Reuse and Salvage For 3500 Engine Cylinder Blocks (0672, 0705, 0762, 1201, 1217)

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Welcome: q633akn
Product: WHEEL LOADER
Model: 992G WHEEL LOADER 7HR
Configuration: 992G Wheel Loader 7HR00001-UP (MACHINE) POWERED BY
3508B Engine

Reuse And Salvage Guidelines


Reuse and Salvage for 3500 Engine Cylinder Blocks {0672, 0705, 0762, 1201, 1217}
Media Number -SEBF8255-43 Publication Date -25/09/2015 Date Updated -30/07/2019
Caterpillar: Confidential Yellow

i07795214

Reuse and Salvage for 3500 Engine Cylinder Blocks {0672, 0705,
0762, 1201, 1217}
SMCS - 0672; 0705; 0762; 1201; 1217

Caterpillar Products
All 3500 Engines
All G3500 Engines

Introduction
Table 1
Revision Summary of Changes in SEBF8255
43 Added Dichtol sealer application process.

Added new serial number prefixes for New Product Introduction (NPI) and changed cutoff
42
length.

Combined guidelines SEBF2120, SEBF2121, SEBF2122, SEBF8219, SEBF8226, SEBF8291,


41
SEBF8437, SEBF9203, SELD0458, and repaired 41 pixelated illustrations.

© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of
this document or the proprietary processes therein without permission may be violation of intellectual
property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts
reusability program. Reuse and salvage information enables Cat dealers and customers to benefit from cost
reductions. Every effort has been made to provide the most current information that is known to Caterpillar.
Continuing improvement and advancement of product design might have caused changes to your product

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which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest
technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback
in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers


This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for
information about canceled part numbers and replaced part numbers. NPR will provide the current part
numbers for replaced parts.

Important Safety Information

Illustration 1 g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This person
should also have the necessary training, skills, and tools to perform these functions properly. Safety
precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not
heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every
possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and
the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating
technique that is not recommended by Caterpillar is used, ensure the safety of yourself and others. Ensure
that the product will not be damaged or the product will not be made unsafe by the operation, lubrication,
maintenance, or the repair procedures that are used.

Improper operation, lubrication, maintenance or repair of this product


can be dangerous and could result in injury or death.

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Do not operate or perform any lubrication, maintenance or repair on


this product, until you have read and understood the operation,
lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger,
warning, or caution. The "WARNING" safety alert symbol is shown below.

Illustration 2 g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this
publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
safety information in this document and the safety information on the machine are not all inclusive.
Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that
the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also,
determine that the operation, lubrication, maintenance, and repair procedures will not make the
machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information
which was available at the time of publication. The specifications, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the service that is
given to the product. Obtain the complete, most current information before you start any job. Caterpillar
dealers can supply the most current information.

Summary
This guideline contains the specifications for the 3500 engine cylinder blocks and spacer plates. Spacer plates
can often be reused with the same performance as new spacer plates. A cylinder block that meets the
specifications in this guideline can be expected to give normal performance until the next overhaul.

Service Letters and Technical Information Bulletins

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NOTICE

The most recent Service Letters and Technical Information Bulletins


that are related to this component shall be reviewed before beginning
work. Often Service Letters and Technical Information Bulletins
contain upgrades in repair procedures, parts, and safety information
that pertain to the parts or components being repaired.

References
Table 2
References
Media
Title
Number
M0080689 Reuse And Salvage Guidelines, "Cylinder Block Cleaning and Audit Procedure"

Reuse and Salvage Guidelines, "Inspection and Reuse Guideline of Cylinder Liners in
SEBF8068
Cat Engines"
Reuse and Salvage Guidelines, "Inspection and Reuse of Critical Fasteners Used in All
SEBF8301
Engines"

SEBF8357 Reuse and Salvage Guidelines, "General Cleaning Methods"

Reuse and Salvage Guidelines, "Fundamentals of Arc Spray for Reconditioning


SEBF9238
Components"
Reuse and Salvage Guideline, "Fundamentals of Flame Spray for Reconditioning
SEBF9240
Components"

Reuse and Salvage Guideline, "Cylinder Block Salvage Procedure Using Belzona® 1311
SEHS8869
(Ceramic R Metal)"
SEHS8919 Reuse and Salvage Guideline, "Reuse and Salvage for Cast Iron Cylinder Blocks"

SEHS9031 Special Instruction, "Storage Procedures for Caterpillar Products"


SMHS7606 Special Instruction, "Use Of 1P-4000 Line Boring Tool Group"

SMHS7727 Special Instruction, "Use of 8T-0455 Cylinder Liner Projection Indicator Group"

Special Instruction, "Using 5P-4175 Boring Tool Group and 5P-1618 Counterboring
SMHS8839
Tool Group"
Disassembly and Assembly, "3500 and 3500B High Displacement Engines for
SENR1126
Caterpillar Built Machines"

Tooling and Equipment

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The tooling listed in Table 3 is for all salvage repairs. Some tools will not be required based on individual
repair needs.

Table 3
Required Tools and Equipment

Part
Part Description
Number
1P-3537 Dial Bore Gauge

2S-0115(1) Hard Washer


4C-3845 Grinding Wheel
4C-6329 Flex-Hone
4C-9500 Quick Cure Primer

4C-9507 Retaining Compound

5P-0333(4) Crowfoot Socket


5P-1630 Adapter

5P-1657 Shaft

5P-1769(2) Washer
5P-4175(3) Counterboring Tool Group

5P-4175 Counterboring Tool Group


6V-2012(4) Depth Micrometer

6V-2025 Cutter Assembly

8H-0707 1/4 × 20 Allen Head Screw


8H-8559 Modified Extension Assembly

8T-0455(4) Liner Projection Tool Group


8T-2682 Plate

9U-5271 Glass Beads

154-9731 Thread Lock Compound


169-5464 Quick Cure Primer

178-2502 3508 Main Bearing Threaded Insert


178-2503 3516 Main Bearing Threaded Insert

178-2351 Reamer

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Tap
178-2353
First Operation
Tap
178-2356
Second Operation

178-2462 Reamer
Tap
178-2463
First Operation

Tap
178-2465
Second Operation

178-2467 Installation Sleeve


178-2468 Installation Sleeve
222-3117 Brake Cleaner
263-9070 Steel File

266-3736 Impact Wrench


303-9339 Lint Free Shop Towels

365-1197 Liner Brush


385-4007 Liner Seat Insert Installation Tool

386-3364 Straight Edge Liner

373-5840 Leak Test Tool for Liner Seat Insert


434-6509 Leak Test Tool for Water Ferrule Insert

441-3674 Water Ferrule Driver


448-3698 Profilometer

473-0493(5) Insert Kit (Standard Diameter)

473-0494(5) Insert Kit (Oversize Diameter)


Inside Micrometer Set
473-8688 2-12 inch
or
473-8689 Inside Micrometer Set
50-300 mm

Outside Electronic Micrometer Set


473-8690
0-4 inch

Outside Electronic Micrometer Set


473-8691
2-6 inch

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Outside Electronic Micrometer Set


473-8692
6-12 inch
489-0635 Insert Driver Tool

PT-2801 Basic Kit (Jig fixture)

PT-2801-3 Service Kit


Threaded insert used in 3500 Family Series Engine [current block style, 53.3 mm
PT-8760
(2.10 inch) long]

Threaded insert used in 3500 Family Series Engine [old block style, 69.9 mm (2.75 inch)
PT-8762
long]
- Impact Socket
- End Mill

- Isopropyl Alcohol
- Loctite 640
(1) Use with the tools for the water ferrules
(2) Use with the counterboring tool, the manual tool, and the insert installation tools
(3) Additional information about this tool group can be found in Tool Operating Manual, NEHS1022.
(4) Use with the counterboring tool
(5) Each Insert Kit includes one insert and one integral seal

When replacement parts are required for this product Caterpillar


recommends using Caterpillar replacement parts or parts with
equivalent specifications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product


damage, personal injury or death.

Measurement Techniques

NOTICE

Precise measurements shall be made when the component and


measurement equipment are at 20° (68° F). Measurements shall be
made after both the component and measurement equipment have had
sufficient time to soak at 20° (68° F). This will ensure that both the
surface and core of the material is at the same temperature.

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Measurement Tooling include precision inside and outside diameter micrometers capable of measuring four
decimal places in inches or three decimal places in millimeters. Measuring tools should be calibrated using
gage blocks certified to a national standard such as the National Institute of Standards and Technology
(NIST).

Ensure that several sample measurements are taken at different locations on the same feature. Measure
diameters of internal bores in several places to identify tapered and or oval conditions.

Initial Cleaning of the Engine

Illustration 3 g06238164

Cap all machined surfaces and plug all the hoses and fuel lines.

Clean all the external surfaces before the engine is disassembled. Clean all the external surfaces before the
engine is brought into the shop. Use a high-pressure washer to spray the engine with hot water and soap or
174-6858 Cleaner.

Personal injury can result from working with cleaning solvent.

Because of the volatile nature of many cleaning solvents, extreme


caution must be exercised when using them. If unsure about a particular
cleaning fluid, refer to the manufacturer's instructions and directions.

Always wear protective clothing and eye protection when working with
cleaning solvents.

NOTICE

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All reconditioned components should be cleaned again before


assembly. Any debris or residue on the parts such as metal chips,
carbon deposits, or sludge can enter the system. Debris or residue can
cause early engine failures.

After the initial cleaning of the engine, disassemble the engine. Refer to the appropriate Disassembly and
Assembly manual for your engine.

All fasteners should be compared against Reuse and Salvage Guidelines, SEBF8301, "Inspection and Reuse
of Critical Fasteners Used in All Engines". Pay special attention to head bolts, main bolts, connecting rod
bolts, and rocker shaft bolts when considering reusability. Any visual damage to the bolts should disqualify
the bolt from reuse.

Note: Itis recommended to replace all cylinder head bolts and the spacer plates (if applicable) on any engine
that has experienced a failure of the top deck/cylinder head joint.

Cleaning the Cylinder Block


One of the major reasons for a bearing failure after an engine overhaul is damage caused by debris in the oil
passages. Remove all dirt, debris, and metal shavings from all openings, ports, and passages. Refer to
M0080689Reuse And Salvage Guidelines, "Cylinder Block Cleaning and Audit Procedure" for cylinder
block cleaning.

NOTICE

Failure to remove all dirt, debris, and/or metal shavings from openings,
ports, and passages, will result in damage to the engine and the related
components. A cylinder block that is not cleaned thoroughly will result
in piston seizure or rapid wear of the cylinder bores, pistons, and
piston rings. Only the thorough use of a rotary brush will correctly
remove abrasive particles.

Note: Do not use surface reconditioning pads on the top deck of the block, spacer plates, and cylinder
head surfaces.

Specifications for 3500 Engine Cylinder Blocks


Specifications

Refer to Table 4 and Illustration 4 for dimensions and nomenclature of 3500 Engine specifications.

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Illustration 4 g06181001
A typical cylinder block for 3500 Engines. Refer to Table 4 for specifications and dimensions.

Specifications for the Cylinder Block

Table 4
3500 Cylinder Block Specifications

Part
Dimension Description Minimum Maximum
Number

Specifications of the Camshaft Bore (A)

Diameter of the bore of the 91.980 mm 92.020 mm


N/A
block A Series (3.6213 inch) (3.6228 inch)

Installed bearing bore diameter 85.94 mm 86.06 mm


N/A
A Series (3.383 inch) (3.388 inch)
A
Diameter of the bore of the 97.980 mm 98.020 mm
N/A
block B Series (3.8575 inch) (3.8590 inch)
Installed bearing bore diameter 91.980 mm 92.100 mm
N/A
B Series (3.6213 inch) (3.6260 inch)
Specifications of the Crankshaft Bore (B) After Torquing the Main Bearing Cap Bolts

Diameter of the Bore of the Block

169.722 mm 169.762 mm
Standard bore N/A
B (6.6820 inch) (6.6835 inch)

0.63 mm (0.25 inch) oversize 170.352 mm 170.392 mm


N/A
bore (6.7068 inch) (6.7083 inch)

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ID of the Installed Bearing


160.142 mm 160.211 mm
Standard ID of the bearing 149-6031
(6.3048 inch) (6.3075 inch)

0.63 mm (0.025 inch) undersize 159.507 mm 159.576 mm


149-6032
ID (6.2798 inch) (6.2825 inch)
1.27 mm (0.050 inch) undersize 158.872 mm 158.941 mm
149-6033
ID (6.2548 inch) (6.2575 inch)

0.63 mm (0.025 inch) oversize 160.142 mm 160.211 mm


149-6034
OD (6.3048 inch) (6.3075 inch)

0.63 mm (0.025 inch) undersize 159.507 mm 159.576 mm


149-6035
ID and oversize OD (6.2798 inch) (6.2825 inch)
0.63 µm
Surface texture of the main bore 2.5 µm
C (24.803 µinch) N/A
of the block (98.42 µinch) Ra
Ra

585.40 mm
Dimension from the top deck of New cylinder block N/A
(23.047 inch)(1)
D the cylinder block to center line
of the crankshaft 585.62 mm 586.00 ± 0.15 mm
N/A
(23.056 inch)(2) (23.071 ± 0.006 inch)

Dimension from horizontal


229.65 mm
E center line of crankshaft bearing 230.35 mm (9.069 inch) N/A
(9.041 inch)
bore to bottom of block
F Thickness of the spacer plate Refer to "Specifications and Salvage for Spacer Plates"

Flatness of the Shaded area


0.00 0.05 mm (0.002 inch) N/A
top deck (9)
G
Refer to Full length
Illustration 5. 0.00 0.15 mm (0.006 inch) N/A
of block
Angle of the top deck

H Angle 30 degrees
N/A
Tolerance ±0.25°
Distance from center line of
I dowel hole to center line of 226 ± 0.06 mm (8.898 ± 0.002 inch)
crankshaft bore.
(1) 3500 Series A Series Engines (MUI and EUI)
(2) For 3500 Series B Series Engines including High Displacement Engines.

