M.I.

100
*Rev. B

INTENANCE

CRANKCASE MAIN BEARING STEEL BORE

ALIGNMENT QUALIFICATION

ilNTRODUCTlON
The purpose of this maintenance instruction is to define the dimensions
and limits which control the size, shape, and alignment of the 567 and
645 crankcase main bearing bores. The text of the instruction is divided
into four main sections as follows:

1. Determining If Line Bore Is Necessary.

II. Preparation For Line Bore.

III. Qualification Of Line Bore.

A: Granite Table Method.

B. Measuring Bar Method.

IV. Engine Rebuild And Load Testing

A flow chart is provided to show the recommended basic sequence to be

followed so that this qualification process can be performed efficiently.

*This bulletin is revised and supersedes previous issues of this number.

1 Areas of change are indicated by vertical bars.

DE-LM October 1984

M.I. 100

I REQUALIFY
COMPONENTS
I
MAJOR
I

II
NOTE
REF.
MAIN
INSP.
BRG
BOOK
CONDITION -
1I
FAIL I - --- - _ _-----_
REQUIRED -1
------a-----_-
1
REAPPLY MAIN r A. 11 -t 5 MILS STUD STRETCH1
BRG CAPS --1
, -------------
B. 25 + 5 MILS STUD STRETCH-;
I

I
---------e---w--_ -_

‘MEASURE STEEL -J--REUSE SPEC:

BORE DIAMETERS MAX. VARIATION
I MAX. 8.2540”
I MIN. 8.2470” BETWEEN ACC. END
PASS 1 DIA. & GEN END DIA.
7 fNY ONE “*‘) I IN ANY ONE BORE IS 0.003”
------------------

REMOVE MAIN BEARING

--------_----e-w- --I_
CAPS - REMACHINE
CAP SEARATIONS

,
-----m--e--

REMOVE MAIN BRG x.11+5 MILS STUD STRETCH;

CAPS & REAPPLY 1 B. 25k5 MILS STUD STRETCHJ
------------
I -- --
rL17iE-~cRE ?%uFrc3liloN:- 1
MEASURE STEEL BORE
DIAMETERS-RECORD DATA MAX. VARIATION I
--“t MAX. 8.2540”
I MIN. 8.2480” BETWEEN ACC. END & 1
I GEN. END DIA. IN ANY I
REMACHINE ’ (ANY ONE DIA’) ONE BORE IS .0025” ’
I- -------,-------e-J

