Usage:
introduction
- * Dimensions in inches (mm)
Indicates change.
The 9N6275 Cylinder Sleeve can be used for reconditioning of the cylinder blocks for the engines above, when oversize pistons cannot be used, or because of pin holes, cracks or scoring in the cylinder walls. Make a good inspection of the cylinder block to be sure it is usable. Install the sleeves according to the procedure given in this instruction.
Use the boring tools and the honing machine given in the chart that follows, or equipment with equal precision, to give the machined specifications given in this instruction. Additional tools needed are also given in the chart.
Boring specifications for cylinder sleeve installation
NOTE: Dimension (A) is the original bore diameter.
1. Put the boring tool in position. Use the centerline of the original cylinder bore, and make the new bore to a size of 4.6865"Ø ± .0005" (1190.38Ø ± 0.013), dimension (B), to a depth of 7.747" ± .005" (196.77 ± 0.13), dimension (C). Dimension (C) is measured from the top surface of the cylinder block. The new bore size must be within .002" (0.05) total runout of the centerline of the original cylinder bore.
2. The angle at location (D) is 0.01" X 45° (0.3x45°) maximum.
3. Remove the sharp corner, or any burrs at the bottom edge (E) of the bore. A slight chamfer at location (E) is permissible.
installation of cylinder sleeve
1. Remove the 9S6074 Adjusting Screw and 1P2329. Insert from 1P820 Hydraulic Puller (1) and install 6V2183 Forcing Screw (2). Put clean No. 2 disel fuel on sleeve (3). Use hydraulic puller (1) with forcing screw (2) and 1P2393 Puller Plate (4), 6V2195 Speed Nut (5), 6V2194 Puller Plate (6) and 1D5119 Nut (7) to pull sleeve (3) into the cylinder bore, until the bottom of the sleeve comes in contact with the counterbore [locations (A)] at the bottom of the bore.
2. After installation of sleeve (3) in the new bore, it is permissible for a maximum of .005" (0.13), dimenstion (B), of the sleeve to be above the top surface of the cylinder block. It is also permissible to machine the top end of the sleeve, if desired, so it is even with the top surface of the cylinder block.
3. At the inside diameter [location (C)], at the top of the insert, machine a 30° chamfer .040" ± .010" (1.02 ± 0.25) deep.
NOTE: For engines that have a 5.00" (127.0) stroke, grind away any part of the sleeve that extends below edge (D), into the connecting rod clearance area shown.
4. If not already done, use the 1P3565 Chamfering Group as shown, to remove the sharp corner at the bottom of each cylinder bore. This is necessary to prevent any scuffing of piston skirts. The chamfer must be approximately 10° x .09" (10° x 2.3).
5. Hone the bore of each cylinder sleeve according to the specifications in the chart that follows.
NOTE: Mount cylinder block on .675" (17.145) riser plates. Use 42" (1067) long bar, move clamps and riser blocks to extreme ends of carriage.
5. The complete scratch pattern of the cross hatch must be the same in both directions, and have an angle of 150° ± 10° as shown at location (E). The scratches must be .001"-.002" (0.025-0.050) deep, and the plateau [surfaces (F)] must be 40-65% of the surface. The scratch pattern must also be free of any material that can bend over and close the open area [locations (G)] of the scratch pattern, as seen when magnified 100 times.
6. The honed surface must also be free of glaze or burnish.
Glaze: The surface of the cylinder walls is a brown color. This is caused when the honing stones do not cut correctly, or the honing stones get hot and cause oxidation of the honing oil.
Burnish: The cylinder walls can have a smooth finish, or the surface can be shiny, but there are areas of the bore that have not been honed correctly. This is because the honing stones have not been in contact with these areas of the bore.
7. During performance of the honing procedure, check the size of the bore in the sleeve at several locations in the length of the bore, and around the circumference. Specific locations to measure are at points that are perpendicular (at right angles) to the crankshaft centerline, .25" (6.4) from each end, and at the center of the cylinder sleeve, as shown above. These three specific locations are primary gauge points during and after honing.
8. After the honing procedure is complete and before assembly of the engine, remove the camshaft bearings to permit cleaning of the cylinder block. Use a strong detergent and water solution to thoroughly clean the cylinder block, the main oil gallery and oil supply passage, camshaft bearing oil passages, and the cylinder bores. Thoroughly clean the cylinder block in an agitator-type cleaning tank.
NOTE: The brushes in the 1P5580 Brush Group will make it easier to do the cleaning procedure. Put a coat of clean SAE 30 engine oil on all machined surfaces after the cleaning procedure is done. Keep the cylinder block under a cover until time for assembly.
| NOTICE |
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The result of incomplete cleaning will be piston seizure or rapid wear of the cylinder sleeve bores, pistons and rings. Only thorough use of a rotary brush will correctly remove abrasive particles. |