Top Deck Flatness Specification

The flatness specification (G), Table 4 of the top deck must be contained to the required specification with

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the shaded area (9) for each cylinder. Refer to Illustration 5. The width of area (9) is 270.00 mm
(10.630 inch) or the width of the area from either side of the center line of the bore is 135.00 mm
(5.315 inch). This flatness requirement must be met for each cylinder bore.

Illustration 5 g01393805
Shaded area (9) must meet the flatness requirement (G) which is given in Table 4.
(4) 135.00 mm (5.315 inch)
(5) 270.00 mm (10.630 inch)
(9) Surface of the top deck

Top Deck Surface Texture and Waviness Specifications

Inspect the surface of the top deck for signs of damage such as pitting or erosion. The surface must be smooth
and free of nicks and gouges. The surface must be free of any damage that could result in an incorrectly
seated liner or an incorrectly sealed gasket.

Table 5
Top Deck Surface Texture and Waviness Specifications

2.5 µm (98.43 µinch) Ra


Top Deck
Roughness Sampling Length or Cutoff - 2.54 mm
Surface Texture
(0.10000 inch)
3500B
350-1412 Minimum
Block
Top Deck Waviness
Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch)
of spacing (1)

2.5 µm (98.43 µinch) Ra


Roughness Sampling Length or Cutoff - 2.54 mm
3500E Top Deck (0.10000 inch)
456-6312
Block Surface Texture Average
Roughness Peak
to Valley Height - 19.0 µm (748.03 µinch) Rz

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Minimum
Top Deck Waviness
Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch)
of spacing(1)
(1) For waviness spacing smaller than 5.0 mm (0.20 inch) use maximum waviness height of 0.00254 PER mm (0.00010 PER inch)
spacing.

Top Deck (Angle) Specification

The specification of angle (H) of the top deck must be maintained. The specification of the flatness (G) of the
top deck must be maintained. The surface of the machined deck must meet two requirements for this
specification.

Illustration 6 g01393964
Angle of the top surface of the deck.
(D) Distance from the center line of crankshaft bore to the surface of top deck
(6) Horizontal center line of crankshaft bore
(7) Parallel plane that must contain the surface of the top deck
(8) Surface of the top deck

1. The surface must not be machined to less than the minimum specified distance (D) from the center line
of the crankshaft bore.

2. The angle of the surface must be within two parallel planes that are separated by 0.13 mm (0.005 inch).
The machined surface must fall within these parallel planes. The machined surface must be within the
maximum and minimum tolerances for the dimension (D).

Lengths of Blocks Specification

Refer to Table 6 for length dimensions of the cylinder blocks and Illustrations 7 and 8 for examples.

The length of the cylinder block is measured from the front thrust face to the ends of the cylinder blocks. The
3508, 3512, 3516 cylinder blocks are measured from front of the thrust face to the respective side of the

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cylinder block. The G3520 cylinder block is measured from the rear thrust face to each end of the cylinder
block.

Illustration 7 g06181008
3508, 3512, 3516 Cylinder Blocks

Illustration 8 g06181011
G3520 Cylinder Block

Table 6
Cylinder Block Lengths and End Face Surface Texture

Engine Model Dimension Description Value

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576 ± 0.2 mm
A Thrust face to front face of block
(22.7 ± 0.010 inch)
3508
624 ± 0.2 mm
B Thrust face to rear face of block
(24.570 ± 0.010 inch)

846 ± 0.2 mm
A Thrust face to front face of block
(33.3 ± 0.010 inch)
3512
894 ± 0.2 mm
B Thrust face to rear face of block
(35.197 ± 0.010 inch)
1116 ± 0.2 mm
A Thrust face to front face of block
(43.937 ± 0.010 inch)
3516
1164 ± 0.2 mm
B Thrust face to rear face of block
(45.827 ± 0.010 inch)
4.5 ± 0.2 mm
C Thrust face to rear face of block
(0.178 ± 0.010 inch)
G3520
2810.5 ± 0.2 mm
D Thrust face to front face of block
(110.650 ± 0.010 inch)

0.08 mm
Surface Flatness of Block Ends
(0.003 inch)

Surface Texture of Block Ends Ra = 3.2 µm (125.98 µinch) or better


0.1 mm
Runout to the Crank Axis
(0.004 inch)

Visual Inspection
Damage of the Cylinder Block

Cracking

Cylinder blocks with cracks on the top deck surface under the liner flange can be repaired with metal spray or
inserts. Cracking that extends from a coolant passage or from a bolt hole into the cylinder block bore cannot
be salvaged.

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Illustration 9 g01393786
Cracks extend from bolt holes (1) and coolant passages (2) into the bore of the cylinder block.
Do not use the block again.

Coolant Passage Pitting

Pitting of the cylinder block near the coolant passages or under the liner seat can result in external coolant
leaks.

Illustration 10 g01393798
Damage from pitting (3) around the coolant passages

If the pitting is deeper than 0.13 mm (0.005 inch) or if the pitting has occurred completely around the coolant
passage, then repair the pitting by using one of the following methods.

Cylinder Block Pitting Near the Upper Liner Seal

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Illustration 11 g06181013
Example of pitting as it relates to the Upper Liner Seal.
(1) Liner cross section
(2) Cylinder Block
(3) Upper Liner Seal cross section
(4) Pitting

In some conditions, pitting can develop in the cylinder block liner bores near the bottom edge of Upper Liner
Seal (3). If pitting in the upper bore is discovered, then the location and severity must be considered when
assessing repair options.

Pitting discovered in this area of the block does not necessarily need to be salvaged. Pitting can vary in
location and severity. Usually the pitting is cosmetic in nature and the cylinder block can be reused without
durability concerns.

Note: Pitting measurements are not exact dimensions and measuring the pitting severity with a high degree of
precision is not necessary. A liner bore inspection tool or calipers are sufficient for measuring from the top
deck. A visual estimation is adequate for determining pitting depth. Refer to Figure 91 for the Liner Bore
Inspection Tool print specifications.

Generally, pitting within 4.5 mm (0.17 inch) from the top deck and/or 0.5 mm (0.02 inch) in depth or deeper
will need to be repaired. The measurement 4.5 mm (0.17 inch)is an approximate dimension measure from the
block deck surface.

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Illustration 12 g06046430
Inspection Tool

Illustration 13 g06053709
(5) Sealing Region (less than 4.5 mm from the top deck):
(6) Non-Sealing Region (more than 4.5 mm from the block deck)

1. Non-Sealing Region (more than 4.5 mm from the block deck):


Pitting in the non-sealing region will not interfere with the Upper Liner Seal performance. Salvage is
not required for pitting in this region unless the pitting is severe. Usually, the cylinder block can be
cleaned and reused.

2. Sealing Region (less than 4.5 mm from the top deck):


Pitting may be within or under the sealing surface for the Upper Liner Seal. If the pitting severity is
minimal, then the cylinder block may still be reused without performing a salvage procedure.

Note: Prudence and sound technical judgment is required when deciding between direct reuse of the block
and salvage of the block. Currently, block inserting is the best salvage option available. Dealers must
consider their own experience and aptitude for inserting when considering salvaging the cylinder block.

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Illustration 14 g06024328
Example of moderate to severe pitting that approaches liner bore chamfer.
(A) 4.5 mm (0.17 inch)

Pitting as shown in Illustration 14 ranges from moderate on the left to severe on the right. The pitting on the
left is within the 4.5 mm (0.17 inch) sealing region and begins to approach the liner bore chamfer on the
right. The combination of severe pitting on the right and the proximity to the chamfer would require this
example to be salvaged.

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Illustration 15 g06181019
Examples of pitting severity.
(7) Severe Pitting: Salvage repair needed
(8) Moderate Pitting: Salvage repair needed.
(9) Minimal Pitting: Salvage repair not needed.

Illustration 15 highlights the range of liner bore pitting. In all three examples the pitting was greater than the
4.5 mm (0.17 inch) guidance. However, Example (3) of Illustration 15 must be salvaged due to the severity of
the pitting.

Pitting depth into the cylinder block liner bore can be difficult to measure and analyze. Sound technical
judgment is required when determining the severity of the pitting. If pitting depth is minimal and does not
affect areas that are likely to compromise the Upper Liner Seal performance, then direct reuse of the block
may be possible. If the pitting depth is severe, or the affected area is large enough to compromise the Upper
Liner Seal performance, then salvage procedures may be required.

Due to the case-by case, subjective nature of inspecting and assessing pitting near the upper liner seal,
numerous visual examples have been provided to serve as references. Photos are grouped by severity, notable
facts are presented, and reuse or salvage recommendations are offered. However, the final assessment of
severity and conclusion regarding reuse or salvage remains with the dealership.

The following are three examples of minimal pitting. These photographs are examples that do not need to be
salvaged.

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Illustration 16 g06181020
Minimal pitting depth. Pitting in non-sealing region around entire bore.
Reuse

Illustration 17 g06181021
Minimal pitting depth. Pitting in non-sealing region in few locations around liner bore.
Reuse

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Illustration 18 g06181023
Minimal pitting depth. Pitting in non-sealing region and in few locations around liner bore.
Reuse

The following are three examples of moderate pitting. These examples demonstrate situations that would be
more difficult to determine the need to salvage due to their subjective wear. Prudence and sound technical
judgment is required when deciding between direct reuse of the block and salvage of the block.

Illustration 19 g06052840
Moderate pitting depth. Pitting in non-sealing region and continuous around liner bore.
Reuse

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Illustration 20 g06052868
Moderate pitting depth. Pitting on edge of sealing region and continuous around liner bore.
Salvage

Illustration 21 g06052878
Moderate pitting depth. Pitting in both sealing and non-sealing region and continuous around entire liner bore.
Salvage

The following of severe pitting illustrate damage that is more visually obvious. Usually of such severe
pitting, salvage would be required.

Illustration 22 g06052889
Severe pitting depth. Pitting in non-sealing region and continuous around liner bore.
Salvage

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Illustration 23 g06052918
Severe pitting depth. Pitting in sealing region and continuous around liner bore.
Salvage

Illustration 24 g06052930
Severe spotted pitting depth. Pitting within sealing region and continuous around liner bore.
Salvage

Cylinder Block Top Deck Salvage Options for 3500 Engines


This section contains the procedures to repair top deck damage on 3500 cylinder blocks and the threaded
holes in the top deck of cylinder blocks. The threaded holes can be damaged during an engine rebuild.
Damaged threads can cause improper torque of the head bolts, resulting in possible failure. Using this
threaded insert repair procedure, bolt holes can be repaired to "like new" condition. Use this guideline as the
only source of reference when installing the Kent- Moore® threaded insert.

To repair stripped or cracked head bolt holes, use the PT-2801 Porta-Thread Basic Kit, with the PT-2801-3
Service Kit. A thin-wall solid steel insert with a sealed bottom prevents coolant leakage from the cylinder
head bolt holes. This insert can often repair cracked blocks that, until now, would be scrapped.

Cylinder block repair is made easy using a base plate and drill jig to maintain perfect alignment during
reaming and tapping operations.

Top Deck Threaded Hole Repair

Nomenclature

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Illustration 25 g02119154
Basic Kit (PT-2801)
(1) PT-7270 Loctite Compound (50 cc)
(2) PT-7260 Loctite Primer T [ 178 mL (6 oz)]
(3) PT-2900-6 Super Chip Vacuum and PT-2900-2 90 Degrees Extension
(4) RS-13300-250 Washer (5/8 in SAE)
(5) RS-9103-100 Hex Head Bolt (5/8-18 x 3 in, Grade 5)
(6) PT-2800-32 Drill Jig
(7) PT-2800-33 Base Plate
(8) RS-15100-175 Allen Wrench (1/8 in)
(9) PT-1000-20 Universal Drive
(A) J-34970 Storage Box (not shown)
(B) PT-2801-22 Foam Insert (not shown)

Illustration 26 g06304381

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Service Kit (PT-2801-3)


(10) PT-2800-24 Stud Adapter
(11) PT-2800-30 Installing Nut
(12) PT-2800-26 Stop Collar Assembly
(13) PT-2800-41 Installing Bolt
(14) RS-13-300 Washer (7/8 in SAE)
(15) PT-2800-29 Locating Pin
(16) PT-2800-38 Special Reamer
(17) PT-2800-39 Special Tap
(C) PT-2800-40 Spacer (not shown)

Repair Procedure

Use the following procedure to carry out repair operation:

1. File the top deck to remove all burrs and high spots. Thoroughly clean the area for proper tool location.

2. Attach the drill jig (6) to the base plate (7) using the hex head bolt (5) and the washer (4). Place the
drill jig on the cylinder block, aligning the base plate over two holes across from each other. Use the
cylinder head bolts, washers, and the stud adapters (10) to secure the base plate (7) to the cylinder
block. Torque the bolts to 41 N·m (30 lb ft).

3. Loosen the hex head bolt (5) and position the drill jig (6) over the hole to be repaired. Insert the
locating pin (15) through the drill bushing and into the bolt hole. Tighten the bolt (5) to 40 N·m
(30 lb ft) and remove the locating pin. Refer to Illustration 27.

4. Insert special reamer (16) through drill bushing into top of bolt hole.

5. Install the universal drive (9) in the chuck of an electric drill (slow speed drill is best) and begin
reaming the damaged bolt hole. Stop after reaming to a depth of about one in. Refer to Illustration 27

6. Remove the reamer and clean out shavings with a chip removing unit. Continue reaming to the bottom
of the hole. Remove the reamer and thoroughly clean out all shavings from hole.

NOTICE

To avoid damage to the tooling, keep the reamer shank and drill
bushing free of metal shavings.

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Illustration 27 g06304389
Position drill jig (6) over damaged bolt hole.

Illustration 28 g06304392
Insert tap.
(18) Threaded insert.

7. Insert the special tap (17) through the drill bushing, allowing it to set on top of the hole. Using a
threaded insert (18), adjust the depth stop collar (12) on tap, as shown in the Illustration 28.

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Illustration 29 g06304394
Tap the hole.

8. Using a low speed drill or tap handle, tap the hole. If using a drill, stop when there is a 3.0 mm
(0.12 inch) gap between the stop collar and guide bushing. Finish tapping the hole by hand.

Illustration 30 g06304396
Remove all debris from hole using the chip vacuum or compressed air.

