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ARMY TM 9-2815-255-24 AIR FORCE TO 38G1-95-2 MARINE CORPS TM 2815-24/4 3-41.3.  Repair. If oversized balancer shaft bushings are used, engine block must be line bored. a. Line bore engine block to specification listed below.  Refer to FIGURE 3-114 for References A through E. NOTE Reference all line boring dimensions from front left dowel pin (E). (1) A..  1.653 to 1.655 inches (41.985 to 42.035 mm) (2) B..  10.157 to 10.159 inches (257.985to258.035 mm) (3) C..  2.558 to 2.560 inches (64.986 to 65.036) (4) D..  1.7015 to 1.7025 inches (43.237 to 43.263 mm) b. Make a chamfer 20 to 25 degrees x 0.060 inch (1.5 mm toward front of engine for front and middle bores and toward rear for rear bore to make bushing installation easier. c. Check bores for smoothness after machining. 3-41.4.  Installation. CAUTION Make sure oil hole In bushing (16, FIGURE 3-108) Is aligned with oil passage In block for proper bushing and journal lubrication. a. If removed, use balancer shaft bushing driver (JD-249) to drive new bushings (16) into engine block. NOTE Adequate  bushing-to-balancer  shaft  clearance  exists,  if  shaft  can  be  rotated  by  hand  with  a slight-to-moderate  drag.    It  is  not  necessary  to  hone  bushing  to  obtain  specified  oil  clearance. Excessive clearance can result in shaft seizure. b. If gear (11 or 12) was removed, install as follows: (1) Install key (15) in slot on shaft. (2) Position balancer shaft (13 or 14) in balancer shaft holding tool (JD-247). (3) Install thrust plate (9 or 10) and gear (11 or 12) on balancer shaft.  Be sure timing mark on gear faces away from balancer shaft. (4) Press  gear  onto  shaft  with  a  tube-type  driver  and  arbor  press.    Press  gear  until  a  clearance  of  0.002  to 0.008 inch (0.005 to 0.20 mm) exists between thrust plate and gear/shoulder. c. Make sure engine is at TDC (No.  1 piston on compression stroke), with timing pin engaged in flywheel. 3-165


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