22252
 M.I. 100

PROCEDURE
SECTION I
DETERMINING IF LINE BORE
IS REQUIRED
Obvious failures involving the main bearing/
18302
crankshaft system will require complete disassem-
bly of the engine and in almost all cases will also
require line bore. However, those engines which Fig. 1 - Main Bearing Bore Measurement
have been taken out of service for reasons other
than an obvious failure of this system can have
SECTION II
the main bearing steel bore alignment requalified
with a minimal amount of work. PREPARATION FOR LINE BORE
The condition of lower main bearings removed
from a “running” engine will provide the infor- A. QUALIFICATION OF MAIN BEARING
mation necessary to determine whether or not NUT TORQUE APPLICATION
steel bore alignment requires qualification. Bear-
ings that exhibit wear-exposed bronze in excess Stud stretch measurements should be used as the
of l/8” wide running along either edge of any criteria for monitoring torques. The objective of
one main bearing will require complete engine measuring stud stretch is to determine the actual
disassembly to facilitate crankshaft removal. clamp load of the stud/nut system and thus
ensure that the torquing method is effective. Stud
Bearings found in good condition should be stretch is defined as the overall length change of
replaced with new and will thus allow the engine the stud evaluated as the length when torqued
to be placed back into active service. minus the length after the applied torque is
removed. Measurement should be as follows:
NOTE: For further information on evaluating
main bearings, refer to “Inspection and Using a 16-inch micrometer or Vernier caliper,
Qualification of Engine Main Bearings” measure the length of the stud, being careful not
guide I book published by the Service to locate on the small projections found on the
Department of the Electra-Motive ends of each stud. The preferred method is to
Division of General Motors. hold the measuring instrument against the back
end of the stud with one hand in such a manner
As noted above, an engine which has experienced that one finger touches the stud end and locates
an obvious failure of the main bearing/crankshaft the point of measurement at approximately 3/8”
system, or has bearings which exhibit exposed radially from the side of the stud. The outboard
bronze in excess of the amount indicated above, end measurement point can be visually located in
should be disassembled to facilitate crankshaft line with the inboard end point. Operator ability
removal and the following performed. to use this method, or any other selected
method, should be checked by taking repetitive
PRELIMINARY INSPECTION -- STEEL readings. Note, that in order for these readings to
BORE DIAMETER MEASUREMENTS agree, they must be taken in the same location
on the stud ends to minimize errors due to
With the engine disassembled and the crankshaft
tapered ends.
and main bearings removed, reapply the main
bearing caps as indicated in Section II, Item C-4.
Measure the steel bore diameters as shown in Fig. The method of torque application substantially
1, using bore gauge 8275258 with master affects stud stretch. A qualified air or hydrau-
932 1276. Two sets of readings are required per lically operated wrench is recommended for main
each main frame member (MFM) taken l/2” in bearing nut application. Hand torque application
from each side (accessory and generator ends of of main bearing nuts may not be reliable and can
each MFM). The crankcase may be reused with- be expected to give a stud stretch range as high
out bore remachining if all of the diameter as .016”.
readings are within the limits provided in the
appendix, Table 1. If the crankcase does not To qualify any main bearing nut torque applica-
meet the limits provided, proceed to Section II. tion system. perform the following:
M.J. 100
1. Select twelve studs which have been prepared
normally for main cap application. (See Sec-
tion ZI, Item C.)
2. Torque nuts to 750 ft-lbs.
3. Check and record stud length while torqued.
4. Loosen nuts.
5. Record stud length after removal of torqlle
and determine “stud stretch” by subtracting
from the length recorded in Step A 3 above.
6. Reset wrench or system if necessary and
repeat test until the average stud stretch is
.025” I!I .OOl”.
7. Determine the “stud stretch range” by sub-
tracting the lowest of the 12 values of stud
stretch from the highest of the 12. The stud
stretch range must not exceed .012”.
B. MAIN BEARING CAP AND
CRANKCASE SERRATION
INSPECTION
Crankcases which require line bore must have the
main bearing caps reworked to obtain machining
stock and to upgrade the serration quality.
Rework is to be as follows:
1. A minimum of .040” must be cut off the
crest of the senations during remachining to
ensure adequate cleanup.
2. Cut the nut seat surface to remove any
superficial discontinuities. The nut seat sur-
face should be parallel to the serration pitch
line to within .OlO”.
SERRATION SPECLFICATIONS
NOTE: Serrations should be machined on equip-
ment that has been checked to the speci-
fications listed below. Checking should be
done by cutting senations on a sample
piece of metal (coupon) and placing it on
a shadow graph (comparator) or similar
machine.
1. Serration Spacing.
Measurement from the centerline of No. 2
serration on one bank to the centerline of the
No. 2 serration on the opposite bank must be
9.500” 4 .OlO”. Use gauge 9081052, Fig. 2,
to determine this dimension.
-4
19802
19803
Fig. 2 - Serration Gauge 908 1052
2. Flank Angle.
Flank angle is to be measured by locating
horizontal gauge lines at .020” and .I 20”
below the top of the tooth. Draw a line
(flank line) through the two points where the
gauge lines intersect the tooth profile. This
flank line must form a 30” _+45’ angle to the
vertical. See (A), Fig. 3.
3. Deviation from nominal serration flank.
.0017” - measured perpendicular to nominal
flank surface.
The projected outline of the tooth serration
must fall entirely between two 30” lines
which are .0034” apart. See (B), Fig. 3.
C. APPls,ICAT\ON OF MA\N
BEARING CAP AT LINE BORE
NOTE: Stud stretch measurements cannot be
made on type “567B” or earlier crank-
cases. Equivalent hand torques must be
used.
I. Apply main bearing cap for pre-crush and line
bore using flat plate 8488128 against cap (do
not use flat plates on “567B” and earlier
crankcases), followed by hardened washer
8412532 and nut 8408684. Apply Texaco
Threadtex Lubricant 830773 1 liberally to
stud threads, nut face, and both sides of the
washer.
2. Tighten all nuts for pre-crush as follows:
a. Tighten all nuts to produce 11 + 5 mils
stud stretch (350 ft-lbs Ref.).
b. Tighten all nuts to produce 35 Ir 6 mils
stud stretch (I IO0 ft-lbs Ref. 1850 ft-lbs
for “567B” and earlier crankcases] ).
 M.I. 100