9. Remove the tap and the drill jig fixture from the cylinder block. Clean the hole thoroughly with a chip
removing unit.

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Illustration 31 g06304397
Attach installing bolt (13) to threaded insert and install insert.
(11) PT-2800-30 Installing Nut
(13) PT-2800-41 Installing Bolt
(18) Threaded insert.

10. Thread the special installing nut (11) onto a cylinder head bolt or installing bolt (13). Install the nut to
end of threads, then back off the nut about 1/4 turn.

11. Screw threaded insert onto installing bolt (or head bolt, if used) until it touches the nut. Clean the
outside diameter threads of the insert with 4C-9500 Quick Cure Primer (2). Let dry, then coat with
9S-3263 Thread Lock Compound (1). Using a wrench on the installing bolt, screw the threaded insert
into the block until installing nut bottoms on top of block.

12. With another wrench, hold the bolt and loosen the nut from the threaded insert, then remove the bolt.

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Illustration 32 g06304400
Remove installing bolt (13).

Reconditioning the Cylinder Block

The following table will help direct what type of rework is needed on 3500 Engine Blocks.

Table 7
Block Top Deck Defect
Defect Inspection Defect Limits Rework Type
Location Type
Depth < 0.013 mm No Rework
(0.0005 inch) Required
Surface
Wear 8T-0455 Liner Remilling
(1) Projection Tool Group Depth ≥ 0.013 mm Twin Wire Arc
(0.0005 inch) Spray (TWAS)
Stainless Steel
Insert
Under the Liner Visual Surface
Flange Remilling
8T-0455 Liner
Pitting Projection Tool Group No Pitting Allowed
TWAS
Profilometer/Surface
Texture Gauge Insert

Visual

Cracks Magnaflux No Cracks Allowed Insert

Dye Penetrant

Visual
From top deck ≥ 4.5 mm
Caliper No Rework
(0.17 inch)and/or minimal
Required
pitting
Liner Bore Inspection
In Liner Bore Pitting Tool(2)
Caliper
From top deck < 4.5 mm
(0.17 inch)and/or severe Insert
Liner Bore Inspection
pitting
Tool

Water Ferrule Visual Depth < 0.13 mm No Rework


Pitting
Sealing Areas and (0.005 inch) Required(3)

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Surface
Remilling
8T-0455 Liner
Projection Tool Group Depth ≥ 0.13 mm TWAS
Gasket Sealing
(0.005 inch) or completely
Areas SS Insert
Profilometer/Surface around the cooling passage.
Texture Gauge (4)
Belzona® 1311
(Ceramic R
Metal)

Visual
Between Water
Pitting smaller than 0.8 mm No Rework
Ferrule and Liner Pitting
8T-0455 Liner (0.03 inch) acceptable Required
Flange
Projection Tool Group
(1) Wear step created by fretting under the liner flange
(2) Refer to Figure 91 for tool print specifications.
(3) If surface meets surface texture requirements to ensure water ferrule sealing.
(4) Max-Defined by rework type

It is critical to maintain the correct compression ratio of 3500 Engines during reconditioning. Do not exceed
the minimum specifications of top deck height. The ratio is increased as material is removed from the surface
of the cylinder head and block. If machining alone is not able to remove all the damage, then arc spray
(TWAS) can be performed.

Twin Wire Arc Spray is the Caterpillar recommended block salvage method. Applied properly, arc spray can
salvage the engine block to original parent material specifications with the added benefit of increased
corrosion resistance. The increased corrosion resistance that arc spray provides will help reduce future repair
needs.

Removal of Material

Machining the top deck of the cylinder block is the preferred method of repair when damage is small. When
machining is done on the top deck of the cylinder block, remove the minimum amount of material that is
necessary to remove the damage. Refer to Table 4 for reconditioning specifications.

Top Deck Inserts

Light machining of the top deck and/or arc spray is the preferred repair options for Cat engine blocks. If
metal spray capabilities are not available, then inserting the top deck is an acceptable practice. The top deck
can be inserted in the water ferrule and liner bore locations.

Belzona® 1311 (Ceramic R Metal) as an Alternate Field Repair Option

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Illustration 33 g02602356

A cylinder block with minor pitting near the smaller water seals can also be repaired with Belzona® 1311
(Ceramic R Metal).

Note: The following areas must be covered or plugged during the repair: cylinder bore, inlet port, exhaust
port, and cylinder head bolt openings. These areas could become contaminated if not properly protected.

1. Use a ¾ inch drill bit to remove only enough metal to remove the porous material. The depth of the cut
should not exceed ¼ inch. The water port opening is the pilot on the small seal.

Illustration 34 g06304429

2. Grind an undercut around the middle of the ¾ inch water port opening, using a die grinder with a cutoff
wheel dressed to fit the opening.

3. Sweat the area to be repaired. This can be accomplished by using a propane or acetylene torch. Little
heat is required. This will remove the oil and moisture from the casting.

Note: Caution must be used to prevent the damaging of other seals, gaskets, and components in the
area.

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4. Clean the prepared area with Belzona® 1311 (Ceramic R Metal) cleaner. The Belzona® 1311 (Ceramic
R Metal) cleaner will dry and leave no film residue.

5. To maintain the proper water port diameter a ½ inch diameter by 3 inch long wooden dowel rod will be
installed in the water port opening. Before the rod is installed coat the rod with Belzona® 1311
(Ceramic R Metal) release agent and let dry.

6. Mix the Belzona® 1311 (Ceramic R Metal) material per package instructions.

Note: Do not contaminate the product during mixing. Use a separate measuring devices or thoroughly
clean between the measuring of the two different agents.

7. Wet the area to be repaired. Apply small amounts of the Belzona® 1311 (Ceramic R Metal) with a
small flat stick. Work the Belzona® 1311 (Ceramic R Metal) into the undercut. Make sure that all areas
are wet.

8. Install the ½ inch dowel into the water port. This is after the release agent has been applied to the
dowel and has dried.

9. After the dowel is in position continue applying the Belzona® 1311 (Ceramic R Metal) until the drilled
area is slightly higher than the top deck of the block.

10. After approximately 30 minutes from the original mix time, the applied material can be smoothed. Be
sure to wear rubber gloves and check to see if the surface of the repair material has a dried film, or is
sticky.

11. If the repair material sticks to the finger of the glove, it is still too wet. To get a smooth finish for the
material at the repaired area, dip the fingers of the gloves in water, and work the surface back and forth.
Use only enough water to wet the fingers. Too much water on the Belzona® 1311 (Ceramic R Metal)
repair material can have adverse effect on its mechanical strength.

12. Press firmly to force out any time that may have been trapped in the material during the smoothing
process. If this smoothing procedure is done correctly, it will reduce the time needed for sanding once
the Belzona® 1311 (Ceramic R Metal) repair material has cured.

13. Belzona® 1311 (Ceramic R Metal) repair material can be removed from non-repair areas using
theBelzona® 1311 (Ceramic R Metal) cleaner before the Belzona® 1311 (Ceramic R Metal) hardens.

14. Approximately two to three hours after the Belzona® 1311 (Ceramic R Metal) has been applied, it
should be hard enough for sanding. Remove the excess material and sand flush with the top deck of the
cylinder block. Be careful not to dish the repaired area.

Note: Curing time. When the Belzona® 1311 (Ceramic R Metal) is mixed and used at a temperature of
21° C (70° F), it will develop its full mechanical capabilities in 24 hours

Procedure to Repair the Top Deck with Water Ferrule Inserts

3500 cylinder blocks with pitting around the water passages can be repaired with stainless steel inserts.

NOTICE

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Water ferrule inserts must be installed prior to the liner seat insert
counter-bore being cut. If the water ferrule inserts are installed after
the counter-bore is cut, then the counter-bore will distort.

Do not use oversized diameter water ferrule inserts. Water ferrule inserts must not come into contact with
liner seat inserts. There must be parent block material remaining between the water ferrule and the liner bore
inserts.

Illustration 35 g02602016
(1) pitting around water passages

Illustration 36 g03546077
Pitting in the yellow area does not need repair. If the surface meets surface texture requirements to ensure water ferrule sealing, then
pitting between the water passage and the liner seat are acceptable.

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Water Ferrule Inserts

Table 8
Water Ferrule Inserts

Part No. Description Outer Diameter


20.671 ± 0.006 mm
417-3778 (Small Insert)
(0.8138 ± 0.0002 inch)

30.205 ± 0.006 mm
417-3779 (Large Insert)
(1.1892 ± 0.0002 inch)

Driver adapters for the water ferrule inserts can be fabricated to ease the installation of the inserts. The
drivers should be small enough so that the driver does not totally cover the insert. This will allow better
visual alignment of the insert when the insert is installed into the block.

The driver adapter for the smaller insert should have a shoulder that fits inside the hole in the middle of the
water ferrule insert. The driver adapter for the larger insert should have a counter-bore for the bolt head that
holds the adapter onto the driver handle. This adapter will allow the driver adapter to sit flush on top of the
larger water ferrule insert.

The following illustration and table lists approximate dimensions for the driver adapters.

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Illustration 37 g06181032
(1) Fabricated driver for small water ferrule inserts
(2) Fabricated driver for large water ferrule inserts

Table 9
Callout Dimension
19 mm
A
(0.75 inch)

B Passage for bolt


10 mm
C
(0.40 inch)

28 mm
D
(1.10 inch)
E Counter-bore for bolt head

Water Ferrule Insert Repair Procedure

1. Clamp the cylinder block in place.

Illustration 38 g02602276
A template refers to Illustration 90 for fabrication specifications.

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Illustration 39 g03842018
Dimensions for counter-bore
Refer to Illustration 10 for specifications.
(F) Counter-bore diameter
(G) Counter-bore depth
(H) Counter-bore radius

2. Use an end mill to machine a counter-bore in the water passage. The end mill that is used on the small
counter-bore should be 20.637 ± 0.013 mm (0.8125 ± 0.0005 inch). The end mill that is used on the
large counter-bore should be 30.162 ± 0.013 mm (1.1875 ± 0.0005 inch). Refer to Table 10 and Table
11 for the dimensions of the counter-bore.

If the top deck is not machined after insert installation, then the insert thickness must be measured and
the counter-bore depth adjusted. The counter-bore depth must be cut such that the final water ferrule
insert projection is within ± 0.052 mm (0.002 inch).

Table 10
Dimensions for the Small counter-bore in the Coolant Passage(1)

20.637 ± 0.013 mm
Diameter (F)
(0.8125 ± 0.0005 inch)

Radius (H) 0.63 ± 0.13 mm (0.0250 ± 0.005 inch)


5.000 ± 0.250 mm
Depth (G)(2)
(0.1969 ± 0.0098 inch)
(1) Refer to Illustration 39
(2) If top deck machining is not performed, then depth can be adjusted. Refer to Step 2 above.

Table 11
Dimensions for the Large counter-bore in the Coolant Passage
30.162 ± 0.013 mm
Diameter (F)
(1.1875 ± 0.0005 inch)

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5.000 ± 0.250 mm
Depth (G)(1)
(0.1969 ± 0.0098 inch)
(1) If top deck machining is not performed, then depth can be adjusted. Refer to Step 2 above.

3. Deburr the corner of the counter-bore and use isopropyl alcohol to clean the counter-bore and to clean
the inserts. A clean, lint free cloth should be used to clean any machining residue from the counter-
bores and the inserts.

Note: The radius on the outer diameter of the insert should be toward the cylinder block.

4. To ensure that the insert is pressed fully into the coolant passage, measure the counter-bore depth and
insert thickness. The difference should result in a uniform insert projection of 0.02540 mm (0.001 inch)

5. Apply Loctite 640 to the counter-bore on the outside edges and seating surface sufficiently to create a
continuous seal.

Excessive Loctite may make the final insert projection hard to achieve. If the insert is not seated within
10 minutes of the applying the Loctite, the Loctite can begin to set up keeping the insert from properly
seating. The Loctite will need to be removed and the install process must be started from the beginning.

6. Start installation of the insert by hand into the counter-bore.

Illustration 40 g02602319

7. Drive the insert into the counter-bore of the coolant passage using 441-3674 Water Ferrule Driver.

8. For the large insert ensure that the water feed holes do not overlap after the press fit.

9. Verify that the inserts are properly seated and sealed by performing a leak test.

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Illustration 41 g02602326
An example of an insert pressed into a cylinder block.

Procedure to Leak Test the Water Ferrule Inserts

Loctite must be allowed to cure for a minimum of six hours from the time the last insert was pressed in place
prior to leak testing. If the top deck will be machined, then the leak test must be conducted before and after
machining.

1. Use the 434-6509 Insert Leak Test tool.

2. Apply 207 kPa (30 psi) to the leak test tool.

3. Spray soapy water on the seam where the insert and deck face meet. Spray the entire circumference of
the insert.

4. Inspect for bubbles around the outer diameter of the insert seam on the block face.

If bubbles are present, then remove the insert and investigate the root cause. Do not reuse the removed
insert.

3500 Sealed Insert

This section contains the procedures to install liner seat inserts in the cylinder blocks of 3500 Engines. See
Table 7 for recommended repair options.

Salvaging the 3500 engine block can be accomplished by removing damaged material and replacing the
material with a sealed insert. The sealed insert is a more robust repair option than a non-sealed insert. The
sealed insert design has critical advantages over the non-sealed insert design.

The sealed insert has a metal shim with an integral seal. The integral seal provides a rubber face seal to
prevent coolant leaks from occurring around the insert. Tighter press fit on the insert eliminates the need for
any bonding adhesive. The inserts are backwards compatible. If the block being salvaged was inserted in the
past, then one of the inserts available will be applicable.

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The liner seat inserts are made from stainless steel that provide corrosion resistance. Inserts that are made
from other materials are less resistant against fretting or corrosion.

Cylinder blocks that do not require an insert must have the top edge of the liner bore chamfered to accept the
352-6061 Liner Seal. The chamfer is needed to install the 352-6061 Liner Seal properly. The 353-5617 Insert
and 353-5618 Insert include a machined chamfer to accept the 352-6061 Liner Seal. Refer to the "Procedure
to Chamfer Liner Bores" section within this document for the procedure used to machine the chamfer.

