N14 Base Engine Troubleshooting and Repair Manual – 001-026   Cylinder Block

• Check for main cap fretting.
  Refer to Procedure 001-006 in Section 1.
• Remove the cup plugs.
  Refer to Procedure 017-002 in Section 17.
• Remove the straight thread plugs.
  Refer to Procedure 017-011 in Section 17.
• Remove the pipe plugs.
  Refer to Procedure 017-007 in Section 17.
• Remove the dowel pins.
  Refer to Procedure 017-003 in Section 17.
• Remove the camshaft bushings.
  Refer to Procedure 001-010 in Section 1.

CAUTION  Do not damage the machined gasket surfaces or the camshaft bushings if the bushings have not been removed.

Use a gasket scraper, wire brush, or a fibrous abrasive pad such as Scotch-Brite™ Number 7447, Part Number 3823258, or its equivalent to clean heavy deposits from the cylinder block.

Clean the cylinder liner counterbore ledge and press fit area.

Clean the cylinder liner packing ring bore area.

Clean the cylinder head deck surface.

Clean the main bearing saddles and caps.

Clean the camshaft bore cup plug area.

Clean all gasket surfaces.

Clean all component mounting surfaces.

Clean all oil passages. Use a bottle brush with a long handle.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

NOTE: Cummins Inc. does
not recommend any specific cleaning solution.

Remove the block from the engine stand. Put the block in a cleaning tank.

Follow the instructions of the manufacturer of the cleaning tank and the manufacturer of the cleaning solution.

The best results can be obtained by using a cleaning solution that can be heated to 80°C to 95°C [180°F to 200°F].

Use a cleaning tank that will mix and filter the cleaning solution to get the best results.

WARNING  When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

CAUTION  Make sure all the water is removed from the capscrew holes and the oil passages to prevent rust formation in the cylinder block.

Remove the cylinder block from the cleaning tank.

Clean the oil passages using a steam cleaner. Dry with compressed air.

WARNING  Starting fluid is highly flammable and explosive. Keep flames, sparks, and arcing switches away from starting fluid.

Clean the cylinder block counterbores with a suitable hydrocarbon solvent such as naptha, methyl ethyl ketone (MEK), or trichlorethane 1, 1, 1 (methyl chloroform).

If the cylinder block is
not going to be used immediately, apply a coating of preservative oil to prevent rust. Cover the block to prevent dirt from sticking to the oil.

Use fine emery cloth to remove burrs from the camshaft bushing bore.

Clean the bushing bores.

Measure the cylinder block camshaft bore inside diameter.

If the bore inside diameter is
not within specifications, the bore
must be repaired.

Main bearing service caps do
not have the bore machined to a final specification. If the cap is replaced, the main bearing bore
must be machined. Use the correct parts of the main bearing boring tool, Part Number ST-1177.

Use two centering rings, Part Number ST-1177-39 [4.750-in diameter]. Put the rings in the Number 2 and Number 6 main bearing locations.

Use clean 15W-40 oil to lubricate the main bearing capscrew threads and the flat washers.

Drain the excess oil from the capscrews before installing them.

CAUTION  The main bearing caps are marked for position (1) on the camshaft side and the cylinder block identification (2) on the exhaust side. The cylinder block identification number (3) is stamped on the pan rail on the camshaft side of the block. Install the caps in the correct position with the position number to the camshaft side and its part number toward the rear of the engine.

Align the capscrew holes in the cap with the holes in the cylinder block.

Install the capscrews and the washers through the cap and into the cylinder block.

Hand tighten the capscrews two to three threads.

• Hit the cap with a rubber mallet to push it into the correct position.

The main bearing caps
must not have any side clearance with the block.

Put the checking ring into the cylinder block main bearing saddle.

Put the main bearing cap over the checking ring.