t
.1406 +, .0050”
Flank

L! Gauge Line

(A) (B)
22253

Fig. 3 - Determination Of Serration Quality

c. Select four studs at one intermediate cap E. RECAP APPLICATION FOR

and measure stud stretch as defined in MEASUREMENT OF VERTICAL BORE
Section II, Items A2 thiough A6.
The purpose of this recap operation is to ensure
3. Loosen all nuts; measure and record free that proper seating -dfe MFM and cap serra-
length on the four studs selected in Step 2c tions was attained prior to line bore.
above.
1. Assemble main bearing caps with standard
4. Tighten all nuts for line bore as follows: washers and nuts. Apply Texaco Threadtex
Lubricant 8307731 liberally to both sides of
a. Tighten all nuts to produce 11 + 5 mils washer, stud threads, and nut face.
stud stretch (350 ft-lbs Ref.).
2. Record free length on the four studs selected
b. Tighten all nuts to produce 25 f 5 mils in crankcase machining.
stud stretch (750 ft-lbs Ref. [750 ft-lbs
for “567B” and earlier crankcases] ). 3. Tighten all nuts in two steps as follows:

c. Measure and record length of the above a. Apply torque to produce 11 + 5 mils
four selected studs. stud stretch (350 ft-lbs Ref.).

5. Ready for line bore. b. Apply torque to produce 25 + 5 mils

stud stretch (750 ft-lbs Ref.).

D. LINE BORE 4. Measure and record length of the four se-

lected studs.
The line bore equipment used should be able to
produce a bore surface finish of no greater than 5. Remeasure steel bore diameters. The readings
200 micro inches average. obtained must fall within the cap reapplica-
tion limits shown in Table 1, Appendix.
Following line bore, measure the vertical steel Record the vertica .1 diameters in the appro-
bore diameters. All bore measurements are to be priate columns on the Computation
taken i/2” in from the generator side and l/2” Worksheet.
in from the accessory side of each MFM. Vertical
diameters should be within the 8.253” to 8.249” SECTION III
limits shown in Table 1, Appendix or reworked QUALIFICATION OF LINE BORE
and requalified.
Two procedures are offered to determine steel
Remove flat plate 8488128. Remove all caps. bore alignment. The preferred method requires
M.I. 100

the use of a precision granite table of sufficient

size to support a bare crankcase. Upon request,
the Electra-Motive Division Senice Department
will provide information concerning suppliers of
precision granite tables.

A. GRANITE TABLE METHOD

The crankcase should be placed right side up on

the precision granite table as shown in Fig. 4, It
must be supported on its base rails as follows:

20 cylinder - Supports centered 28”

from ends of crankcase

16, 12, 8 and Supports centered 12”

6 cylinder -- from ends of crankcase

The crankcase should be leveled so that dial

indicator readings at the top of the two end
MFM’s agree within .OlO”. Set dial indicator to
zero for reading at accessory end of No. 1 main
bearing bore.
The granite table’s sole purpose it to provide the
source of reference for determining vertical bore
alignment (case line data). This data, along with
the recap steel bore diameter readings (Section II,
E 5) is used to mathematically compute several
alignment functions.
The case line readings, Fig. 5, are obtained using
a dial indicator mounted on a surface gauge, l/2”
19164
in from each main frame accessory and generator
end face and must be made with all caps applied Fig. 5 - Bore Alignment Measurement
and torqued per Section II, E above. Take two Using Dial Indicator

