Detroit Diesel — Cylinder Block Preparation

Repair & overhaul

From a Detroit Diesel service manual — check it applies to your exact model before use.

Procedure

1. Remove cylinder heads, pistons, liners, and other hardware.
2. Protect crankshaft, oil, and coolant passages from machining debris; clean top of block.
3. Remove cylinder block dowel pins using Snap-On CG503 or equivalent.
4. Remove coolant pump and rear lifting bracket.
5. Protect internal engine parts with oiled sponge filler in cylinder block.
6. Retract cutting bit of PT-2250-B; leave cap screws loose.
7. Center tool on block top using J-41065 counter bore cutter tool.
8. Raise depth stop collars; lower tapered cutter plate into bore; rotate to center.
9. Install two opposing cylinder head bolts with washers and spacers; tighten to 41 N·m (30 lb·ft).
10. Raise tapered cutter head; install depth set spacer; extend cutting tool until it touches 0.15 mm feeler gauge; tighten Allen head screws.
11. Lower cutting plate and cutter into counterbore until touching lower surface; rotate lock collars to bronze bushing.
12. Set depth of cut by adjusting top collar to allow liner shim between collars; tighten thumb screw; remove shim.
13. Lubricate tool bushing; back off lower collar two graduations 0.0254 mm (0.001 in. each); rotate T-handle clockwise with moderate pressure; stop at random positions; continue backing off 0.0508 mm (0.
14. Raise handle; insert spacer block under lower collar; remove hold-down bolts and spacers to remove tool.
15. Retract cutter bit into cutter plate for storage.

Source: Detroit Diesel service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

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