Tighten all older block (prior to ESN 11875596) main bearing capscrews in alternating sequence to the following torque values:

All newer blocks (ESN first 11875596)
must be tightened in alternating sequence to the following torque values:

Replace the main bearing shells number one through number six.

NOTE: Main bearings number one through number six do
not have thrust bearings.

Use clean 15W-40 oil to lubricate the bores of the two centering rings, Part Number ST-1177-39, and the checking bar, Part Number ST-1177-16.

Insert the bar through the centering rings while slowly rotating the bar. The bar
must turn easily.

If the bar does
not turn easily, check to make sure the main bearing caps are installed correctly. If they appear to be okay, move one of the centering rings to another bearing location.

Slide one end of the bar out of a centering ring.

Slide the checking ring, Part Number ST-1177-13, onto the bar.

Insert the bar into the centering ring.

Apply lubrication to the outside diameter of the checking ring.

Use your hands to install the checking ring into the main bearing bore. If the ring will
not slide through the bore, check the bore for burrs. If the ring will still
not slide through the bore, the bore is undersize and
must be repaired.

Use a 0.08 mm [0.003 in] feeler gauge that is
not more than 13 mm [0.50 in] wide.

Center the checking ring in the bore.

Try to put the feeler gauge between the checking ring and the bore.

Rotate the gauge in the bore at both sides of the checking ring.

The bore alignment of the main bearing is okay if:

• the gauge does
  not enter at any point
• the gauge will enter but will
  not slide through or around the bore and the alignment bar will rotate with the gauge inserted.

The bore alignment of the main bearing is
not okay if:

• the gauge enters and slides around the bore. This means that the bore is oversize and
  must be repaired.
• the gauge will enter on one side
  only, but can slide around the bore. This means that the bore is tapered and
  must be repaired.

NOTE: This procedure does
not check main bearing bore alignment but will identify bore diameters that do
not meet specifications.

If the tools to check the main bearing bore alignment are
not available, use a dial bore indicator to measure the main bearing bore inside diameters.

Support the rear portion of the block on a flat surface to obtain the most accurate measurement of the inside diameter.

Measure the inside diameter in the three positions shown. The inside diameter
must be completely round within 0.0190 mm [0.00075 in].

CAUTION  All measurements of the cylinder block must be made when the block is positioned on a flat surface. If the block is mounted on the engine stand, the measurements can be wrong because of distortion.

Inspect the gasket surfaces.

Inspect for burrs or damage.

Use an Arkansas stone or a crocus cloth to remove the burrs.

Check the top surface of the block for wear. If fretting damage, scratches, cracks, or corrosion deeper than 0.08 mm [0.003 in] are present in an area where a head gasket seal ring or a grommet makes contact, the surface
must be repaired. There
must not be any defect which extends more than 2.41 mm [0.095 in] from the edge of the coolant passage.

Fretting damage in any other area is acceptable if it does
not change the protrusion measurement of the counterbore or the cylinder liner.

Use a 610 mm [24 in] caliper to measure the height of the cylinder block from the main bearing bore outside diameter to the cylinder head deck surface.

If the height of the block is less than 422.12 mm [16.619 in], a 0.25 mm [0.010 in] oversize head gasket
must be used.

The height of the block
must not vary more than 0.05 mm [0.002 in] from end to end of the block. If the block height is
not within specifications, the top surface of the block
must be machined or the block
must be replaced.

If the top surface of the block is machined, the ledge depth of the cylinder liner counterbore
must be machined.

Liner installation tool, Part Number 3823615, is used to press the cylinder liner into the cylinder block. Protrusion can be checked while the liner is held down by the installation tool.

Put the force plate (3) across the top of the liner with the step in the liner bore. Tap the top of the force plate with a soft hammer to square up and start the liner into the press fit bore.

Put the installation tool bridge (1) across the liner and install the two cylinder head capscrews finger tight to hold the bridge down. Rotate the force plate until the areas where the protrusion measurements will be taken are exposed.

CAUTION  Do not use an impact wrench to tighten the liner force plate screw.