22254
Fig. 4 - Crankcase Supported On Precision
Granite Table

-6
 M.I. 100

independent sets of dial indicator readings. Any example sheet provided is for a 16 cylinder
discrepancies between individual readings which crankcase.
are in excess of .0005” must be resolved. Record
the final corrected readings on the computation 2. Columns B and C are case line dial indicator
worksheet for Granite Table Inspection (sample readings taken at the accessory and generator
provided in the Appendix Section), end respectively of each main bearing bore.
The following sign convention must be used:
Before mathematically computing the alignment Towards topdeck is pos. (+), away from top-
functions on the worksheet it is very important deck is neg. q-j.
to understand each of the functions from a
physical standpoint. The following definitions are
provided along with an appropriate figure to NOTE: Dial indicator readings are recorded as
explain each alignment concept. positive (+) when gauge travel is towards
the topdeck and negative (-) when gauge
1. Case Line - travel is away from the topdeck. Because
The relative vertical position of the crank- of the inverted position of the gauge dial
case portion of the main bearing bores, indicator, plus (+) gauge readings are
Fig. 6. recorded as minus values.
2. Cap Line --
The relative vertical position of the main 3. Column D is the average ordinate for case line
bearing cap portion of the main bearing for each main bearing bore. This is found by
bores, Fig. 6. calculating the average of column B and C, or
[Act. + Gen.l/2 = AVG.
3. Vertical Bow - Example: [(-2.5) + (-1.2)] /2 = -1.8 mils.
The maximum deviation of the center of
any one main bearing bore from a line 4. Column E is the STEP between two adjacent
drawn through the centers of the gener- main bearing bore averages. Step is calculated
ator and accessory end main bearing bores algebraically to determine sign convention
is the crankcase vertical bow. The 16 using the following equation :
cylinder crankcase shown in Fig. 7 has a Y, - Y, = Step 1,2 Y, - Y2 = Step 2,3 etc.
maximum bow of -.003” or -3 mils sag. Example: (-1.5) - (-1,8) = +0.3,
Positive bow is referred to as crown. (-0.3) - (-1 S) = +I .2 etc.
4. Step/Effective Step - 5. Column F is a constant factor used to adjust
The difference in vertical position be- step when the span between main bearing
tween two adjacent main bearing bores bores is not 16.625” for the purpose of
(case or cap line), Fig. 8. calculating EFFECTIVE STEP. This is only
necessary on 16 and 20 cyl. engines because
5. Slope Change - the span distance between the two center
The relative vertical position of two adja- main frames is l/2 the distance between any
cent effective steps (case or cap line), two intermediate main frames, therefore, the
Figs. 9 and 10. factor is 2.
6. Case And Cap Tilt -- 6. Column G is the effective step which is the
The difference between the accessory and product (x’s) of Column E and its corre-
generator positions of any one main bear- sponding factor in Column F.
ing bore, Fig. 11.
7. Column H is the case line SLOPE CHANGE
An explanation on how to use the computation or the algebraic difference between two adja-
worksheet (for use with the granite table) fol- cent effective steps (Column G).
lows. A master worksheet, as well as a completed Example : x2 - x1 or (+1.2) (+0.3) = +0.9,
example sheet is provided in the Appendix (t-0.6) -(+I .2) = 0.6 etc.
Section.
8. Column I is the algebraic difference between
NOTE: For ease in calculating data, record as the case line readings at the generator end
mils; where .OOl” equals 1 .O mil. (Column C) and the case line readings at the
accessory end (Column B) which equals case
1. Column A indicates the main bearing position line tilt (per gauge length), or Z, - ZA or
number for 16 and 20 cylinder engines. The (-1.2)-(-2.5) = +1.3.

-7.
MA. 100

i I
I
i
I I
I 1
I I

-8-
 M.I. 100

I
I I
I
I

I
1 i
 t Gen 4CC.
End
I
Sign Convention
End fnd

Case Line Data 5 = + Towards Top

+0.002” Deck (See Pg. 7)
Case Line Step*
or
Cap Line Step +2.0 Mils
--- --
I Case Line Data 4 =
+0.0003”
EXAMPLE:

*Case Line Step =

Case Line Data 6 =
+0.3 Mils
.-----i-
Case Line Step*

Cap Line Step

f - --
or
+0.3 Mils
-l

Case Line Data 6- EXAMPLE: Step 2

Step “6
Case Line Data 5 *Case Line Step =

I or Case Line Data 5-

G y6 -y5 Case Line Data 4

or or

+0.3 - (i2.0) = -1.7 y5 - y4

or
Step E = -1.7
+2.0 - (+0.3) = +1.7

Eff Step g = -1.7 (2)

= -3.4 Step g = +7.7

Eff Step 54=+l.7 (1)

Not To Scale, Line Bore 1 =+1.7
Conditions Shown Are I,------ 8-5/l 6”
For ltlustrative Purposes
Only.

GRANITE TA 22257

Fig. 8 - Step And Effective Step

,,, ,,
 THE SLOPE CHANGE IS THE RELATIVE VERTICAL POSITION
OF TWO ADJACENT EFFECTIVE STEPS.

Gen. c. SLOPE CHANGE @ #4 Ace.