If the 5P-4175 Counter-boring Tool Group is used to machine the counter-bore, refer to the " 5P-4175
Counterboring Tool Group" section of this guideline for instructions to use and adjust the tool group.

Note: Do not coat the 352-6061 Liner Seal in engine oil for installation. 5N-5561 Silicone Lubricant or
186-1528 Silicone Lubricant is used for lubrication. Refer to the appropriate Disassembly and Assembly
manual for additional assembly instructions.

NOTICE

Water ferrule inserts must be installed prior to the liner seat insert
counter-bore being cut. If the water ferrule inserts are installed after
the counter-bore is cut, then the counter-bore will distort.

Illustration 42 g03818628
Illustration of sealed insert

There are two insert diameter sizes available and both use the same integral sealed shim.

(A) Insert

(B) Integral Seal

The procedure to install the sealed insert involves counterboring the liner bore, cleaning the counter-bore,
installing the shim and insert, machining the liner bore and machining the top deck.

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1. Determine the size of the insert needed is standard or oversized. Blocks that have been salvaged
previously with the standard-size insert, can be salvaged with the 473-0494 Insert Kit (Oversize)
inserts.

Table 12
Previously Inserted Integral Seal Insert and Non-Sealed Insert Cross Reference
Insert Part Outside Serviced Using
Process
Number Diameter Sealed Inserts

Machine counter-bore to correct depth and


NA(1) NA 473-0493 diameter.
Refer to Table 13
Yes Machine counter-bore to correct depth and
212.115 mm
353-5617 diameter.
(8.3510 inch)
473-0494 Refer to Table 13

Yes
212.115 mm Machine counter-bore to correct diameter.
353-5618
(8.3510 inch) Refer to Table 13
473-0494
Yes(2) Inspect counter-bore for proper size and
212.370 mm
335-8971 reuse counter-bore if possible.Refer to
(8.3610 inch)
473-0494 Table 13-
(1) Never previously inserted blocks.
(2) If no additional machine work needs to be performed.

2. Freeze the inserts to aid in installation.

Note: Freeze the insert only, not the integral seal. A temperature difference of 90° C (195° F) between
the block and the insert will aid in installation to allow an easier slip fit of the insert into the counter-
bore.

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Illustration 43 g03817062
counter-bored 3500 cylinder block

Illustration 44 g06181051
Cross section of counter-bore
(A) Counter-bore Diameter
(B) Counter-bore Depth
(C) 0.8 mm (0.0312 inch) Radius

3. Counter-bore the liner bore.

Counter-bore the liner bore to the specifications given in Illustration 44 and Table 13. Ensure that the
surface texture for the counter-bore is kept at Ra 3.2 µm (125.98 µinch).

Table 13
Integral Seal Counter-Bore Dimensions

Counter-bore Diameter Counter-bore Depth


Part Number
(A) (B)(1)
473-0493 211.989 ± 0.025 mm 7.620 ± 0.025 mm
Insert Kit (Standard) (8.3460 ± 0.0010 inch) (0.3000 ± 0.0010 inch)
473-0494 212.238 ± 0.025 mm 7.620 ± 0.025 mm
Insert Kit (Oversize) (8.35581 ± 0.00098 inch) (0.3000 ± 0.0010 inch)
(1) The precise counter-bore depth can be calculated by combining the measured thickness of the insert and the thickness of

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the metal portion of the integral seal.

4. Clean the bore and deburr counter-bore. Remove any metal shavings from the counter-bore area and
use isopropyl alcohol to remove any oil or dirt residue.

Illustration 45 g03817069
Integrated seal installed.

5. Place the 433-4929 Integral Seal into the counter-bore.

6. Retrieve the frozen insert from the freezer and set onto the counter-bore.

Illustration 46 g03817087

7. Use appropriate tooling, orient the tooling onto the insert, and finger tighten the bolts.

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Illustration 47 g03817118
Install tooling will not contact the block face

8. Use an impact or socket driver with a crossing pattern tighten the four bolts evenly to press the insert
squarely into the counter-bore. Torque the four bolts to 200 N·m (150 lb ft)

Note: The tooling will sit proud of the block when fully pressed in. This design is to concentrate the
installation force onto the insert and to allow room for water ferrule inserts.

Illustration 48 g03817098
Inspect insert projection with tooling in place.

9. Leave the tooling in place, use the liner projection tooling to measure insert projection in the notches of
the tooling. The tooling applies pressure on top of the insert to replicate the cylinder head onto the
liner.

10. When all inserts have been installed, bore the inside diameter of the insert to be flush with the liner
bore.

11. Mill inserts flush with the top deck of the cylinder block.

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12. Reinstall the tooling and using the liner projection tooling check insert projection again for each bore.
This inspection ensures that the inserts have not shifted during the milling process.

Inserts installed in the field can be installed such that the insert does not require machining of the top deck.
Field installation requires measuring the deck height to verify the depth of the counter-bore.

Machining of the top deck is recommended when the entire block is being salvaged. Machining the top deck
ensures that the projection of the insert is within the correct specifications.

Machining the top deck has the following advantages:

Machining ensures that the correct flatness and insert projection are obtained.

Machining simplifies the salvage process by not requiring a tighter tolerance control and liner
projection measurement.

Machining removes pitting from the water ferrules and the liner flange which may be necessary.

Leak Test

If the top deck will be machined, the leak test must be conducted before and after machining.

Illustration 49 g06181057

1. Install the 373-5840 leak test tool in the bore.

2. Connect an air hose and apply 206.8 kPa (30.00 psi) to the leak test tool.

3. Spray soapy water on the deck where the liner insert and the deck face meet. Spray the entire
circumference of the insert.

4. Inspect for bubbles around the outer diameter of the insert on the block face. If no bubbles are
observed, repeat the test for the next cylinder.

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If bubbles are present, remove the insert and investigate the root cause.

Procedure to Chamfer Liner Bores

If the cylinder block does not have a liner bore chamfer, does not require liner seat inserts, or has previously
had installed non-chamfered stainless steel liner bore inserts, then the top deck edge of the bore for the liner
must be chamfered to accommodate the 352-6061 Liner Seal.

Machining Process

Illustration 50 g02603916
(1) Cutter

NOTICE

Cut the chamfer on the largest bore first. Locating the tool on the
largest bore first will minimize the possibility of having to readjust the
tooling and ensure that a uniform liner flange mounting surface is
maintained.

Note: Cleanliness of the upper liner bore is critical to ensure a proper cut.

1. Thoroughly clean the block deck face and upper liner bore before locating the cutter body and tool.

2. Check the diameter of the bore for out of roundness. The diameter of the upper liner bore is
199.000 + 0.040 mm - 0.025 mm (7.8346 + 0.0016 inch - 0.0010 inch). A distorted bore cannot be
chamfered.

3. Locate the tool at the bore. The plate should slide into the bore when located properly.

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4. Clamp the tool to the block. Tighten the bolts slowly and evenly to prevent the plate from becoming
cocked in the bore. The bolts should be tightened to 80.0 N·m (60.00 lb ft).

5. Retract the holder from the bore and install the cutter so that the edge with the angle will intersect the
top corner of the liner bore and the block deck face. When tightened, the cutter body will spin free.

Illustration 51 g02603921
(2) spacer

Illustration 52 g06181092
Example of optimal starting position.
(1) Cutter

6. Touch the cutting edge of the cutting tool off the corner of the upper liner bore and the block deck face.
Use a 2.00 ± 0.20 mm (0.079 ± 0.008 inch) shim or spacer (2) between the depth adjusting nut in place.
Remove the 2.00 ± 0.20 mm (0.079 ± 0.008 inch) shim or spacer (2) from tool once depth is set.

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Note: When setting the cutting tool off the edge of the liner bore, allow for 2.00 ± 0.20 mm
(0.079 ± 0.008 inch) of vertical travel.

Illustration 53 g02604016

7. Use a drill to run the tool until the tool reaches the present depth.

Note: Deburr any sharp edges. Use the 365-1197 Liner Brush to deburr the upper and lower edge.

Illustration 54 g06181095
(D) Angle of the chamfer
(E) Depth of the chamfer

Table 14
Chamfer Dimensions

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(D) 11° ± 1°
(E) 2.00 ± 0.20 mm (0.079 ± 0.008 inch)

Illustration 55 g02604097
Finished chamfer

Inspect the entire chamfer to ensure a uniform cut around the circumference of the bore. The chamfer should
maintain the proper depth around the circumference. If the chamfer is not even, the tool should be reset and
the chamfer should be cut again.

Note: There is no difference in performance or reliability between a straight chamfer and the counter-bore
found on the 353-5617 Insert, the 353-5618 Inserts, and the 335-8971 Insert. The counter-bore is used on the
353-5617 Insert, the 353-5618 Insert, and the 335-8971 Insert for mass production purposes.

Cylinder Block Lower Liner Bore Salvage Procedure for 3500


Engines
Salvage of the Lower Liner Bore

Note: Before performing the process review all the steps and ensure that the correct tooling and equipment is
available.

This section gives two methods that are used to salvage the cylinder block liner bores on 3500 Engines. The
first method uses a process that is known as step bore operation. A step, which is part of the cylinder block
casting, is created by machining an oversized bore in the cylinder block casting to a specified depth. A sleeve
is then inserted into the oversize bore and pressed against the step. The remaining step provides a positive
stop and ensures a good seal. The second method machines the oversize bore completely through the block
with no step. The sleeve is then retained by screws that are threaded into the sleeve and the cylinder block
casting. The second method involves machining an oversized bore in the block casting to accept a fabricated
sleeve. Two blind holes are drilled and tapped through the block and into the sleeve.

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Step Method

Illustration 56 g06181097
Sleeve and Step Method of salvage
(1) Block
(2) Sleeve

Illustration 57 g06441440
Machine the bore to specified dimensions.

Table 15
Engine Block Lower Repair Bore
Callout Dimensions

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(A) Ø 198.5 ± 0.25 mm (7.81495 ± 0.00984 inch). Use upper liner bore as a datum for all
Diameter of liner bore repairs. Probe at least 8 evenly spaced points on bore to establish an
Upper Liner accurate bore center line. Clean and inspect beforehand to ensure that there is no
Bore debris or damage to the bore.

(B)
Diameter of Ø 197.83 ± 0.12 mm (7.789 ± 0.005 inch).
Lower Repair Surface texture - < 2.5 µm (98.42520 µinch Ra) and <16 µm (629.9213 µinch Rz)
Bore
(C)
Counter-Bore R 0.5 mm (0.01969 inch) MAX
Radius

(D)
Step of Lower 3.00 mm (0.118 inch)
Repair Bore

The lower liner bore seal repair procedure consists of:

CMM dimensional checks/measurements

Machining the bore of the lower liner for the repair sleeve

Cleaning of counterbore

Installing the repair sleeve into the counterbore

Machining the sleeve to print specifications

Refer to Illustration 57 and Table 15 to machine the counterbore for the lower liner sleeve into the cylinder
block. Ensure the liner bore (A) and (B) are concentric to the liner bore diameter. The preferred process for
machining the counterbore is with a CNC machine.

Note: Before any machining is started, ensure that calibration has been performed on your equipment. Refer
to your manufactures owner's manual for determination of instruments, equipment, and test devices according
to industrial requirement.

1. Establish X/Y/Z axis and ensure that engine block is square on machine.

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Illustration 58 g06433131

2. Clean and inspect beforehand to ensure that there is no debris or damage to the bore. Use the individual
upper liner bore (A) as a datum for machining each individual cylinder you intend to repair. Probe at
least 8 evenly spaced points on bore to establish an accurate bore center for each individual cylinder
bore center line. Datum (A) must be established and then extended down, use this as the center line for
locating and aligning the step bore for the lower liner bore repair sleeve and especially for finishing ID
after bore repair sleeve is installed.

3. Ensure to plug all cylinder head bolt holes before starting. Failure to plug holes will allow machining
chips, turnings etc. to fill the cylinder bolt holes.

Note: If bolt holes are not cleaned, thread damage will occur.

4. Use boring tooling with a radius of 0.5 mm (0.01969 inch) max, machine bore diameter (B), and Step
(D). Refer to Table 15 and Illustration 57.

5. Ensure that the surface texture is < 2.5 µm (98.42520 µinch Ra) and < 16 µm (629.9213 µinch Rz). No
tool drag marks allowed on diameter.

6. Cat® does not manufacture a direct replacement part for the lower sleeve. The material must be
machined from adequate sized, fully compatible, general-purpose gray iron casting respectively. Their
size, circularity, free shape, Rz, Ws, and Wt characteristics are critical and must be controlled to
exacting tolerances. Refer to specifications in Illustration 59 and Table 16.

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Illustration 59 g06441454
Lower Repair Sleeve

Table 16
Dimensions for Machining the Sleeve

Item Dimension

Actual engine block bore diameter + 0.20 ± 0.05 mm (0.008 ± 0.002 inch)
(E) interference fit.
Outer Diameter Surface texture - < 2.5 µm (98.42520 µinch Ra) and < 16 µm
(629.9213 µinch Rz)
(F)
2.54 mm (0.100 inch)
Sleeve Thickness
(G)
36.00 mm (1.420 inch)
Sleeve Height

(H)
0.80 mm (0.030 inch)
Chamfer

(J)
Angle of 45° ± 1°
Chamfer

7. Chuck the cut stock into a lathe and machine the outer diameter of the sleeve to produce a
0.20 ± 0.05 mm (0.008 ± 0.002 inch) interference fit (E) into the bored hole.

Rough cut passes will remove 3.81 mm (0.15 inch) of stock per pass. Keep the temperature as
cool as possible when rough cutting stock to maintain roundness requirements.

Finish cut passes will remove 0.254 mm (0.01 inch) of stock per pass.

Surface texture - < 2.5 µm (98.42520 µinch Ra) and < 16 µm (629.9213 µinch Rz). No tool drag
marks allowed on diameter.

Finish facing part width, stock removal will remove 0.0508 mm (0.002 inch) of stock per pass.

8. Machine a 0.80 mm (0.030 inch) chamfer (H) at 45° on outside edge. Refer to Illustration 59.

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9. Measure for run out on the lathe before finish sleeve is parted from parent stock.

