TRUCK SERVICE MANUAL
ENGINE
The following service tools or tools of equal quality are
CYLINDER BLOCK
considered necessary to repair and or rebuild the cylinder
INSPECTION
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.
Service
Tool
Tool Number
Name
Note: Inspection of cylinder block must be performed on a flat
surface to prevent distortion, do not leave on engine stand.
ST-526
Boring Machine
ST-1010
Counterboring Tool (Water Hole)
Using Dye Penetrants To Locate Flaws
ST-1059
Counterboring Tool (Cylinder Liner)
ST-1064
Adapter Plate
Use dye penetrate method for locating cracks, porosity, leaks,
ST-1065
Tool Holder
etc. Clean suspected defective area with kerosene or other
ST-1081
Boring Tool
grease-removing cleaner.
ST-1084
Bore Adapter
ST-1096
Lower Bore Chamfer Kit
Apply dye penetrate allowing time for it to dissolve or enter into
ST-1168
Counterbore Salvage Tool
the defect (usually about fifteen minutes); do not "force" dry.
ST-1177
Boring Tool (Main Bearing Bore)
Remove all excess penetrant and apply developer so defect
ST-1228
Camshaft Bushing Drive Kit
will stand out; cracks usually show up as a solid or dotted line;
ST-1250
Cylinder Liner Bore Salvage Tool
however, caution must be observed as this can be a non-
ST-1252
Concentricity Gauge
damaging forging lap. Porosity usually shows up as dots in
ST-1272
Head Capscrew Thread Salvage
local areas. The wider the area spreads, the larger the defect.
Tool
Desirable (Or Equivalent) Service Tools
Corrosion
Corrosion most frequently occurs on portions of block nearest
ST-205
Plug Gauge (Connecting Rod)
cylinder liners and is evidenced by pitting. Discard block if
ST-547
Gauge Block
area cannot be cleaned, or if area is distorted and cannot be
ST-560
Ring Groove Gauge
repaired by sleeving as outlined under "Parts Replacement
ST-561
Checking Fixture (Connecting Rod)
and Repair" following.
ST-563
Locating Mandrel (Connecting Rod)
ST-598
Bushing Mandrel (Gear Cover)
Camshaft Bushings
ST-861
Chamfering Tool (Connecting Rod)
Use inside micrometers or dial bore gauge to measure
ST-896
Ring Gauge (Connecting Rod)
camshaft bushing inside diameter.
Mark bushings for
ST-897
Ring-Gauge (Connecting Rod)
replacement if worn larger than "Worn Limit" (Table 1-1) (1) or
ST-903
Ring Gauge (Main Bearing Bore) ST-
are chipped, scored or scratched. If bushings have turned in
1171
Bushing Mandrel (Accessory Drive) ST-
block bore, check block bore size; see Table 1-1 (1). Make
1178
Puller (Main Bearing Cap)
certain oil passages between bushings and block oil holes are
ST-1184
Cylinder Liner Hold Down Tool
properly aligned. If bushing replacement is necessary, see
ST-1242
Mandrel Set
"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.
1-1).
If
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
repair.
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."
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