Tighten the forcing screw (2).

Check for correct protrusion.

Use a depth gauge, Part Number 3823495, to measure the liner protrusion at four points 90 degrees apart.

The following equipment is needed to measure the counterbore and the liner press fit area.

• Dial bore gauge kit, Part Number 3375072, or the equivalent
• Extension, Part Number 3375073.

Use dual gauge set ring, Part Number 3823292, (159.86 mm [6.294 in] and 160.88 mm [6.334 in]) to set the dial bore gauge.

Concentricity gauge, Part Number ST-1252.

Depth gauge, Part Number 3823495.

Use Scotch-Brite™, Part Number 3823258, and a medium grit hone to clean the head deck and the liner counterbore. Wipe clean. Do
not use compressed air to clean the block if done in chassis. Compressed air tends to blow dirt and debris into engine cavities and oil passages.

Measure below the counterbore in two directions as shown.

If the bore measures other than the above tolerances, it
must be bored again or sleeved to the correct lower press fit.

Use inside micrometers or the correct liner flange as a go/no-go gauge to check the upper bore.

If the counterbore is less than 167.23 mm [6.584 in], it
must be machined again.

Use concentricity gauge, Part Number ST-1252, to measure the relationship between the upper and the lower bore. The dial indicator reading
must not exceed 0.279 mm [0.011 in].

Make sure that the contact points rest against the press fit area below the counterbore when setting and reading the indicator.

Check the counterbore for cracks or porosity.

If there is a crack, it usually can be seen in the corner between the upper bore area and the ledge.

Most cracks will run horizontally around the counterbore. If any cracks of any size can be seen running horizontally around the counterbore, all the coolant passages that are close to the bore
must be repaired.

Circumferential cracks in the counterbore ledge that do
not extend more than one-half the width of the ledge are acceptable.

Circumferential cracks that extend more than one-half the width of the ledge
must be repaired with a sleeve.

If there is a porous area below the counterbore ledge that is close to a capscrew hole, the hole
must be repaired.

If there is a porous area above the counterbore ledge that is closer to a coolant passage, the passage
must be repaired.

Cylinder blocks with vertical cracks that extend down over the counterbore ledge that can
not be machined out using a 0.750-in long sleeve can
not be repaired.

If the liner has
not been removed, do so at this time.

Use liner puller ring, Part Number 3823264, and a liner puller, either Part Number 3375627 or Part Number 3376015, to remove all liners.

The liner puller ring is used to retain an upper deck repair sleeve when removing a cylinder liner.

To use, put the puller ring around the liner being removed and position with the flat side clearing the adjacent liner. Rest the feet of the puller on the top of the puller ring and use the puller as instructed.

A depth gauge, Part Number 3823495 or its equivalent, is required to check the counterbore depth and the ledge angle.

CAUTION  Make sure the indicator does not contact the counterbore radius. It will not give you a true indication of the ledge angle and can cause liner damage.

Use a depth gauge, Part Number 3823495. Measure the angle of the counterbore ledge at four equally spaced points.

Measurement (2)
must never exceed measurement (1) or be less than measurement (1) by more than 0.025 mm [0.001 in].

Machine the ledge again if the measurement near the counterbore edge (2) exceeds the measurement near the radius (1).

The desired protrusion is the total sum of the thickness of the liner flange and the seal rings minus the counterbore depth.

Cylinder liners and sealing rings are available in the following sizes:

If the ledge angle is okay and a sealing ring is available that will give you the correct protrusion, use that sealing ring.

Two sealing rings can be used to achieve correct protrusion.