End / End
/
Cap Line /
/
/
/
/
/
/
/
/

Sign Convention
+ Towards Top

I Deck (See Pg. 7)

Syp i -0.004”
Step
3
2
-0.004”

7
I
I
Example: *Case Line /
Slope Change = ,
I
Case Line Step i -
I
2 I
Case Line Step 3 /
or

or
SC, = 0
Not To Scale. Line Bore
Conditions Shown Are Slope Change @ #4 = 0
For Illustrative Purposes
Only. GRANITE TABLE
L

Fig. 9 - Slope Change Vs. Step (Zero Slope Change Illustrated)

 SLOPE CHANGE IS THE RELATIVE VERTICAL POSITION
OF TWO ADJACENT EFFECTIVE STEPS.

Slope Change @ #4

I
-I
Sign Convention
L --_----- + Towards Top
Deck (See Pg. 7)
I
Step 5 -0.004”
I I
0.008”
I Step g +0.004”

*Case Line
Slope Change

SC4 =

+4.0-t-4.0) =

+4.0 + 4.0 = 8.0

SC, = 8.0 Mils

s; = s;
Slope Change At #4 = 8 Mils

Not TO Scale. Line Bore

Conditions Shown Are
For Illustrative Purposes
Only. GRANfTE TABLE

22259
Fig. 10 - Slope Change Vs. Step (8 Mils Change Illustrated)
Case Tilt = \ kc.
Case Line Data, Gen. - Gen. Sign Convention Ind
Case Line Data, Act. End t Towards TOP
or Deck (See Pg. 7)
ZG-ZA or
3.6 -3.4 = +0.2

Cap Tilt =
Case Tilt + *Steel Bore Diff.

+0.2 + (-.ggr= -0.4 Case Tilt = +.2

- - --
T

*Steel Bore Difference = -_ --- __-------

4 -ljY---IL--
--
Act. End Steel Bore - Gen. +2.0
End Steel 6ore

+1.4 - (+&I = -0.6

- Recap Bore
- Diameters I
w Gauge Length ------+ From Nominal

Zero Reading At
Accessory End Of
No. 1 Main Bearing
Bore
-_--0

t
Cap Tilt = -0.4

+3.6

Not To Scale. Line Bore Case Line /

Conditions Shown Are
Readings
For illustrative Purposes
Only. J Crankcase S/N 75J3-1507 1
3:
GRANITE TABLE 22260 k

z
Fig. 11 - Case And Cap Tilt 0
M.I. 100

9. Columns J and K are vertical recap steel bore B. GRANITE MEASURING BAR METHOD
variations from the nominal bore diameter of
8.2500”, taken at the accessory end and NOTE: This procedure should only be used to
generator end respectively. The following sign determine steel bore alignment when a
convention is used: pas.(+) = Larger than precision granite table is not available.
nominal and neg.(-) = Smaller than nominal.
Example : A vertical steel bore dia. of The granite measuring bar 8467738 and gauge
8.251 I” is expressed +l.l mils; 8.2488” is assembly 8467737 are used to determine cap line
-1.2 mils. data, after the recap operation has determined
that the steel bore diameters are within accept-
10. Column L is the steel bore difference, which able limits. The bar, Fig. 12, consists of a 42”
is the accessory end steel bore size minus the long piece of polished granite with a square cross
generator end steel bore size. section and a fluid level attached to one end. The
level is used to establish horizontal attitude trans-
Example: (+l. 1) - (+1.3) =-0.2.
versely in the bore. The bar is supported by three
11. Column M is the CAP TILT per gauge length. pairs of ball-head legs spaced in such a manner
It is equal to the algebraic sum of Columns I that only two pairs of legs are in use per each
and L or case line tilt plus steel bore differ- run (the span distance between the center MFM’s
ence. Example: (+1.3) + (-0.2) = +l.l. is one half the distance between intermediates
and thus requires an additional set of legs).
12. Columns N and 0 are the cap line calcula- The gauge assembly consists of a standard clock-
tions for the accessory end and generator end wise dial type instrument with an automatic
respectively. Jt is the algebraic difference revolution counter. The numerical values obtained
between the case line dial indicator readings in this bore alignement check are merely relative;
and the steel bore variation from nominal; or meaning that there is no prior setting of the
Column B - Column J = Column N etc. and gauge in a master fixture. Gauge travel adjust-
Column C - Column K = Column 0 etc. ments are not necessary as this has been pre-
Example: (-2.5) - (+l. I) = -3.6 and established in the design make-up of the bar and
(-1.2) - (+I .3) = -2.5 etc. gauge assembly. Close attention must be paid,
however. to the number of sweeDs the nointer
13. Column P is the average ordinate for cap line 1

makes around the dial or the revolution counter,

at each main bearing bore and is calculated so that consistent numerical data can be
the same as the average ordinate for case line obtained.
(Column D).

