BEARING-THRUST 7W9416 - Caterpillar

General Information
The 4.5" Bore, V8 (Direct Injection) Engine can be reconditioned to provide performance characteristics comparable to a new engine. The reconditioned engine will operate satisfactorily if certain reconditioning precautions are observed.Performance and oil control comparable to a new engine can be obtained only if the necessary machining is done to the required Specifications. Cylinder block reconditioning requires an automatic honing machine to control size, surface finish, and crosshatch pattern of the cylinder bores. A manually operated hone does not give satisfactory results and is not recommended.To facilitate reconditioning, pistons and rings are available .020 in. (0.51 mm) and .040 in. (1.02 mm) oversize.Connecting rod and main bearings are available .010 in. (0.25 mm) and .020 in. (0.51 mm) undersize.Main bearings are available with a .010 in. (0.25 mm) oversize outside diameter. These bearings are for cylinder blocks that have had the bore for the main bearings bored oversize.Basic Block
Cylinder Block Honing
The following preliminary check is essential to determine if honing is necessary, and if so, the size to hone.Measure all cylinder bores during disassembly using the 1P3537 Bore Gauging Group. This group includes a 1P3535 Dial Bore Gauge Group and a 1P3536 Size Setting Fixture Group. The bore gauging group provides more accurate measurements than other methods, such as inside micrometers. When setting the gauge, always be sure the gauge pin has sufficient travel to measure the points of maximum wear in the bore. In a cylinder bore, maximum wear is usually across the diameter perpendicular to the crankshaft centerline, either at the top or bottom of ring travel. Normal wear usually will not exceed .020 in. (0.51 mm); however, if bore wear is greater than .020 in. (0.51 mm), hone the block .040 in. (1.02 mm) oversize. The fact that the block can be honed both .020 in. (0.51 mm) and .040 in. (1.02 mm) oversize will allow a block to be reconditioned twice under normal wear conditions. The standard bore size is 4.5000 to 4.5015 in. (114.300 to 114.338 mm).
1P3537 BORE GAUGING GROUPWhen reconditioning an engine, the bore size is the determining factor as to the necessity of honing the bores. If bores are worn .006 in. (0.15 mm) more than the standard size, the block should be honed. However, additional service may b obtained without honing if wear does not exceed the maximum wear limit of .0085 in. (0.216 mm).Before honing, inspect the bottom of each cylinder bore adjacent to the main bearing saddle or web. Some of the saddles may overlap the edge of cylinder bores enough to interfere with honing. Where overlap exists, machine a relief in the saddle to provide clearance for the honing tool. The radius of the relief must be concentric with the cylinder bore and .030 .005 in. (0.76 0.13 mm) larger than the bore radius. The relief extends .62 in. (15.7 mm) beyond the bottom of the bore, as shown. This provides adequate clearance for honing.
RELIEF IN SADDLES and CHAMFER AFTER HONINGWhen honing, check bore