
camshaft bushing inside diameter.
Mark bushings for
Ring-Gauge (Connecting Rod)
replacement if worn larger than "Worn Limit" (Table 1-1) (1) or
Ring Gauge (Main Bearing Bore) ST-
are chipped, scored or scratched. If bushings have turned in
Bushing Mandrel (Accessory Drive) ST-
block bore, check block bore size; see Table 1-1 (1). Make
Puller (Main Bearing Cap)
certain oil passages between bushings and block oil holes are
Cylinder Liner Hold Down Tool
properly aligned. If bushing replacement is necessary, see
"Parts Replacement and Repair."
Cylinder Liner Counterbore
Standard Tools-Obtain Locally
1. Check upper liner counterbore and remove burrs, dirt, etc.,
so liner will enter without distortion (A, Fig.
Dial Bore Indicators
counterbore exceeds limits listed in Table 1-1 (2) for the top
1/2 inch Electric Drill
0.250 inch [6.35 mm] depth, mark blocks for counterbore
The counterbore ledge must be smooth and
perpendicular to the liner bore to within 0.005 inch [0.13mm]
total indicator reading. Use a straight edge to check flatness
of top of block. Refer to "Top Surface Refinishing."