through T are used to calculate PROCEDURE:

14. Columns Q
CAP LINE step, effective step and slope The crankcase should be resting on its exhaust
change. The calculations are identical to those deck and should be as level as reasonably pos-
used to find case line, step, effective step and sible. The main bearing caps should be applied
slope change respectively in Columns E, F, G, and torqued per Section II, E 3.
and H.
The measuring bar is then placed in the first
The main bearing line bore graph (master and three consecutive main bearing bores starting at
example sheets provided in Appendix) is used to the No. 1 MFM. It is suggested that the bar
determine vertical bow. The numerical values supporting legs be consistently located in the
listed in Columns D or P on the worksheet are center of the MFM’s in which they are placed.
used as the data poi& on the graph. A scale
must be assigned to the horizontal lines on the The gauge assembly is placed on top of the bar at
graph so that they include the range of values the accessory end of the NO. 1 MFM. The gauge
from either Column D or P. Plot the data points is then moved from side to side within the bore
on the graph under the appropriate main bearing until a maximum reading is obtained, Fig. 12.
position number. Draw a straight line to connect Two readings are taken and recorded per bore
the two end data points and from the line of with the data points located l/2” in from the
reference determine the max. vertica! sag (-) or accessory and generator end faces. After Yne
crown (+). readings have been obtained for the first three

-14-
 M.I. 100

Fig. 12 - Granite Measuring Bar In Place

bores, the bar is then moved to the next adjacent follows. A master worksheet, as well as a com-
MFM and leveled; meaning that the bar should pleted example are provided in the Appendix.
now span MFM’s 2, 3, and 4. This will provide
NOTE: For ease in calculating data, record as
the second run of readings (starting at the acces-
mils; where .OOl” equals 1 .O mil.
sory end of the No. 2 MFM), and this sequence is
followed through the remaining bores of the 1. Column A indicates run numbers for. 16 or 20
crankcase. The readings obtained are recorded on cylinder crankcases. Each run number deter-
the computation worksheet (for measuring bar) mines the location of the measuring bar
provided in the Appendix. within the crankcase.
NOTE: It is vitally important that at least two 2. Column B is the main bearing position
truly independent sets of readings are numbers for a 16 and 20 cylinder crankcase
taken per crankcase with the measuring per run.
bar method to insure repeatable, and thus
accurate, results. Of the two sets of 3. Columns C and D are the CAP LINE dial
readings, any discrepancies between indi- indicator readings for the accessory and gener-
vidual readings which are in excess of ator ends respectively.
.0005” (.5 mils) must be resolved.
4. Column E is the average ordinate for each
An explanation on how to use the computation main bearing bore. This is found by calcu-
worksheet (for use with the measuring bar) lating the average of Columns C and D, or

