TM 5-3895-359-14&P
Selection of New Cylinder Liner
The cylinder bores in a new cylinder block are
classified as # 1, #2 or #3 (Table I) designating the
specific size range for each bore and the appropriate
cylinder liner that may be fitted to each bore. The
classification number is stamped on the fire deck of the
cylinder block adjacent to each cylinder bore.
A new standard size cylinder liner is also classified as #
I, # 2 or # 3 as illustrated in Fig. 9 and Table 1.
Although the block bores and liners should be measured
to determine the liner-to-block clearance, the selection
of a liner is narrowed down to only those in the
appropriate classifications or possibly a .001" oversize
liner.
Before installing a liner in a used cylinder block, always
lightly hone the block bore (refer to Page 10-2-9).
After honing the block bore, check the bore
measurements to determine if a standard liner
(classification # , #2 or #3) or possibly a .001 " oversize
liner car he used (refer to Tables I and 2). A push fit
between the liner and the block is desirable. If an
adequate push lit cannot be obtained, it may be
necessary to bore the block to receive an oversize liner.
Fig. 8 - Checking Bore of Cylinder Line Using
Tool J 5347-01
When it becomes necessary to install an oversize liner,
the same care in selective tolerance fitting must be
in master ring gage J 5580-1. Also check the liner for
adhered to. However, it may be more difficult to select
taper and out-of-round. It is not necessary to measure
an oversize liner since the size range is not broken
the inside diameter or taper of a new liner.
down into classifications.
NOTE: Dial bore gage master setting fixture J
In deciding whether boring is necessary or not, keep in
23059-01 may be used in place of the master
mind that each bore in a used block must not be outof-
ring gage.
round or tapered more than .002 ". If the average block
bore is over 4.6285" the cylinder block should be bored
The piston-liner clearance must be within the specified
oversize.
limits (Page 10-2-133). Also, the taper must not exceed
.002" and the out-of-round must not exceed .0025" on a
To determine what size to bore the cylinder block for an
used liner. If the out-of-round exceeds .0025 ", rotate
oversize liner, each service liner used must be
the liner 90 in the block bore and recheck.
measured on the outside diameter for size in three
places (under the flange, between the flange and the
New service liners, standard and oversize, have an
ports, and above the ports). The cylinder bore size will
inside diameter of 4.2489 " to 4.2511 "':
be determined by the average liner measurement
taken at the three positions.
Cylinder liners are available in .001 ", .005 ", .010 ",
.020 " and .030 " oversize on the outside diameter.
EXAMPLE:
When an oversize liner is installed, stamp the amount of
Service liner O.D. measures 4.6280 "
oversize on top of the cylinder bore adjacent to the liner
O.D. size = 4.6280"
counterbore.
plus clearance = .0005"
bore size = 4.6285"
Then. 4.6285 " + .001" boring tolerance will allow a
10-2-95