When machining work is done on an assembled block, special precautions are required to protect other engine components from contamination. To protect cam bushings, main bearings, crankshaft rod journals, and coolant passages, the areas listed below
must be covered as noted:

• Put chip control plugs, Part Number 3823231, into the lower liner bores to catch metal chips and dust.
• Cover the coolant passages in the liner cavity, on the exhaust side, with Damtite, Part Number 3823232, or some type of formable substance such as modeling clay.
• Cover the push tube openings, on the cylinder
  not being machined, with masking tape.
• Cover the oil transfer holes with masking tape or plastic plugs.
• The boring tool will cover the oil transfer hole and partially cover the push tube opening on the cylinder being machined. Cover the part of the push tube opening
  not covered by the boring tool base with Damtite, Part Number 3823232, or modeling clay.
• Wrap the crankshaft rod journals with clean shop towels and tape to prevent dirt entry into the oil holes.
• After machining, clean the liner cavities and capscrew holes of dirt and metal dust with a wet and dry vacuum cleaner.

Read the complete procedure before beginning to machine the block.

This procedure describes how to machine the counterbore ledge and the diameter to accept a 20/40 oversize lower press fit liner.

To machine for the oversize lower press fit liner, the following tools are required.

Counterbore boring machine, Part Number 3377356, or Porta-Tool®, Part Number PT-2050.

Locator plate/tool holder, Part Number 3822955.

Cutting tool, Part Number ST-1168-91 (2 each).

The following tools are required to check the bore after machining:

• Dial bore gauge kit, Part Number 3375072 or its equivalent
• Extension, Part Number 3375073.

Gauge set ring (6.334 in), Part Number 3822913 or Part Number 3823292, for dial bore gauge.

Concentricity gauge, Part Number ST-1252.

Check the counterbore tool for bearing wear at least every 6 months or after cutting each 100 counterbores.

Check the machine oil level. Low oil level can cause incorrect bore diameter or poor surface finish.

Use the cylinder liner counterbore tool, Part Number 3377356 or Part Number PT-2050, to machine the counterbore to accept the upper deck repair sleeve.

The jaws of the vise
must have copper plate to prevent damage to the counterbore tool.

To check for bearing wear, clamp the counterbore tool in a vise.

Mount a Starrett® “Last Word,” Gem 222, or its equivalent dial indicator on the base with the indicator point against the shaft.

Install a driver shaft, Part Number ST-1168-46, contained in counterbore tool kit, Part Number 3377356, or its equivalent on the shaft of the counterbore tool for greater leverage.

Adjust the dial indicator to read “0”. Move the shaft toward and away from the indicator.

If the total indicator reading exceeds 0.088 mm [0.0035 in], the bearings are excessively worn and
must be replaced. Excessive oil loss can indicate a worn bearing.

Install the drive unit, Part Number 3377350 or Part Number ST-1168-1, on the base plate, Part Number ST-1168-28, if
not already installed.

Position the cutter plate assembly with the taper edge away from the base plate.

Align the keyway in the plate with the key in the shaft.

Install the cutter plate on the shaft. Install the washer and the nut.

Align the counterbore tool with the counterbore by unlocking the drive mechanism and pushing down the drive shaft until the taper cutter seats in the counterbore.

Make sure the cutter plate is in complete contact with the counterbore. This will make sure there is correct alignment.

Rotate the base plate until the mounting holes align with the cylinder head mounting capscrew locations.

Install the four cylinder head capscrews, the square washers, and the standard adapters.

Raise the drive shaft to the full upright position and lock it in place.

A micrometer block, Part Number 3376552, is used to set the cutting tool.

The micrometer block is preset at the factory. Occasionally, because of rough handling, the micrometer block can become miscalibrated.

Verify the accuracy of the micrometer block before setting the cutting tool.

The setting standard, Part Number ST-1168-52, is precision machined and marked with the serial number of the counterbore tool with which it was shipped. Do
not intermix setting standards between counterbore tools.

Use setting standard, Part Number ST-1168-52, to verify the micrometer reading.

Put the setting standard (1) with the side stamped “UP” between the cutter stop (2) and the micrometer spindle (3).

Turn the micrometer thimble (4) until the spindle (3) fits snugly against the setting standard (1).