Illustration 60 g06367866

10. Once part is off the lathe in free state, use a micrometer and measure the OD of the sleeve. Measure 4
evenly spaced points on the sleeve and average the measurements. Ensure it does not exceed actual
bore diameter + 0.254 mm (0.01 inch).

11. Machine the sleeve height (G) 36.00 mm (1.420 inch) to allow for blending.

Illustration 61 g06431712
Example of lower liner bore cleaning .

12. Thoroughly clean the sleeve and the counterbore with a lint free towel and isopropyl alcohol, until all
oils and debris are removed and nothing more comes off onto a clean section of the towel.

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Illustration 62 g06431719
Example of lower liner bore drying.

13. Dry the surfaces with clean dry air, verify that the sleeve and the counterbore are dry.

Note: There cannot be any foreign material in the counterbore or on the sleeve.

14. Ideally cylinder bore axis will be oriented parallel to the vertical.

15. Ensure the tip of the Loctite® 620 bottle is clean.

Illustration 63 g06431729

a. Using a new clean brush liberally apply Loctite® 620 around 100% of the counterbore surface
only, there should be no dry area of the counter bore wall after application.

Note: The sleeve must be installed within 2 minutes of applying the Loctite® to the counterbore.

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This time limit will ensure that the debris will not adhere to Loctite and contaminate the joint.

16. Ensure that sleeves are cleaned prior to freezing, lower the temperature of the sleeve to −85° C
(−121° F) to ease in assembly. Sleeve must be installed within half a minute of removing from freezer.

Illustration 64 g06431736

17. Using clean gloves, install sleeve with the chamfer toward the cylinder block.

18. Ensure that sleeve is evenly pressed squarely into the counter-bore and fully seated.

19. The Loctite® should extrude along the entire inner circumference of the bore between the sleeve and
the bottom of the counterbore.

Note: If the Loctite® is not extruded along the entire circumference, then the sleeve must be removed
and the installation procedure must be repeated with a new sleeve.

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Illustration 65 g06368427

20. Use an 9U-6182 Inspection Mirror and a 0.025 mm (0.001 inch) feeler gauge to check for space
between the bottom of the counterbore and the sleeve. Check around the entire circumference. If the
feeler gauge goes into the joint, then the sleeve is not properly seated.

Note: Perform this step within 5 minutes of applying the Loctite® to prevent the Loctite® from
hardening before the feeler gauge can be inserted into the gap.

If the feeler gauge can be inserted at any point along the circumference:

Remove the sleeve

Investigate the cause for the sleeve not properly seating.

Correct the cause (Cleaning, foreign material removal, or excessive Loctite® removal).

Repeat the installation procedure.

21. Remove the excess Loctite® using a clean lint free towel.

22. Allow at least 8 hours for curing before proceeding to final machining and wash operations.

23. Final machining can be done after verifying that sleeve is properly seated.

Illustration 66 g06441491

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Table 17
Engine Block Actual Dimensions
Callouts Dimensions

(A)Diameter of Upper Liner Ø 198.5 ± 0.25 mm (7.81495 ± 0.00984 inch). Ensure runout from
Bore (A) to (P) within 0.15 mm (0.00591 inch) max.
(K)Angle of Chamfer 30°
(L)Diameter of Lower Liner Ø 193.65 ± 0.05 mm (7.624 ± 0.002 inch).
Bore Surface Texture 3.2 µm (125.98 µinch) Ra
Ø 199.9 ± 0.5 mm (7.87006 ± 0.01969 inch)
(M)Diameter of Chamfer
Surface Texture 5.5 µm (216.54 µinch) Ra
Ensure that (P) lower bore is perpendicular with top deck within
(N)Top Deck Surface
0.03 mm (0.00118 inch).
(P)Depth of Chamfer from
239.0 ± 0.3 mm (9.40943 ± 0.01181 inch)
Head Deck Surface.

24. Machine inside diameter of sleeve to Ø 193.65 ± 0.05 mm (7.624 ± 0.002 inch) (L). Ensure to maintain
the surface texture of 3.2 µm (125.98 µinch) Ra. Make sure that the repair sleeve has zero movement
relative to the block.

25. Refer to Table 17 and Illustration 66, and machine the chamfer, depth, and diameter on top of the
sleeve ensuring to maintain the surface texture of 5.5 µm (216.54 µinch) Ra for proper liner o-ring
assembly.

26. Use 4C-6329 Flex Hone to remove burrs or sharp corners from the sleeve after machining.

27. After the 8 hours of cure time has elapsed and while performing the final wash ensure that the
temperature does not increase over 100° C (212° F). The Loctite® can degrade and result in leaks.

Pin Method

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Illustration 67 g01919894
Sleeve and Pin Method of salvage
(1) Block
(2) Sleeve
(3) Screw (pin)

Illustration 68 g06441501
Machine the bore to specified dimensions.

Table 18
Engine Block Lower Repair Bore
Callout Dimensions

(A) Ø 198.5 ± 0.25 mm (7.81495 ± 0.00984 inch). Use upper liner bore as a datum for all
Diameter of liner bore repairs. Probe at least 8 evenly spaced points on bore to establish an

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Upper Liner accurate bore center line. Clean and inspect beforehand to ensure that there is no
Bore debris or damage to the bore.
(R)
Diameter of 201.00 ± 0.12 mm (7.913 ± 0.005 inch).
Lower Repair Surface texture - < 2.5 µm (98.42520 µinch Ra) and <16 µm (629.9213 µinch Rz)
Bore

The lower liner bore seal repair procedure consists of:

CMM dimensional checks/measurements

Machining the bore of the lower liner for the repair sleeve

Cleaning of counterbore

Installing the repair sleeve into the counterbore

Machining the sleeve to print specifications

Refer to Illustration 68 and Table 18 to machine the counterbore for the lower liner sleeve into the cylinder
block. Ensure the liner bore (D) and (L) are concentric to the liner bore diameter. The preferred process for
machining the counterbore is with a CNC machine.

Note: Before any machining is started, ensure that calibration has been performed on your equipment. Refer
to your manufactures owner's manual for determination of instruments, equipment, and test devices according
to industrial requirement.

1. Establish X/Y/Z axis and ensure that engine block is square on machine.

Illustration 69 g06433131

2. Clean and inspect beforehand to ensure that there is no debris or damage to the bore. Use the individual
upper liner bore (A) as a datum for machining each individual cylinder you intend to repair. Probe at

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least 8 evenly spaced points on bore to establish an accurate bore center for each individual cylinder
bore center line. Datum (A) must be established and then extended down, use this as the center line for
locating and aligning the step bore for the lower liner bore repair sleeve and especially for finishing ID
after bore repair sleeve is installed.

3. Ensure to plug all cylinder head bolt holes before starting. Failure to plug holes will allow machining
chips, turnings etc. to fill the cylinder bolt holes.

Note: If bolt holes are not cleaned, thread damage will occur.

4. Machine bore diameter (R). Refer to Table 18 and Illustration 68.

5. Ensure that the surface texture is < 2.5 µm (98.42520 µinch Ra) and < 16 µm (629.9213 µinch Rz). No
tool drag marks allowed on diameter.

6. Cat® does not manufacture a direct replacement part for the lower sleeve. The material must be
machined from adequate sized, fully compatible, general-purpose gray iron casting respectively. Their
size, circularity, free shape, Rz, Ws, and Wt characteristics are critical and must be controlled to
exacting tolerances. Refer to specifications in Illustration 70 and Table 19.

Illustration 70 g06441517
Lower Repair Sleeve

Table 19
Dimensions for Machining the Sleeve

Item Dimension

(S)
42.00 mm (1.650 inch)
Sleeve Height

(T)
4.06 mm (0.160 inch)
Sleeve Thickness

Actual engine block bore diameter + 0.20 ± 0.05 mm (0.008 ± 0.002 inch)
(U) interference fit.
Outer Diameter Surface texture - < 2.5 µm (98.42520 µinch Ra) and < 16 µm
(629.9213 µinch Rz)

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(V)
0.80 mm (0.030 inch)
Chamfer
(W)
Angle of 45° ± 1°
Chamfer

7. Chuck the cut stock into a lathe and machine the outer diameter of the sleeve to produce a
0.20 ± 0.05 mm (0.008 ± 0.002 inch) interference fit (U) into the bored hole.

Rough cut passes will remove 3.81 mm (0.15 inch) of stock per pass. Keep the temperature as
cool as possible when rough cutting stock to maintain roundness requirements.

Finish cut passes will remove 0.254 mm (0.01 inch) of stock per pass.

Surface texture - < 2.5 µm (98.42520 µinch Ra) and < 16 µm (629.9213 µinch Rz). No tool drag
marks allowed on diameter.

Finish facing part width, stock removal will remove 0.0508 mm (0.002 inch) of stock per pass.

8. Machine a 0.80 mm (0.030 inch) chamfer (V) at 45° on outside edge. Refer to Illustration 70.

9. Measure for run out on the lathe before finish sleeve is parted from parent stock.

Illustration 71 g06367866

10. Once part is off the lathe in free state, use a micrometer and measure the OD of the sleeve. Measure 4
evenly spaced points on the sleeve and average the measurements. Ensure it does not exceed actual
bore diameter + 0.254 mm (0.01 inch).

11. Machine the sleeve height (S) 42.00 mm (1.650 inch) to allow for blending.

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Illustration 72 g06431712
Example of lower liner bore cleaning .

12. Thoroughly clean the sleeve and the bore with a lint free towel and isopropyl alcohol, until all oils and
debris are removed and nothing more comes off onto a clean section of the towel.

Illustration 73 g06431719
Example of lower liner bore drying.

13. Dry the surfaces with clean dry air, verify that the sleeve and the bore are dry.

Note: There cannot be any foreign material in the bore or on the sleeve.

14. Ideally cylinder bore axis will be oriented parallel to the vertical.

15. Ensure the tip of the Loctite® 620 bottle is clean.

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a. Using a new clean brush liberally apply Loctite® 620 around 100% of the bore surface only,
there should be no dry area of the bore wall after application.

Note: The sleeve must be installed within 2 minutes of applying the Loctite® to the bore. This
time limit will ensure that the debris will not adhere to Loctite and contaminate the joint.

16. Ensure that sleeves are cleaned prior to freezing, lower the temperature of the sleeve to −85° C
(−121° F) to ease in assembly. Sleeve must be installed within half a minute of removing from freezer.

Illustration 75 g06431736

Illustration 76 g01927674
Example of installed sleeve.

17. Using clean gloves, install sleeve with the chamfer toward the cylinder block.

18. Remove the excess Loctite® using a clean lint free towel.

19. Allow at least 8 hours for curing before proceeding to final machining and wash operations.

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20. Machine the sleeve so that the sleeve is flush with the bottom of the bore.

Illustration 77 g01927694

21. Secure the sleeve from the bottom side of the block in two places that are 180° from each other. Use
two 1/4 × 20 Allen Head Screws with 25.0 mm (1.00 inch) long threads and Loctite®. Refer to
Illustration 77.

22. Drill and tap screw holes with 2/3 of the hole into the block and 1/3 into the new sleeve. The depth of
the hole should be approximately 22.0 mm (0.87 inch) deep.

23. After screws are installed and tight, remove the screw head by cutting or grinding.

24. Blend the surface of the screw into the block and sleeve using a blunt ended tool with a 0.79 mm
(1/32 inch) diameter and a pneumatic hammer. This will produce the appearance of a rough casting to
the repaired area.

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Illustration 78 g06441491

Table 20
Engine Block Actual Dimensions

Callouts Dimensions
(A)Diameter of Upper Liner Ø 198.5 ± 0.25 mm (7.81495 ± 0.00984 inch). Ensure runout from
Bore (A) to (P) within 0.15 mm (0.00591 inch) max.
(K)Angle of Chamfer 30°

(L)Diameter of Lower Liner Ø 193.65 ± 0.05 mm (7.624 ± 0.002 inch).


Bore Surface Texture 3.2 µm (125.98 µinch) Ra
Ø 199.9 ± 0.5 mm (7.87006 ± 0.01969 inch)
(M)Diameter of Chamfer
Surface Texture 5.5 µm (216.54 µinch) Ra
Ensure that (L) lower bore is perpendicular with top deck within
(N)Top Deck Surface
0.03 mm (0.00118 inch).

(P)Depth of Chamfer from


239.0 ± 0.3 mm (9.40943 ± 0.01181 inch)
Head Deck Surface.

25. Machine inside diameter of sleeve to Ø 193.65 ± 0.05 mm (7.624 ± 0.002 inch) (L). Ensure to maintain
the surface texture of 3.2 µm (125.98 µinch) Ra. Make sure that the repair sleeve has zero movement
relative to the block.

26. Refer to Table 20 and Illustration 78, and machine the chamfer, and diameter on top of the sleeve
ensuring to maintain the surface texture of 5.5 µm (216.54 µinch) Ra for proper liner o-ring assembly.

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27. Use 4C-6329 Flex Hone to remove burrs or sharp corners from the sleeve after machining.

28. After the 8 hours of cure time has elapsed and while performing the final wash ensure that the
temperature does not increase over 100° C (212° F). The Loctite® can degrade and result in leaks.

Repairing the Hole for the Main Bearing Bolt


The threaded holes in the main bearing bore of cylinder blocks can be damaged during an engine rebuild.
Damaged threads can cause improper torque of the main bearing bolts, resulting in possible cylinder block
and crankshaft failure. Bolt holes can be repaired back to the original functionality by using this repair
procedure with the threaded insert.

Nomenclature

Illustration 79 g06304407
Modified 8H-8559 Extension Assembly
(G) Three flats that are equally spaced

1. Remove the male square drive end (7) of the extension to the specified length that is given in Table 21.

2. Machine the extension to rest of the dimensions in Table 21.

3. Machine three equally spaced flats (6) on the end of the extension. Refer to Illustration 79.

Table 21
Modified 8H-8559 Extension Assembly
Item Dimension

(A) New length 127.0 mm (5.00 inch)

(B) 50.8 mm (2.00 inch)

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(C) 38.1 mm (1.50 inch)


(D) 0.8 mm (0.03 inch) by 45° C/R

(E) Diameter 12.7 + 0.0 - 0.3 mm (0.50 + 0.00 - 0.01 inch)

Illustration 80 g01637471
The tools are for 3500 series engines. Refer to Table 22 and Table 23 for identification.

