TM-9-2320-260-34-1
TRUCK, 5-TON, 6X6, M809 SERIES (DIESEL)
TECHNICAL MANUAL; DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE; VOLUME 1 OF 2
JULY 1994
TM-9-2320-260-34-1 - Page 192 of 657
TM 9-2320-260-34-1
3-50. CYLINDER LINERS AND CYLINDER BLOCK MAINTENANCE (Contd)
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WARNING
Compressed air source will not exceed 30 psi (207 kPa). When
cleaning with compressed air, eyeshields must be worn. Failure to
wear eyeshields may result in injury to personnel.
Clean water pump air bleed hole (1) in number one cylinder bore (2) with compressed air.
Blow all dirt and drycleaning solvent from screw holes (4) with compressed air.
Remove scale from liner counterbore ledge (3).
Clean carbon from lower liner bore (5).
NOTE
Cylinder block must be on flat surface or work bench for
inspection.
Inspect cylinder block (7) (para. 2-9) for worn surfaces, pitting, corrosion, nicks, gouges, burrs,
eroded water holes, damaged threads, distortion, and cracked areas. Replace cylinder block (7)
if worn, pitted, corroded, or cracked.
NOTE
Ensure counterbore ledge is 90° to liner bore.
Measure counterbore (6) depth and diameter. Counterbore (6) diameter must be 6.5615-6.5635 in.
(166.66-166.71 mm) (dimension “A”). Counterbore (6) depth must be 0.350-0.352 in. (8.89-8.94 mm)
(dimension “B”). Replace cylinder block (7) or notify your supervisor for refinishing if depth or
diameter exceeds limits.
Position telescoping gage on inner rim of counterbore (6).
Move gage around circumference of counterbore (6) taking readings at three intervals of 120°.
The difference in readings is the distortion. If the distortion is greater than 0.0014 in. (0.0356 mm),
replace cylinder block (7) or notify your supervisor for machining.
Using depth micrometer, measure counterbore (6) depth in several places. The difference in readings
is the distortion. If the distortion is greater than 0.001 in. (0.025 mm), replace cylinder block (7) or
notify your supervisor for machining,
Inspect counterbore (6) for flat, level surface. If counterbore (6) slants downward toward center of
cylinder liner (2), replace cylinder block (7) or notify your supervisor for machining.
NOTE
l Cylinder liners must protrude 0.003-0.006 in. (0.076-0.152 mm)
above cylinder block.
l Shims are used to compensate for counterbore depth wear.
Using outside micrometer, measure outside flange (10) of cylinder liner (8). Do not include bead (9)
in measurement. Record measurement.
Using gage block, measure depth of counterbore ledge (3). Record measurement.
Subtract measurement of counterbore ledge (3) from measurement of outside flange (10). Determine
shim thickness necessary to obtain 0.003-0.006 in. (0.076-0.152 mm) protrusion of cylinder liner (8).
Record shim thickness.
3-140
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