The micrometer
must read 5.000 in.

Do
not overtighten the micrometer against the setting standard.

When micrometer adjustment is required, loosen the socket head screw (5) and move the cutter stop (2) slightly away from the micrometer (4).

Set the micrometer to read 5.000 in.

Slide the cutter stop (2) to fit snugly against the setting standard (1) and securely tighten the socket head capscrew (5).

Loosen the micrometer thimble (4) and tighten it to fit snugly against the setting standard (1).

The micrometer
must read 5.000 in.

Repeat the adjustment procedure if the micrometer reading is
not correct.

Two machining cuts are required to machine the cylinder block to accept a 20/40 oversize lower press fit cylinder liner.

Use a micrometer block, Part Number 3376552. Set one cutting tool, Part Number ST-1168-91, to 6.334 in for the lower press fit diameter. Set a second cutting tool, Part Number ST-1168-91, to 6.588 in for the upper counterbore area.

Loosen the set screw in the back of the cutting tool.

Push the spring-loaded adjusting pin all the way into the body of the cutting tool.

Tighten the set screw.

Set the micrometer to the desired dimension for the specific cutting tool (upper press fit or lower press fit).

Put the cutting tool into the micrometer block and hold it firmly against the cutter stop.

Loosen the set screw on the cutting tool and allow the adjusting pin to extend out against the micrometer spindle.

When loosening the adjusting screw, do
not allow the adjusting pin to contact hard against the micrometer spindle. Tool damage can occur.

Tighten the set screw.

Check the cutting tool length by loosening the micrometer. Turn the micrometer until the spindle touches the cutting tool, and read the micrometer.

Repeat the setting process until the cutting tool length is accurately set.

Loosen the micrometer and remove the cutting tool from the micrometer block.

Retract the cutter plate from the bore and lock the drive in the full upright position.

The cutting tool
must be inserted into the cutter holder slot with the puller hole down.

Install the 6.334-in cutting tool for the lower press fit area in the cutter plate. The tool
must extend a minimum of 3.0 mm [0.12 in] over the edge of the counterbore. Tighten the set screw for the cutting tool.

Unlock the drive and gently push down on the drive shaft until the cutting tool contacts the top of the block.

Put the 23.6 mm [0.930 in] side of the depth set block, Part Number 3823291, between the set collar and the counterbore tool housing.

Move the set collar down against the set block and tighten the set screw in the stop collar.

CAUTION  Do not leave the cutting tool extended. Failure to push the tool all the way into the cutter plate will result in major damage to the cylinder block.

Retract the cutter plate from the bore and lock the drive in the full upright position.

Loosen the set screw for the cutting tool.

Push the cutting tool into the cutter plate until it fully contacts the main shaft of the counterbore tool.

Tighten the set screw for the cutting tool.

CAUTION  The load will increase when the cutter contacts the counterbore ledge. Keep a firm grip and a balanced stance to maintain control and to avoid personal injury.

Attach a 450 maximum RPM drill and machine until the stop collar contacts the counterbore tool housing.

After the machining is complete, remove the drill. Unlock and raise the drive to the full upright position.

Loosen the set screw for the cutting tool. Insert the cutter key into the small hole in the cutting tool.

Pull the cutting tool from the cutter plate.

Insert the 6.588-in cutting tool for the upper counterbore into the cutter plate. It
must extend a minimum of 3.0 mm [0.12 in] over the edge of the counterbore.

Loosen the set screw for the cutting tool.

The cutting tool
must be inserted into the cutter holder slot with the puller hole down.

Unlock the drive and gently push down on the drive shaft until the cutting tool contacts the top of the block.

Put the 9.53 mm [0.375 in] side of the depth set block, Part Number 3823291, between the set collar and the counterbore tool housing.

Move the set collar down against the set block and tighten the set screw in the stop collar.