Table 22
Thread Repair Tooling
(Late 3500 Series Engines with 22.23 mm (0.875 inch) bolt thread)

Item Quantity Part Number Description


1 1 178-2351 Reamer

Tap
2 1 178-2353
First Operation
Tap
3 1 178-2356
Second Operation
4 1 178-2467 Installation Sleeve

5 1 178-2503 Threaded Insert

Table 23
Thread Repair Tooling
Early 3500 Series Engines with 19.05 mm (0.750 inch) bolt thread
Item Quantity Part Number Description

1 1 178-2462 Reamer
Tap
2 1 178-2463
First Operation

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Tap
3 1 178-2465
Second Operation
4 1 178-2468 Installation Sleeve

5 1 178-2502 Threaded Insert

Repair Procedure

Note: Tapping the holes is performed by using two separate taps. Refer to Table 22 and Table 23 for the
correct taps.

Illustration 81 g01638134

1. Insert the reamer in the damaged main bearing hole.

Illustration 82 g06304409
Ream damaged bolt hole.

Note: Reaming will be easier and quieter if cutting oil or a lightweight lubricating oil is sprayed into
the hole at regular intervals.

2. Secure the modified end of the 8H-8559 Extension Assembly into the chuck of the 12.7 mm
(0.50 inch) variable speed drill and then tighten.

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3. The internal square end of the extension should be connected to the external square drive of the reamer.

4. Use a slow rotational speed to start reaming the damaged threads. Feed the reamer with moderate
pressure.

5. After reaming to a depth of 25.4 mm (1.00 inch), stop the drill and remove the reamer.

6. Clean all chips and shavings from the hole by using compressed air. Continue reaming to the bottom of
the hole. Remove the reamer and thoroughly clean all chips and shavings from the hole.

NOTICE

To avoid damage to the tooling, keep the reamer flutes free from metal
shavings.

Illustration 83 g01638142
Chamfer the bolt hole.

7. Chamfer the hole by using a tool for metal chamfering or by using the 4C-3845 Grinding Wheel.

8. Clean all chips and shavings from the hole by using compressed air.

Illustration 84 g01638140
Thread the hole with the thread tap.

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9. By using a handle for a tap, socket extension, tapping fluid or cutting oil, and the first tap, thread the
hole until the pilot at the end of the tap bottoms.

10. Remove the tap for the first operation.

11. Clean all chips and shavings from the hole by using compressed air. Tap the hole by using the second
tap.

12. Clean all remaining chips and shavings from the hole.

13. Clean the internal threads by using 138-8441 Brake Cleaner.

14. Dry the threads by using compressed air.

15. View the threaded hole by using a flashlight to ensure that there are no remaining chips.

Illustration 85 g01638273
(4) Installation sleeve

16. With the hex end of the installation sleeve (4), thread the installation sleeve (4) onto a clean main
bearing bolt. Thread the installation sleeve (4) to the end of the threads. Then loosen the installation
sleeve about one-half to three-fourths of a turn.

Illustration 86 g01638275
(5) Threaded Insert

17. Start threading the threaded insert (5) onto the same main bearing bolt. Refer to illustration 86.

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18. Thread the threaded insert until the insert contacts the sleeve. Refer to illustration 87.

19. Ensure that there is a snug fit between the insert and the sleeve. There must be a snug fit between the
insert and the sleeve.

20. Clean the threads on the outside diameter of the insert with 169-5464 Quick Cure Primer and allow the
threads to dry.

Illustration 87 g01638278
Sleeve and threaded insert

21. Coat the threads on the outside diameter of the insert with 154-9731 Thread Lock Compound.

Illustration 88 g06304411

22. Screw the threaded insert into the block to the bottom of the tapped hole. Use a wrench in the hex of
the installation sleeve. The installation sleeve should be tightened an additional thirty degrees.

Note: Once the insert is started in the block, continue the installation until the insert is seated at the
bottom of the hole. Failure to install the insert without stopping will cause the insert to become stuck.

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Illustration 89 g01638648

23. Loosen the installation sleeve without allowing movement of the main bearing bolt. Then, remove the
bolt.

24. Use a file or a stone to remove any burrs or high spots from the mating surface of the block.

Cylinder Block Salvage Tooling


Water Ferrule Template

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Illustration 90 g06181376
This template will help locate the areas needing rework on the block.
(a) Drill Ø 28.58 ± 0.03 mm (1.12519 ± 0.00118 inch) 4 HOLES Marked with (an s). Press bushing flush with bottom surface.
(1) Two ROLL PINS Ø 9.52 mm (0.37480 inch)
(2) Drill (4) Bushings ANSI P-78-12-.8125
(3) Plate of 1018 Steel
(4) Drill Bushing ANSI P-96-12-1.1875
(AA) Square plate 305 ± 3 mm (12.00 ± 0.12 inch) each side
(AB) Plate Thickness 12.7 mm (0.50 inch)
(AC) Roll Pin Protrusion 15 mm (0.59 inch) MAX
(AD) Bushing thickness 19.1 mm (0.75 inch)
(A) 200.0 ± 0.3 mm (7.87 ± 0.01 inch)
(B) 105.0 ± 0.3 mm (4.13 ± 0.01 inch)
(C) 52 ± 1 mm (2.05 ± 0.04 inch)
(D) 54.5 ± 0.8 mm (2.15 ± 0.03 inch)
(E) 11.5 ± 0.3 mm (0.45 ± 0.01 inch)
(F) 16.7 ± 0.3 mm (0.61 ± 0.01 inch)
(G) 90.0 ± 0.3 mm (3.54 ± 0.01 inch)
(H) 100 ± 3 mm (3.94 ± 0.11 inch)
(I) 145.5 ± 0.8 mm (5.73 ± 0.03 inch)
(J) 188.5 ± 0.3 mm (7.42 ± 0.01 inch)
(K) 216.7 ± 0.3 mm (8.53 ± 0.01 inch)

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(A1) 32 ± 1 mm (1.26 ± 0.04 inch)


(B1) 35.8 ± 0.3 mm (1.41 ± 0.01 inch)
(C1) 132.0 ± 0.3 mm (5.20 ± 0.01 inch)
(D1) 204.5 ± 0.3 mm (8.05 ± 0.01 inch)
(E1) 230.0 ± 0.8 mm (9.06 ± 0.03 inch)
(F1) 236.7 ± 0.3 mm (9.32 ± 0.01 inch)

Liner Bore Inspection Tool

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Illustration 91 g06181381
All measurements shown are in millimeters.

Counter-bore Tool Group

5P-4175 Counterboring Tool Group

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This section includes a procedure to rework the base of the tool group, if necessary. Basic maintenance items
are also included to keep the tool working properly. This section also contains a procedure to check the
accuracy of the tool group.

Illustration 92 g01628368
Nomenclature for 5P-4175 Counterboring Tool Group

Table 24
5P-4175 Counterboring Tool Group
Item Part Number Description

1 5P-4175 Counterboring Tool Group

2 8H-3127(1) Bolt
3 5P-1629(1) Drive Group

- 5P-1628(2) Drive As
- 5P-1627(2) Sprocket

- 4B-9806(2) Socket Setscrew

4 5P-1631(1) Chain As
5 6V-2120(1) Sprocket

6 5P-1630 Drive Adapter


- 6V-4984 Setscrew
(1) Part of 5P-4175 Counterboring Tool Group
(2) Part of 5P-1629 Drive Group

Modifying the Base Adapter for the Tool Group

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The base of the boring tool may require modification to permit clearance for the tool holder that is used on
3500 Engines. 5P-4175 Counterboring Tool Group with a serial number of 150-Up has already been modified
so this procedure is not necessary.

1. Scribe a mark on the drive assembly and the base adapter to make sure that the base is reinstalled in the
original position.

2. Remove the base adapter from the drive assembly.

Illustration 93 g02666138
Enlarge diameter (AB) of the base adapter to 231.6 mm (9.12 inch).

3. Turn over the base adapter and make the bore larger according to the dimensions in Illustration 93.

4. Check the bottom surface of the base adapter and remove any nicks or burrs.

5. Align the scribe marks and install the base adapter in the original position on the drive assembly.

Illustration 94 g01637219
(1) Plate
(2) Boring tool
(3) Nut and washer

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6. Assemble plate (1) on boring tool (2). Make sure that the slot on the plate is down and that the pilots on
the boring tool and on the plate are clean.

7. Install the washer and nut (3). Tighten the nut to 70 ± 7 N·m (50.0 ± 5.0 lb ft).

Maintenance of the Drive Assembly

Illustration 95 g01637245
(1) Plate
(2) Boring tool
(4) Knob
(5) Oil level plug

1. Remove plug (5) and check the oil level in the hydraulic unit.

Note: Boring tool group (2) must be in the horizontal position to check the oil level.

2. If necessary, fill the unit with oil and install plug (5). The correct oil for this tool is SAE 10, SAE 20, or
SAE 30 oil.

3. Loosen knob (4) to release the control valve and move plate (1) in and out.

4. Remove plug (5) and check the oil level again. Fill with oil, if necessary.

Note: If the oil level is low or the drive chain is loose, the tool will not cut smoothly.

5. Tighten knob (4).

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Illustration 96 g01637312
(1) Plate
(6) 6V-4984 Setscrew

6. Check the adjustment of 6V-4984 Setscrew (6).

a. To adjust the setscrew, tighten adjustment screw (6).

b. Loosen setscrew (6) by one quarter turn.

c. If installation of plate (1) is difficult, inspect setscrew (6) for damage. The setscrew should be
replaced if the setscrew is worn.

Note: The tool will also drag if plate (1) is worn. Inspect inside of the plate and install a new
plate, if necessary.

Check the Accuracy of 5P-4175 Counterboring Tool Group

The liner seat inserts are precisely machined so the counter-bore in the top deck must be parallel to the top of
the cylinder block within 0.03 mm (0.001 inch). Follow this procedure to check the accuracy of 5P-4175
Counterboring Tool Group. The tool should be checked at specific intervals to maintain accuracy. Also, check
the tension of the drive chain during the inspection.

Note: The top deck of the cylinder block and the edge of the cylinder that will be counter-bored must be free
of debris, carbon buildup, and burrs before the tool group is installed on the cylinder block.

The accuracy of the boring tool can be done on any cylinder block if the top deck is in good condition or the
top deck is ground smooth and flat. The top deck must be smooth and flat to make sure that all depth
measurements are correct. All the adjustments and settings in this procedure must be made according to the
bore size of the cylinder block that is used for the accuracy check.

Illustration 97 g01637322

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(1) Plate
(2) Boring tool
(4) Knob

1. Position boring tool (2) on the cylinder block.

2. Release control knob (4) so plate (1) will go into the pilot bore of the cylinder liner.

Illustration 98 g01637327
(7) 4C-6548 Stud
(8) 6B-6682 Full Nut
(9) 5P-1769 Washer

3. Use 4C-6548 Stud (7) with 5P-1769 Washer (9) and 6B-6682 Full Nut (8) to fasten the boring tool to
the cylinder block. Tighten the nuts to 70 ± 7 N·m (50.0 ± 5.0 lb ft).

Note: The tool holder must rotate freely after the nuts are tightened.

4. Move up plate (1) into the base plate and lock the plate in place with control knob (4).

5. Set the cutting tool to the correct diameter.

Illustration 99 g01637338
(10) Cutter
(11) Base and micrometer
(12) Micrometer

a. Install 4C-6561 Master Gauge into the base and micrometer (11). The base and micrometer are

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part of 9U-7986 Micrometer Depth Gauge Gp.

b. Adjust micrometer (12) until the stem is against the master gauge.

c. Remove the master gauge and install cutter (10).

d. Adjust the cutter to a diameter that is 0.13 mm (0.005 inch) larger than the measured diameter of
the bore.

Illustration 100 g01637414

6. Clean slot (13) in the plate.

Illustration 101 g01637377

7. Install cutter (10) and tighten screw (14).

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Illustration 102 g01637380

8. Carefully loosen knob (4) and move down the cutter until cutter (10) is against the top deck of the
cylinder block.

Illustration 103 g01637383

9. Put a 0.08 mm (0.003 inch) feeler gauge under adjusting nut (15). Adjust nut (15) so the nut is against
the feeler gauge. Then, tighten bolt (16) to hold the adjusting nut in position.

10. Lift the plate so the cutter is approximately 1.5 mm (0.06 inch) above the top face of the cylinder
block. Close the control valve.

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Illustration 104 g01637396

11. Use a heavy-duty industrial drill and 5P-1630 Drive Adapter (17) to operate the boring tool. Remove
the feeler gauge and start the cut.

Illustration 105 g01637537

12. Stop the cutter immediately when adjustment nut (15) contacts the positive stop.

13. Loosen knob (4) and lift the plate. Then, tighten knob (4) to hold the plate in the up position.

14. Scribe an alignment mark to locate the tool group in relation to the position on the cylinder block.
Then, remove the boring tool from the cylinder block.

15. Use 8T-0455 Liner Projection Tool Group to check the depth of the cut in four locations around the
counter-bore.

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16. If all the measurements in Step 15 are not within 0.03 mm (0.001 inch), refer to the "Adjustment of the
Counterboring Tool Group" section of this guideline. If all the measurements are within 0.03 mm
(0.001 inch), the boring tool is ready to machine the cylinder blocks.

Adjustment of the Counterboring Tool Group

Illustration 106 g01637542

1. When the deepest location of the counter-bore is known, install the counterboring tool group on the
cylinder block. The tool must be installed in the original position.

2. Thoroughly clean housing group (19) and base adapter (20).

3. Loosen four bolts (18) that fasten the housing to the base adapter.

Illustration 107 g01637543

4. Install shims (21) between housing (19) and base adapter (20) next to the deepest point of the counter-
bore. The shims must be put on each side of a bolt or the shim must have a hole for the bolt.

Note: Shims must be installed with complete contact between the surfaces of housing (19) and base
adapter (20).

