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CYLINDER BLOCK
CONNECTING ROD
TM-5-3805-258-24-1 Loader Scoop Type DED 4x4 Articulated Frame Steer 2 1/2 Cubic Yard Bucket (CCE) Airborne/Airmobile Manual
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3304
DIRECT
INJECTION
VEHICULAR
ENGINE
WITH
SCROLL
FUEL
SYSTEM
TM 5-3805-258-24-1
SPECIFICATIONS
(1)
(2)
(3)
CYLINDER LINER
Bore
in liner
(new)
. . . . . . . . . . . . . . . . .
120.68
t
0.03
mm
(4.751
f
.001
in.)
Use
again
maximum
bore
when
measured
near
upper
end of the wear
surface
of the
cylinder
liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120.78
mm
(4.755
in.)
Thickness
of
flange
on liner . . . . . . . . . . . . . .
10.282
t
0.020
mm
(.4048
~
.0008
in.)
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
Make
reference
to
CYLINDER LINER PROJECTION
in
Testing
and
Adjusting
for the
complete
procedure.
1.
Install
gasket
and
spacer
plate
(2)
with
bolts
(3) and two 1
S379
Washers.
Tighten
bolts
(3)
evenly
in four
steps:
1st
step
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Nm (10
Ib.ft.)
2nd
step
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 N.m (25
Ib.ft.)
3rd
step
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 N.m (50
Ib.ft.)
4th
step
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 N.m (70
Ib.ff.)
2.
Install tools
as
shown.
Tighten
bolts
(4)
evenly
in four
steps:
1st
step
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N.m (5 Ib.ft.)
2nd step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N.m (15 Ib.ft.)
3rd step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 N.m (25 Ib.ft.)
4th step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 N.m (50 Ib.ft.)
3. Measure cylinder liner projection with dial indicator (6) in 1P2402
Gauge Body (8) as shown. Measure at four places around each
cylinder liner near the clamped area.
Cylinder liner projection measurements for any cylinder liner
must be . . . . . . . . . . . . . . . . . . . . . 0.033 to 0.175 mm (.0013 to .0069 in.)
Maximum permissible difference between all four
measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (.()()2 in.)
Maximum permissible difference between average
projection of any two cylinder liners next
to each other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (.002 in.)
Maximum permissible difference between average
projection of ail cylinder liners under
one cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (.003 in.)
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.
I
SHIM THICKNESS, COLOR CODE, AND PART NUMBER
I
~
(.007
in.)
(.008 in.)
(.009 in.) (.oI5 in.) (.o3o in.)
4. Minimum permissible depth to machine counterbore to
adjust
cylinder
liner
projection
.
.
.
0.76
mm
(.030
in.)
Maximum permissible depth to machine counterbore to
adjust cylinder liner projection . . . . . . . . . . . . . . . . . . . . 1.14 mm (.045 in.)
Install a 0.76 mm (.030 in.) shim plus any added shims necessary
to get the correct cylinder liner projection.
NOTE: Be sure that the 0.76 mm (.030 in.) shim is directly under the
cylinder liner flange.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Crossbar (from 8B7548 Puller).
Spacer plate.
S 1589 Bolt with two 1 S379 Washers.
1 D4595 Bolt.
3H465 Plate.
1 P2403 Dial Indicator.
1 P2394 Adapter Plate.
1 P2402 Gauge Body.
2-17
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