CAUTION  Do not leave the cutting tool extended. Failure to push the tool all the way into the cutter plate will result in major damage to the cylinder block.

Retract the cutter plate from the bore and lock the drive in the full upright position.

Push the cutting tool into the cutter plate until it fully contacts the main shaft of the counterbore tool.

Tighten the set screw for the cutting tool.

Attach a 450 maximum RPM drill and machine until the stop collar contacts the counterbore tool housing.

Keep a firm grip and a balanced stance.

After the machining is complete, remove the drill. Unlock and raise the drive to the full upright position.

Loosen the set screw for the cutting tool.

Insert the cutter key into the small hole in the cutting tool.

Pull the cutting tool from the cutter plate.

Remove the counterbore tool mounting capscrews, the spacers, and the washers.

Remove the counterbore tool.

Use a medium grit hone to remove any burrs and sharp edges from the counterbore area.

Wipe the counterbore area with a clean cloth. Do
not use compressed air in chassis. Compressed air tends to blow dirt and debris into engine cavities and oil passages.

Use dial bore gauge, Part Number 3375072, with extension, Part Number 3375073, or equivalent, to measure the lower bore. Use gauge set ring, Part Number 3822913 or Part Number 3823292 (160.88 mm [6.334 in] diameter), to set the dial bore gauge. The lower bore
must be 160.85 to 160.90 mm [6.333 to 6.335 in].

If the lower bore diameter is less than 160.85 mm [6.333 in], it
must be machined again to the correct dimensions using this same procedure.

If the bore diameter is greater than 160.90 mm [6.335 in], the bore
must be fitted with an upper deck repair sleeve. If the bore is already sleeved, continue with the remaining inspections in this procedure.

Use inside micrometers or the liner flange as a go/no-go gauge to check the upper bore.

Check to see if the liner flange fits into the counterbore. If it does
not, use an inside micrometer to verify that the press fit will be less than 0.05 mm [0.002 in] on the liner flange.

The oversize lower press fit counterbore
must check 167.23 to 167.39 mm [6.584 to 6.590 in]. If the counterbore is less than 167.23 mm [6.584 in], it
must be machined again. If the counterbore is greater than 167.39 mm [6.590 in] but less than 167.89 mm [6.610 in], it is acceptable.

Use concentricity gauge, Part Number ST-1252, to measure the relationship between the upper and lower bore. The total indicator reading
must not exceed 0.279 mm [0.011 in].

Make sure that the contact points rest against the press fit area below the counterbore when setting and reading the indicator.

After machining, check the counterbore for cracks or porosity.

If the counterbore depth and the ledge angle have been measured and are correct, do
not continue with this procedure. If either the depth or the ledge angle is incorrect, this procedure
must be followed.

After the block counterbore and lower bore are machined to 20/40 oversize lower press fit, an upper deck repair sleeve is installed, or protrusion is
not correct, the counterbore ledge
must be machined to obtain the correct liner protrusion.

The desired counterbore depth is the total sum of the thickness of the liner flange and the seal rings minus the cylinder liner protrusion.

CAUTION  Make sure the micrometer is not resting on the liner bead when measuring the flange thickness. Protrusion is measured from the top of the flange. If taken from the bead, protrusion will be low, resulting in a loss of engine compression.

Measure the liner flange thickness of the liner to be installed with micrometers and record.

Measure the sealing ring that will be installed into the cylinder block being machined. Reference the following table:

Cylinder liners and sealing rings are availability in the following sizes:

Use a medium grit hone. Remove any nicks and burrs from the cylinder block head deck surface and the counterbore ledge. Nicks and burrs will prevent the tool from seating correctly.

Use a depth micrometer or a depth gauge, Part Number 3823495, to measure the counterbore depth. Measure at four equally spaced points. Record the measurements.

This will assist in determining the amount of material that
must be removed from the counterbore.