-15
M.I. 100
(act. + gen.l/2 = AVG.
Example: t(4.7) + (5.5)]/2 = 5.1 mils.
5. Column F is the STEP between two adjacent
main bearing bores’ averages per run. Step is
calculated algebraically to determine sign
convention using the following equation:
Y,-Y, =Step 1,2 Y,-Y, =Step 2,3 etc.
Example: (4.0)--(S.l)=-1.1,
(4.3) - (4.0) = 0.3 etc.
6, Column G is a constant factor used to adjust
step when the span between main bearing
bores is not 16.625” for the purpose of
calculating EFFECTIVE STEP. This is only
necessary on 16 and 20 cylinder engines
because the span distance between the two
center main frames is one half the distance
between any two intermediate main frames;
therefore, the factor of 2 is used.
7. Column H is effective step which is the
product (x’s) of Column F and its cone-
sponding factor in Column G.
8:Column I is the uncorrected cap line slope
change value which is defined as the algebraic
difference between two adjacent effective
steps (Column H).
Example: (0.3) - (-1 .l> = 1.4 mils.
9. Column J is a slope change correction used to
adjust for sag or crown present within the
measuring bar. This correction value equals
twice the amount of sag (neg. -) or crown
(pos. +) found in the bar.
NOTE: The bar correction factor is provided with
each measuring bar assembly and should
be checked annually at Electra-Motive.
Contact your service representative to
make necessary arrangements to have this
function performed.
10. Column K is the corrected SLOPE CHANGE
value obtained by determining the algebraic
sum of Column 1 and the bar correction value
in Column J.
Example: (I .4) f (-0.6) = 0.8 mils.
11. The back side of the computation worksheet,
Fig. A-4 Part 2 of 2, begins with Column L
-16-
which provides the main bearing position
numbers for 16 and 20 cylinder engines.
12. Column M is the same corrected slope change
data taken from Column K on the front side
of the computation worksheet.
13. Columns N and 0 are intermediate steps
required to obtain the main bearing line bore
graph. The values are obtained by calculating
the cumulative sum of the slope change
figures in Column L, starting at the center of
the engine and working towards the top and
bottom of each Column. As shown on the
example worksheet provided, the corrected
slope change value for the No. 6 main bearing
(-2.2) is algebraically added to the corrected
slope change value for the No. 5 main bearing
(0.9). The total (-1.3) is then algebraically
added to the No. 4 main bearing corrected
slope change value (-0.6) ; equals (-1.9) etc.
The exact same procedure is followed for the
readings obtained in Column 0. As shown on
the sample worksheet, the corrected slope
change value of the No. 6 main bearing (-2.2)
is again algebraically added to the cumulative
value for the No. 5 main bearing in Column
N (-1.3). The total (-3.5) is then added alge-
braically to the cumulative value of the No. 4
main bearing (-1.9) etc.
14, The figures obtained in Column 0 are used to
plot data points on the main bearing fine bore
graph, Fig. A-5, as shown in the example
provided.
A scale must be assigned to the horizontal
lines so that they include the range of values
from Column 0. Plot the data points on the
graph under the appropriate main bearing
position number. The center mains on 16 and
20 cyl. crankcases will always be zero data
points. A straight line is then drawn through
the two end points and from this line of
reference the vertical bow or crown is
determined.
The sample computation shows the maximum
vertical height of the case occurs at the No. 6
main bearing (7.7 mils) and the crankcase is
crowned.
 M.I. 100

SECTION IV Section II, Item C 4. Assemble the engine with

new or requalified material and install in an
ENGINE REBUILD appropriate test cell facility (engine application
AND LOAD TESTING will so dictate) and prepare for break-in or load
test. Be sure to properly fill the engine’s lube oil
Position the crankcase in such a manner as to system and pre-lube prior to start up.
facilitate main bearing cap removal and crank-
shaft installation. Apply new main bearings and It is recommended that the break-in or load test
the crankshaft in accordance with the procedure procedure used, includes a “feel over” check of
outlined in the appropriate Engine Maintenance the crankshaft/main bearing svstem before
Manual. Tighten all main bear&g cap nuts per advancing engine’speed and loas. d

APPENDIX
NOTE: The following limits apply only when the main bearing stud stretch is .025” + .006”.

TABLE 1
STEEL BORE DIAMETER LIMITS
(DIMENSIONS IN INCHES)

REMACHINED REUSE WITHOUT

AS LINE AFTER CAP ANY BORE
BORED* RE-APPLICATION REMACHINING
ANY ONE DIAMETER (MAX.) 8.2530 8.2540 8.2540
(MIN.) 8.2490 8.2475 8.2470
Max. variation between NO
accessory end diameter REQUIRE- .0025 .003
and gen. end diameter MENT
in any one steel bore

*Reference only. Dimensions obtained after cap reapplication are to be used for qualification.

TABLE 2
LINE BORE ALIGNMENT LIMITS
(DIMENSIONS IN INCHES)

REMACHINED REUSE W/O REMACHINING

CASE LINE & OR CAP LINE
MAX. BOW (-) OR CROWN (+) MAX. BOW
20 cyl. -.Oll +.016 .020
16 cyl. -.007 +.010 .OI 2
12 cyl. -.005 +.007 .008
8 cyl. -.005 +.007 .008
6 cyl. -.005 +.007 .008
Max. slope change - Case Line + .005 * k.007”
Thousandths/l6.625” Cap Line 5.0065 2.0085
i

*Reference only. Cap line dimensions are to be used for qualification.