Note: A shim with thickness of 0.03 mm (0.001 inch) will normally change the depth of cut
approximately 0.05 mm (0.002 inch).

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5. Repeat the procedure in the "Check the Accuracy of 5P-4175 Counterboring Tool Group" section to
recheck the accuracy of the boring tool.

6. Continue to add shims if the depth of cut is not within 0.03 mm (0.001 inch).

Note: Before any machining is performed, the diameter of the bores and the flange thickness of the
liner seat insert should be verified.

Tool Modifications

Modification to the 8T-2682 Plate

Illustration 108 g06181395

Illustration 109 g06181400


View AA
(AC) Slot for clearance of cutter 12.7 mm (0.50 inch)

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Illustration 110 g02603817


Plate that has been modified
(AC) Slot for clearance of cutter 12.7 mm (0.50 inch)

The 8T-2682 Plate will need to be modified sometimes when the cutter does not fit. This modification will
allow the 6V-2025 Cutter Assembly to slide deeper into the cutter slot.

The slot (AC) should be 12.7 mm (0.50 inch) wide. The slot should be 12.7 mm (0.50 inch) deep. This slot
can be enlarged with a 12.7 mm (0.50 inch) end mill.

Modification to the 6V-2025 Cutter Assembly

Illustration 111 g02603841

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Illustration 112 g06181403


(AD) 8.00 ± 0.50 mm (0.315 ± 0.020 inch)
(AE) 11° ± 1°

The cutter will also have to be modified to chamfer the block properly. The modifications to the 6V-2025
Cutter and the 8T-2682 Plate are detailed in FT drawing FT-3166 Tool Assembly.

Note: The modified 6V-2025 Cutter can be used on previously installed non-chamfered stainless steel liner
bore inserts. The cutter may wear at an accelerated rate in this case.

Always check the condition of the cutter before use to ensure proper performance.

Specifications and Salvage for Spacer Plates


Once the spacer plate is removed from the engine compare the spacer plate to the measurements in this
section. Then compare the spacer plate to the types of damage that are shown in this section. If the type of
wear or damage to the spacer plate is not shown to be reusable, then do not use the spacer plate again.

General Information

The 110-6994 Spacer Plate is needed with the 118-9494 Cylinder Liner that has a larger diameter of the
flange.

Because the spacer plate is made out of aluminum, the spacer plate requires special handling to prevent
damage.

The 110-6994 Spacer Plate replaced the 9Y-1485 Spacer Plate that replaced the 8N-6864 Spacer Plate. The
118-9494 Cylinder Liner is replacing the 110-6993 Cylinder Liner that replaced the 8N-6861 Cylinder Liner.

Nomenclature

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Illustration 113 g01493683


Spacer Plate for 3500 Engines.

Table 25
Spacer Plate
Hole Quantity Description

1 2 Dowel Hole
2 4 Large Water Port

3 4 Small Water Port

4 8 Large Bolt Hole


5 1 Oil Supply Hole

6 2 Small Bolt Hole


7 1 Follower Pocket

General Procedure

These instructions must be followed in sequence to determine if a spacer plate is reusable.

1. Make a visual check of the general condition of the spacer plate and look for obvious damage to the
spacer plate.

2. Clean the spacer plate thoroughly.

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3. After cleaning the spacer plate, visually inspect the spacer plate for cracks, corrosion, erosion, and
other damage.

Plate Thickness

Table 26
Plate Thickness
Part
Thickness Minimum Thickness Surface Texture
Number

12.313 ± 0.025 mm 12.288 mm


110-6994 N/A
(0.4848 ± 0.0010 inch) (0.4838 inch)
12.333 ± 0.025 mm 12.308 mm
362-9677 N/A
(0.4856 ± 0.0010 inch) (0.4846 inch)
Ra 1.6 µm
12.363 ± 0.025 mm 12.338 mm (62.99213 µinch)
519-7297
(0.48673 ± 0.00098 inch) (0.48575 inch) Rz 18.0 µm
(708.6614 µinch)

Initial Inspection

Before cleaning the spacer plate, make a quick visual inspection for bending, scratches, deep cuts, heat, and
impact damage. Do not reuse any spacer plate that has the following.

Cracks with spalling of material

Burned path from exhaust gas leakage with measurable width and depth in any area

Illustration 114 g01493684


Bent spacer plate or warped spacer plate

Do not use the part again.

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Illustration 115 g01493685


Impact damage to the edge of the spacer plate affects the thickness of the spacer plate and the sealing capability of oil.

Do not use the part again.

Illustration 116 g01493686


Deep cut (8) between large bolt hole (4) and the hole for the clearance of the cylinder liner.

Do not use the part again.

Illustration 117 g01493687


The illustration shows a deep cut (9) around the large water port (2).

Do not use the part again.

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Cleaning Aluminum Spacer Plates

The aluminum spacer plate requires more care during handling and cleaning. Extra care will prevent damage
to the spacer plates, and extra care will also retain reusability. Recommended materials for cleaning are brake
cleaner solvent and/or blasting with 9U-5271 Glass Beads.

Steps for cleaning aluminum spacer plates

1. Use only glass beads. Do not use aluminum oxide or an abrasive material. Do not mix any material
with glass beads.

2. Do not use wire brush or wire wheel.

3. Do not sand or grind the spacer plate.

4. Do not use Scotch Brite pads to clean spacer plates.

Brake fluid can be used to clean PtFE Teflon residue from spacer plates. Glass beads should be used with
certain precautions to clean aluminum plates. Glass beads tend to alter plate dimensions. Glass beads can hide
cracks that are normally seen during visual inspection.

Note: Do not use glass beads that are larger than 0.2311 mm (0.0091 inch) in size to clean the spacer plate.

For the best results, use glass beads that are size 10. The size of the glass beads must be 0.0889 mm
(0.0035 inch) to 0.1499 mm (0.0059 inch). The air pressure must be from 550 kPa (79.8 psi) to 620 kPa
(89.9248 psi). Change the glass beads and check the nozzle regularly for best results.

Cleaning Steel Spacer Plates

The following methods are also acceptable for cleaning the steel spacer plate:

Aluminum oxide

Wire brush or wire wheel

Scraping or sanding

Glass beads can be used to clean the spacer plates. Change the glass beads and check the nozzle regularly for
best results. Use the following specifications for glass beads:

Size 10 glass beads.

0.088 mm to 0.149 mm (0.0035 inch to 0.0059 inch)

550 kPa to 620 kPa (80.0 psi to 90.0 psi) air pressure

Note: Do not use glass beads that are larger than 0.23 mm (0.009 inch) to clean the spacer plate. Large glass
beads may damage the spacer plate.

Visual Inspection for Unacceptable Cracks and Depressions

After cleaning, check both sides of the plate for cracks and connecting depressions on the surface due to
corrosion, erosion, and handling damage in the following areas.

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1. Check within 6.0 mm (0.24 inch) along the edge of the plate and the opening for the valve mechanism.

2. Check within 6.5 mm (0.26 inch) along the edge of the gasket. This area is the conjunction of the
gasket and the plate.

3. Inside and 6.0 mm (0.24 inch) around oil supply hole (5).

4. Check within 6.0 mm (0.24 inch) around small water ports and large water ports (2 and 3).

Illustration 118 g01493688


Deep scratch (10) and damage (11) around oil supply hole (5).

Do not use the part again.

Do not use the spacer plate again if either type of damage is present in any of the four areas that are specified
in "Visual Inspection for Unacceptable Cracks and Depressions" section.

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Illustration 119 g01493689


The illustration shows the maximum allowable amount of erosion. The arrow points out erosion around the water port.

Use the part again.

Note: Do not use a spacer plate again if the spacer plate has a greater amount of erosion on any of the four
areas that are mentioned in "Visual Inspection for Unacceptable Cracks and Depressions".

Areas that are outside of the areas that are mentioned in "Visual Inspection for Unacceptable Cracks and
Depressions" may have depressions on the surface with a maximum depth of 1.0 mm (0.04 inch) and 6.0 mm
(0.24 inch) in diameter. This applies to both sides of the plate.

Illustration 120 g01493690


Depressions (12) around small bolt hole (6) and depressions (13) along edge.

Use the part again.

Use the spacer plate again if the depressions (12) are the only damage that is present and the depressions are
less than 1.0 mm (0.04 inch) in depth. Take measurements after the raised areas are removed with a file.

Do not use the part again.

Do not use the spacer plate again if the depressions (13) are present. No depressions are allowed within
6.0 mm (0.24 inch) along the edge of the spacer plate.

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Illustration 121 g01493692


The arrow points to a crack without a measurable width. This kind of crack is a hairline crack.

Do not use the part again.

Precautions for Measuring the Projection of the Liner

Do not use steel washers or excessive torque to hold down the spacer plate for the measurement of projection.
Instead, use brass and fibrous washers under bolt heads. Also use correct torques to prevent damage to spacer
plates.

Thermal Spray Procedures for Top Surface Deck

NOTICE

Clean dry air is defined as ISO 8573 - Class 3 air or better.

All sprayed coatings are considered to be porous. Porosity is the measurement of the density of a coating
when compared to the same type of material in solid or cast from. Generally, the porosity of a coating will be
found to be beneficial for bearing type applications since the coatings will retain lubrication.

When a lubrication function is not desired or where the coating will be exposed to a corrosive type of
environment or where fluid leakage is not desired, the coating should be treated with a sealer. The preferred
sealer is Dichtol WFT 1532, but alternative sealers are: Loctite 290, Metco 185 Sealer, or a wick type air
drying sealer. These types of sealers are easy and simple to apply.

Dichtol WFT 1532 Sealer Application Process

1. Ensure to wear the proper Personal Protection Equipment (PPE) when handling solvents.

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2. Thoroughly clean all wire spray surfaces with a lint free towel and isopropyl alcohol, until all oils and
debris are removed and nothing more comes off onto a clean section of the towel.

Illustration 122 g06425186

3. Pour 177.6 mL (6.0 oz) of Dichtol WFT 1532 Sealer into a paint tray.

4. Using a 101.6 mm (4.0 inch) x 1/4" Microfiber NAP Roller, dip the roller in the sealer and roll it on the
pan. Do not use excessive pressure to apply sealer—an even, light pressure is all that is needed.
Continue to roll the until it has an even coat of sealer. Avoid redipping the roller into the sealer directly.
Oversaturating the roller may cause streaks of sealer to run when you roll it on.

Note: NAP rollers will produce the smoothest finish and are ideal metal surfaces.

Illustration 123 g06428111

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5. Start the timer for 1 minute.

Illustration 124 g06440903

6. Apply Dichtol to only two cylinders at a time in the correct sequence order dictated in Illustration 124.
Repeat the application until 1 minute has elapsed.

7. To remove any streaks or runs in the Dichtol, reapply Dichtol with roller and immediately wipe away
with clean lint free towel.

8. Use a clean lint free towel and remove all Dichtol, repeat the process on the adjacent two cylinders.

9. Once all surfaces have been sealed with Dichtol, wait a minimum of 4 hours to allow the Dichtol to
completely dry before any washing or assembly.

Spraying Under Top Supported Liner

Listed below are the arc and flame spray procedures for providing a sufficient thermal spray coating on top
decks. Based on complexity and process variables, arc spray is the preferred technology for this process.

Arc spray is the only validated and approved process for spraying under top supported liner flanges. Flame
spray should only be used for deck height recovery with the use of inserts under the liner flanges.

Arc Spray Equipment and Procedure

Table 27
Minimum Surface
3.2 µm (125.9843 µinch)
Texture Before Spray
Reason for Spraying Restore deck height to specification

Arc Spray Equipment


SmartArc by Oerlikon Metco, TAFA 8830 MHU, or TAFA 8835 MHU
Type

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Wire TAFA 75B Wire or equivalent Nickel Aluminum Wire


2.0 mm (0.08 inch) (Should Target 0.60 mm (0.024 inch) to 1.20 mm
Max Spray Thickness
(0.05 inch) Spray Thickness)

Spray Angle 90°

Substrate Pre-Heat
22.2 °C (72.00°F) to 66°C (150.8°F) Do not direct arc on area to be sprayed.
Temperature
Substrate Temperature
During Spraying Not to 148°C (300°F)
Exceed

Grit blast - If the entire mating surface is to be arc sprayed, some shops prefer
to pre-machine the surface. This process removes any major damage, allows
for a recommended minimum 0.25 mm (0.010 inch) coating, reduces technique
dependency in producing an even coating, and can reduce material cost and
finish machining time.
Surface Preparation
Method
Precautions and care must be taken to properly mask and remove all grit
from block surface and cavities.
Time between surface preparation and thermal spray application should
be minimal. Allowing excessive time between preparation and thermal
spray will result in unacceptable coating performance.
Machining Method Milling

Equipment Required Rottler 99Y or similar


Recommended Cutting
Sandvik R245 12T 3MPM 1010
Tool

Blast Media
Pressure Type Only (Aluminum Oxide Grit)
Recommendation

Finishing Equipment
Milling
Type

Finishing Equipment Rottler 99Y or similar

Table 28
Check
Arc Spray Procedure
List
Pre-machine block and degrease block deck surface.
Clean Part Visual inspection for imbedded oils or other contaminants should be
conducted during preheat.

Undercut Must not exceed 2.0 mm (0.08 inch) spray thickness

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All edges must have at least 0.25 mm (0.010 inch) to 0.50 mm (0.020 inch)
Chamfer
chamfer.
Remove Oxide Use fiber flap brush or Clean/strip disc

Clean Spray Area Commercial degreaser ( Methyl Alcohol or Acetone)

Grit blast - If the entire mating surface is to be arc sprayed, some shops
prefer to pre-machine the surface. This process removes any major damage,
allows for a recommended minimum 0.25 mm (0.010 inch) coating, reduces
Mask for Grit technique dependency in producing an even coating and can reduce material
Blast cost and finish grinding time.