Use any of the following counterbore ledge boring machines:

When machining work is done on an assembled block, special precautions are required to protect other engine components from contamination. To protect cam bushings, main bearings, crankshaft rod journals, and coolant passages, the areas listed below
must be covered as noted:

• Put chip control plug, Part Number 3823231, into the lower liner bores to catch metal chips and dust.
• Cover the coolant passages in the liner cavity, on the exhaust side, with Damtite, Part Number 3823232, or some type of formable substance such as modeling clay.
• Cover the push tube openings, on the cylinder
  not being machined, with masking tape.
• Cover the oil transfer holes with masking tape or plastic plugs.
• The boring tool will cover the oil transfer hole and partially cover the push tube opening on the cylinder being machined. Cover the part of the push tube opening
  not covered by the boring tool base with Damtite, Part Number 3823232, or modeling clay.
• Wrap the crankshaft rod journals with clean shop towels and tape to prevent dirt entry into the oil holes.
• After machining, clean the liner cavities and capscrew holes of dirt and metal dust with a wet and dry vacuum cleaner.

Set the cylinder block counterbore tool over the cylinder bore to be machined.

Lower the cutter plate until it touches the counterbore ledge. The taper on the cutter plate will center the tool in the cylinder bore.

There
must be clearance between the stop collar and the housing. Turn the collar until there is clearance.

Make sure the cutter plate is in complete contact with the counterbore. This will make sure there is correct alignment.

Align the holes in the adapter plate (4) with four cylinder head capscrew holes in the block. Install the washers, the spacers, and the cylinder head capscrews.

Raise the cutter plate and insert the C-spacer, Part Number 3823608, between the lower stop collar and the housing.

Turn the bottom stop collar down and raise the cutting tool until it is above the counterbore ledge.

Use an Allen wrench. Turn the bit extending device until the tool bit touches the counterbore inside diameter.

CAUTION  Do not turn the handle clockwise. The tool will damage the bore.

Use the handle to turn the tool
counterclockwise. Listen for the sound of the tool bit scraping the bore wall as it is turned a minimum one-half turn.

If the sound is
not continuous as the handle is turned, use the bit extending device to push the toll bit against the bore opposite the first position.

Turn the tool another one-half turn and listen again for the sound of the bit.

Check for a burr that can mislocate the ledge cutting machine if it touches at only one point.

Use an Allen wrench. Tighten the two tool bit locking screws.

Back off the lower stop collar and allow the bit to contact the ledge.

Back off the upper stop collar, if necessary.

Make sure there is space between the lower stop collar and the C-spacer.

Put a feeler gauge less than the depth you wish to remove but
not more than 0.08 mm [0.003 in] between the stop collar and the C-spacer.

Tighten the thumb screw on the bottom stop collar.

Apply downward pressure to keep the tool bit against the ledge while turning the handle
clockwise.

Machine the bore until the bottom stop collar contacts the C-spacer.

Extend the handle toward the tool side of the cutter plate and turn
clockwise with light downward pressure.

Measure the counterbore depth with depth gauge, Part Number 3823495.

Subtract the actual counterbore measurement from the desired depth of the counterbore calculated earlier.

Put a feeler gauge the thickness of the material to be removed on top of the lower stop collar and turn the top stop collar down until it touches the feeler gauge.

Tighten the thumb screw to lock the top stop collar.

Each of the marks on the lower stop collar is approximately 0.025 mm [0.001 in].

Turn the bottom stop collar
counterclockwise three marks to lower the cutting tool.

Cut the ledge until the lower stop collar touches the C-spacer.

Adjust the lower stop collar up three marks or less each time and cut until there are three marks, 0.08 mm [0.003 in], left before the lower stop collar touches the upper stop collar.

Extend the handle toward the cutting tool side.

Apply light downward pressure and cut until the cutting stops.

There is approximately 0.08 mm [0.003 in] left to remove.

Move the lower stop collar up one mark for each remaining 0.025 mm [0.001 in]. Do
not exceed 0.08 mm [0.003 in].