-17-
ML 100
 DATE -

ENGINE SERIAL NO. 76D3-1 SO5 CRANKCASE SERIAL NO. lhA13

I
2 I -2.5 -1.2 -1.8 1.3 1.1
____ .3 I .3 ’
3 2 -1.7 -1.3 -1.5 - .9 .4 -.6 -1.2 A

4 3 -.h -. I -3 I 0.0 .3
A I I / .h!.z$L_51.3-
5 4 0.0 .5 .3 __ I.1 .5 -I ,I -I .2 .I
~ 1.7 I 1.7
6 5 2.0 2.0 2.0 -.5 0.0 .9 .3 1.1 1.4
.6 2 1.2 - .-
7 6 2.8 2.4 2.6 .9 -.4 .5 -.4 2.3 1.5
___ 2.1 1 2.1 -
8 7 5.4 4.1 4.7 ~ -3.8 -1.3 -.5 -_3 5.9 4.3
-1.7 I -1.7 ____~-__
3 9 8 2.8 3.3 3.0 -.6 1 I / -.6 , I.1 , .5 I -.: -. 7 3.0 2.8

IO 9 2.4 2.4 2.4 - -1.5 0.0 I .o .I 1.4 1.5

____ -2.1 I -2.1 ___-
II IO .5 0.0 .3 -.5 .7 .I 0.0 -. 2 -. 7
I
12

B C D E I; G H I J

(COLUMNS)

22263

Fig. A-2 - 16 & 20 Cylinder Crankcase Line Bore Computation Worksheet

For Use With The Granite Table
 /I $ I/ I

Illllllllllllllll IIlI/lll l/II

I r-- -r-J;-, /il!!l!!!!!!

-2o-
 M.I. 100

ENG. SERIAL NO. 76C3-15 18 CASE SERIAL NO. 76A-115

INSPECTOR DATE
MODEL SD45 TYPE 20-645E3
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A B C D E F G H I J T K

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1 .o 1 1.0
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5 4 6 5 4.7 5.2 4.9 -. -.. .-2.2
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6 5 5.0 5.4 5.2 -
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6 5 7 6 4.9 5.0 4.9 - -.6 7 -.9
8 7 3.2 4.4 3.8 - -. 9 - 1 - -. 9 :. :: .’
4.7 4.9 4.8 _I -
7 6
-.9 ---L -.9
7 6 8 7 3.3 4.5 3.9 -.-A-- 6 8
1 . .:: A
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5.0 4.7 A 6 1 ----L--6
8 7 9 8 4.4
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22265A

Fig. A-4 - 16 & 20 Cylinder Line Bore Computation Worksheet For Use With
Granite Measuring Bar 8467738 (Sheet 1 of 2)
M.I. 100

ENGINE SERIAL NO. 76C3-15 18 CASE SERIAL NO. 76A-115

INSPECTOR DATE
MODEL SD45 TYPE 20-645E3

.8 I
c I \
3 2 -. 2 -5.4 3.0

14 31 -.6 I -3.5 4.7

I I I-
15 41 -2.2 5.6
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4 7.7
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8 7 .8 -. 9 6.5
1
1 9 8 1 -1.3 -1.0 6.1

-2.4 4.4

( 11 10 I 1.2 -5 .o 1.7

-6.4 0.0
222658

Fig. A-4 - 16 & 20 Cylinder Line Bore Computation Worksheet For Use With
Granite Measuring Bar 8467738 (Sheet 2 of 2)

-22-
 M.I. 100

I
i
M.I. 100

Equipment:
Part No.
Did Bore Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8275258
Mgster (8.25OO”‘Nominal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9321276
Serration Gauge - Includes Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9081052
Precrush Plates . . . . . . . . . 8488128
Texaco Threadtex’Lubrfcant #i3& (7b lb’. pail) ’ 1: : : 11: 1: 1: : : 1. . . . . . . . . 8307731
Granite Inspection Table . . . . . . . . . . . . . . . . . . . . . . Contact EMD Service Department
For Supplier Information
Support Blocks . . . . File Drawing #778
Dial Indicator Gauge i Case Line’Readings’-‘ThdIe’ Method . : : 1 1 : 1 : : : . . . . File Drawing #891
Measuring Bar . . . . . . _ . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . 8467738
Dial Indicator Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . 8467737

0 0 0 0 A Service Department Publication l l 0 o

Electra-Motive Division Of General Motors La Grange, Illinois 60525

-24- Litno In U,S.A.