5-11. CYLINDER BLOCK REPAIR (CONT).
(5) If damaged, remove cup plug (5) at front and cup plug (6) from back of cylinder block (7).
(6) If damaged, remove four cup plugs (8) from tappet cover side and four cup plugs (9) from opposite side.
(7) If damaged, remove two dowel rings (10) from top of cylinder block (7).
(8) Remove two pipe plugs (11) on tappet cover side and pipe plug (12) near top on opposite side.
(1) Clean block in tank of hot water and soap at 190°F (88°C) for thirty minutes.
(2) If new piston rings will not seat in cylinder bores, use multi-speed drill, 280 grit flexi-hone, and
(3) To make honing lube, mix one part diesel fuel and one part 30W engine oil.
(4) Drill speed must be 300 to 400 RPM. Do one stroke per second.
(5) Check bore after 10 strokes. Correct crosshatch angle is 15° to 25°. If crosshatch angle is 70°, drill speed is
too slow or stroke is too fast. If crosshatch angle is 10°, drill speed is too fast or stroke is too slow.
(6) If minor grooves are found, use 220 grit sizing hone to correct taper. Step (4) applies,
(7) Check bore after 10 strokes. Maximum taper is 0.003 in. (0.076 mm).
Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective
chip guarding and personal protective equipment (goggles/shield, gloves, etc).
(8) Clean cylinders bores with detergent and hot water. Rinse with clean water and dry with compressed air.
(9) Check cylinder bores for residue. If residue is found, repeat step (8).