Lock the lower stop collar and cut the remaining material.

Move the upper stop collar, if necessary, to attain the desired depth.

Extend the handle, apply downward pressure, and cut.

Measure the counterbore ledge depth.

The ledge
must be to the desired depth.

If the ledge depth is complete, move the upper stop collar until it is in contact with the lower stop collar and lock the upper stop collar.

This presets the depth of any additional counterbores to the same depth of the counterbore just cut.

Make a pencil mark to highlight a line extending from the upper to the lower stop collars.

Lower the bottom stop collar to raise the cutter plate until the cutting tool clears the top of the counterbore ledge.

Loosen the two tool locking screws and retract the cutting tool.

Remove the counterbore ledge cutting tool.

Use a depth micrometer and measure the counterbore depth in the four places shown.

The four measurements
must not vary more than 0.025 mm [0.001 in]. If the measurements exceed the specification, the counterbore ledge
must be machined again.

CAUTION  Make sure the indicator does not contact the counterbore radius. It will not give you a true indication of the ledge angle and can cause liner damage.

Use a depth gauge, Part Number 3823495, and measure the angle of the counterbore ledge at four equally spaced points.

The measurement of the ledge depth
must be taken as near to the counterbore radius (1) as possible and as near to the counterbore edge (2) as possible.

Measurement (2)
must never exceed measurement (1) or be less than measurement (1) by more than 0.025 mm [0.001 in].

Machine the ledge again if the measurement near the counterbore edge (2) exceeds the measurement near the radius (1).

If additional counterbore ledges are to be cut to the same depth, put the machine over the bore to be cut.

Remove the C-spacer and allow the cutter plate to fully contact the bore.

Install the mounting capscrews and the washers.

Raise the cutter plate and insert the C-spacer between the lower stop collar and the housing.

Adjust the lower stop collar until the cutting tool clears the counterbore ledge.

Extend the cutting tool until it touches the counterbore.

Rotate
counterclockwise to check alignment.

Tighten the two screws to lock the tool.

Back off the lower stop collar and lower the cutting tool until it contacts the counterbore ledge.

Back off three additional marks.

Cut the counterbore ledge.

Back off the lower stop collar and cut again in three-mark increments until there are three marks left before touching the upper stop collar.

Move the handle toward the cutting tool side and finish with light downward pressure.

Measure the counterbore depth.

Move the lower stop collar one mark for each remaining 0.025 mm [0.001 in] and finish cutting.

Move the handle toward the cutting tool side and finish with light downward pressure.

Loosen the two tool locking screws and retract the cutting tool.

Remove the counterbore ledge cutting tool.

Use a depth micrometer and measure the counterbore depth in the four places shown.

The four measurements
must not vary more than 0.025 mm [0.001 in]. If the measurements exceed the specifications, the counterbore ledge
must be machined again.

CAUTION  Make sure the indicator does not contact the counterbore radius. It will not give you a true indication of the ledge angle and can cause liner damage.

Use depth gauge, Part Number 3823495, and measure the angle of the counterbore ledge at four equally spaced points.

The measurement of the ledge depth
must be taken as near to the counterbore radius (1) as possible and as near to the counterbore edge (2) as possible.

Measurement (2)
must never exceed measurement (1) or be less than measurement (1) by more than 0.025 mm [0.001 in].

Machine the ledge again if the measurement near the counterbore edge (2) exceeds the measurement near the radius (1).

Repeat this process for each counterbore ledge being cut.

• Install the camshaft bushings.
  Refer to Procedure 001-010 in Section 1.
• Install the dowel pins.
  Refer to Procedure 017-003 in Section 17.
• Install the pipe plugs.
  Refer to Procedure 017-007 in Section 17.
• Install the straight thread plugs.
  Refer to Procedure 017-011 in Section 17.
• Install the cup plugs.
  Refer to Procedure 017-002 in Section 17.