Precautions and care must be taken to properly mask and remove all
grit from block surface and cavities.
Grit Blast
Pressure type only
Equipment
Grit Type and
24 mesh aluminum oxide
Size
Blast Air Pressure 690 kPa (100.0 psi)

Blast Nozzle to
51 mm (2.0 inch) to 150 mm (6.0 inch)
Work Distance

Make sure that surface is clean


Precautions and care must be taken to properly mask and remove all
Remove Blast grit from block surface and cavities.
Mask Time between surface preparation and thermal spray application
should be minimal. Allowing excessive time between preparation and
thermal spray will result in unacceptable coating performance.
Mask for Metal
Tape, Metal Shield, Rubber, Metco Antibond, etc.
Spray
Metal Spray
Smart Arc by Oerlikon Metco TAFA
Equipment Type

Consumable TAFA 75B or Equivalent TAFA 75B or Equivalent


Clamp Pressure 275 kPa (40 psi)

Air
415 kPa (60 psi) 415 kPa (60 psi)
Jets/Pressure

Arc Load Volts 30V 30V

Amps 125 Amps 150 Amps


Gun to Work
Distance 152.4 mm (6.0 inch) 152.4 mm (6.0 inch)
(Standoff)

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Approx. Spray
0.08 mm (0.003 inch)/pass 0.08 mm (0.003 inch)/pass
Rate/Pass
Gun Fixturing
Machine mount or hand held
Method

Traverse Rate of
395.00 mm/s (1.296 Ft/s)
Gun
Finishing
Rottler 99Y or similar
Equipment
Part/Cutter
Rotation Roughing 50 SMPM (150 SFPM)
(Roughing)
Part/Cutter
Rotation Finishing 75 SMPM (250 SFPM)
(Finishing)

Traverse Speed 0.30 mm (0.012 inch) per revolution


0.51 mm (0.020 inch) per side max
Depth of Rough
First pass should remove at least 0.178 mm (0.007 inch) to get below the
Cut
peaks of the spray.

Depth of Finish
0.25 mm (0.010 inch) per side max
Cut

Flame Spray Equipment and Procedure

NOTICE

Flame spray is not a validated or approved process for spraying under


top supported liner flanges.

Table 29
Minimum Surface
3.2 µm (125.9843 µinch)
Texture Before Spray

Reason for Spraying Wear, erosion, center line distance too short to rework

Oerlikon Metco
6P-II by Oerlikon Metco
Equipment Type
Metco Material Metco 453

Finish Thickness As required 0.25 mm (0.010 inch) to 0.38 mm (0.015 inch)


Finishing Allowance Machine 0.64 mm (0.025 inch)

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Spray Angle 90°


Substrate Pre-Heat
22.2°C (72.00°F) to 66°C (150°F)
Temperature

Substrate Temperature
During Spraying Not 204°C (400°F)
to Exceed
Grit blast - If the entire mating surface is to be flame sprayed, some shops prefer
to pre-machine the surface. This process removes any major damage, allows for a
recommended minimum 0.25 mm (0.010 inch) coating, reduces technique
dependency in producing an even coating, and can reduce material cost and finish
Surface Preparation machining time.
Method Precautions and care must be taken to properly mask and remove all grit
from block surface and cavities.
Time between surface preparation and thermal spray application should be
minimal. Allowing excessive time between preparation and thermal spray
will result in unacceptable coating performance.
Finishing Method Machine

Grinding Equipment
Standard head and block grinder
Type
Recommended Wheel Norton 23A30E12VBEP or SGL abrasive HSA24F13-VKP

Machining Equipment
Mill
Type

Recommended Cutter
Sandvik 310-K-10 LNCX
Grade

NOTICE

Precautions and care must be taken to properly mask and remove all
grit from block surface and cavities.

Time between surface preparation and thermal spray application


should be minimal. Allowing excessive time between preparation and
thermal spray will result in unacceptable coating performance.

Table 30
Flame Spray Check
Procedure
Process (6P-II) List
Clean Part Pre-machine block and degrease block deck surface.

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Visual inspection for imbedded oils or other contaminants should be


conducted during preheat.
Undercut Must not exceed 1.5 mm (0.06 inch) spray thickness

All edges must have at least 0.25 mm (0.010 inch) to 0.50 mm


Chamfer
(0.020 inch) chamfer.
Use fiber flap brush or Clean/strip disc
Remove Oxide Visual inspection for imbedded oils or other contaminants should be
conducted during preheat.
Clean Spray Area Metco cleaning solvent or equivalent
Grit blast - If the entire mating surface is to be flame sprayed, some shops
prefer to pre-machine the surface. This process removes any major
damage, allows for a recommended minimum 0.25 mm (0.010 inch)
coating, reduces technique dependency in producing an even coating, and
can reduce material cost and finish machining time.
Mask for Grit Blast
Precautions and care must be taken to properly mask and remove all
grit from block surface and cavities.
Time between surface preparation and thermal spray application
should be minimal. Allowing excessive time between preparation and
thermal spray will result in unacceptable coating performance.
Grit Blast
Pressure type only
Equipment
Grit Type and Size 24 mesh aluminum oxide

Blast Air Pressure 690 kPa (100.0 psi)

Blast Nozzle to
50 mm (2.0 inch) to 150 mm (6.0 inch)
Work Distance

Remove mask, make sure that surface is clean


Remove Blast Mask Visual inspection for imbedded oils or other contaminants should be
conducted during preheat.

Mask for Metal


Tape, Metal Shield, Rubber, Metco Antibond, etc.
Spray

Metal Spray
6P-II Hand Held Thermo Spray System by Oerlikon Metco
Equipment Type

Nozzle 6P-C7A-K "K" Nozzle

Air
6P-3/Cooling Air 140 kPa (20.0 psi) to 170 kPa (25.0 psi)
Capacity/Pressure

Oxygen Pressure 210 kPa (30.0 psi)

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Oxygen Flow 1190 L/h (42.0 cfh)


Fuel Gas Pressure 100 kPa (15.0 psi)

Fuel Gas Flow 1415 L/h (50.0 cfh)


Carrier Gas
380 kPa (55.0 psi)
Pressure
Carrier Gas Flow 1050 L/h (37.0 cfh)
Spray Rate/Build 5.5 kg (12.00 lb) per hour
Up 0.10 mm (0.004 inch) to 0.15 mm (0.006 inch) per pass
Gun to Work
178 mm (7.0 inch)
Distance
Traverse Rate of
36 SMPM (120.0 SFPM)
Gun
Gun Fixturing
Machine mount or hand held
Method
Per Pass Thickness 0.10 mm (0.004 inch) to 0.15 mm (0.006 inch) per pass

Finishing
Standard head and block grinder, Milling machine
Equipment

Part/Cutter Rotation 92.0 SMPM (300.00 SFPM)

Rough 203 mm (8.0 inch) per minute finish


Traverse Speed
38.1 mm (1.5 inch) to 51.0 mm (2.01 inch) per minute

0.03 mm (0.001 inch) to 0.05 mm (0.002 inch)


Depth of Rough Cut
0.25 mm (0.010 inch) to 0.38 mm (0.015 inch)

0.03 mm (0.001 inch)


Depth of Finish Cut
0.13 mm (0.005 inch) to 0.25 mm (0.010 inch)

Thermal Spray Procedures for Crankshaft Main Bearing Saddle


Area

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Illustration 125 g06370992

Part Description

Table 31
Base Metal Cast Iron

Hardness N/A

Arc Spray Equipment and Procedure

Table 32
Maximum Surface Texture 1.6 µm (62.99213 µinch)
Reason for Spraying Bearing Failure

Mating Part Contact Area & Material Crankshaft main bearing


SmartArc by Oerlikon Metco, TAFA 8830 MHU, or
Arc Spray Equipment Type
TAFA 8835 MHU
Wire TAFA 30T Wire Top Coat, TAFA 75B Wire Bond Coat

Finish Thickness As required


Spray Angle 90°

Substrate Pre-Heat Temperature 66.0° C (150° F) Do not direct arc on area to be sprayed

Substrate Temperature During Spraying Not


148.0° C (300° F)
to Exceed

Auxiliary Cooling Filtered shop air

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Rotation/Traverse Device Hand held


Surface Preparation Method Undercut and grit blast

Machining Method Line bore


Recommended Cutting Tool ISCAR DNMG 432 TFIC507

Blast Media Recommendation Pressure Type Only (Aluminum Oxide Grit)

Finishing Equipment Type Line boring machine

Table 33
Check
Arc Spray Procedure
List
Clean Part Degrease in hot caustic solution
Undercut Not required

Chamfer All edges - 45° to 0.08 mm (0.0030 inch)

Remove Oxide Use fiber flap brush or Clean/strip disc


Clean Spray Area Commercial degreaser

Mask for Grit Blast Use a metal mask or duct tape

Grit Blast Equipment Pressure type only


Grit Type and Size 20 mesh aluminum oxide

Blast Air Pressure 690 kPa (100.0 psi)


Blast Nozzle to Work
51 mm to 150 mm (2.0 inch to 6.0 inch)
Distance

Remove Blast Mask Make sure that surface is clean


Mask for Metal Spray Antibond or Blue Layout Dye

Metal Spray Equipment Smart Arc by Oerlikon


TAFA
Type Metco

Consumable (Bondcoat) TAFA 75B TAFA 75B

Clamp Pressure 275 kPa (40 psi)


Air Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)

Arc Load Volts 30V 30V


Amps 125 Amps 150 Amps

Gun to Work Distance


128 mm (5.0 inch) 128 mm (5.0 inch)
(Standoff)

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0.038 mm 0.038 mm
Spray Rate/Bond Pass
(0.0015 inch)/pass (0.0015 inch)/pass
Consumable (Topcoat) TAFA 30T TAFA 30T

Clamp Pressure 275 kPa (40 psi)

Air Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)
Arc Load Volts 31V 31V
Amps 150 Amps 175 Amps

Gun to Work Distance


166 mm (6.5 inch) 166 mm (6.5 inch)
(Standoff)
0.0023 mm 0.0023 mm
Spray Rate/Build Up
(0.00009 inch)/pass (0.00009 inch)/pass

Traverse Rate of Gun 11 SMPM (36 SFPM)


Gun Fixturing Method Hand held

Finishing Equipment Line boring machine


Part/Cutter Rotation
Roughing 50 SMPM (150 SFPM)
(Roughing)
Part/Cutter Rotation
Finishing 75 SMPM (250 SFPM)
(Finishing)

Coolant Oil based synthetic - 40:1 ratio


Traverse Speed 0.30 mm (0.012 inch) per revolution

Depth of Rough Cut 0.51 mm (0.020 inch) per side max


Depth of Finish Cut 0.25 mm (0.010 inch) per side max

Additional Finish Method Flex hone if necessary

Flame Spray Equipment and Procedure

Table 34
Maximum Surface Texture 1.6 µm (62.99213 µinch)

Reason for Spraying Bearing failure


Mating Part Contact Area & Material Crankshaft main bearing

Oerlikon Metco Equipment Type 6P-II by Oerlikon Metco


Metco Material Metco 453 Grind 463

Finish Thickness As required

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Finishing Allowance 0.51 mm (0.020 inch) per side


Spray Angle 90° to bore

Substrate Pre-Heat Temperature 38° C (100° F)


Substrate Temperature During Spraying Not to
149° C (300° F)
Exceed
Auxiliary Cooling If desired
Rotation/Traverse Device Hand held

Rotation/Traverse Speed 15 SMPM (50 SFPM)


Surface Preparation Method Grit Blast
Finishing Method Machine
Norton 23A30E12VBEP or SGL abrasive HSA24F13-
Recommended Wheel
VKP
Machining Equipment Type Line Boring Machine

Recommended Cutter Grade ISCAR DNMG 432 TFIC507

Table 35
Flame Spray Process (6P- Check
Procedure
II) List

Clean Part Degrease in hot caustic solution


Undercut Not required

Chamfer All edges - 45° to 0.08 mm (0.030 inch)

Remove Oxide Use die grinder or flapper wheel


Clean Spray Area Metco cleaning solvent or equivalent

Mask for Grit Blast Use metal mask or duct tape


Grit Blast Equipment Pressure type only

Grit Type and Size 24 mesh aluminum oxide

Blast Air Pressure 690 kPa (100.0 psi)


Blast Nozzle to Work
51 mm to 150 mm (2.0 inch to 6.0 inch)
Distance
Remove Blast Mask Remove mask, make sure that surface is clean

Mask for Metal Spray Metco Anti-Bond or blue layout dye

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Metal Spray Equipment


6P-II Hand Held Thermo Spray System by Oerlikon Metco
Type
Auxiliary Cooling If desired

Nozzle 6P-7CA-K "K" Nozzle

Air Capacity/Pressure 6P-3/Cooling Air 140 - 170 kPa (20.0 - 25.0 psi)
Oxygen Pressure 210 kPa (30.0 psi)
Oxygen Flow 1190 L/h (42.0 cfh)

Fuel Gas Pressure 100 kPa (15.0 psi)


Fuel Gas Flow 1415 L/h (50.0 cfh)
Carrier Gas Pressure 380 kPa (55.0 psi)
Carrier Gas Flow 1050 L/h (37.0 cfh)
5.5 kg (12.00 lb) per hour 0.10 - 0.15 mm (0.004 - 0.006 inch)
Spray Rate/Build Up
per pass

Gun to Work Distance 230 mm (9.0 inch)


Rotation Speed of Part
N/A
(RPM)
Rotation Speed of Part N/A

Traverse Rate of Gun 15 SMPM (50.00 SFPM)

Gun Fixturing Method Hand held


Bond Pass/Thickness 0.13 mm (0.005 inch)

Top Coat/Thickness As required


Finishing Equipment Line boring machine

Part/Cutter Rotation 46 to 55 SMPM (150.0 to 180.0 SFPM)

Traverse Speed 0.08 mm (0.003 inch) or less


Depth of Rough Cut 0.25 mm to 0.51 mm (0.010 inch to 0.020 inch)

Depth of Finish Cut 0.13 mm to 0.25 mm (0.005 inch to 0.010 inch)


Additional Finish Method Flex hone if necessary

Thermal Spray Procedures for Main Bearing Cap

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Illustration 126 g03513357


This is an example of a standard bearing cap. (A) is the bore dimension of the bearing cap, (B) is the width of the bearing cap, and
(C) is the height of the bearing cap.

Illustration 127 g03334317


This is an example of a V bearing cap. (A) is the bore dimension of the bearing cap, (B) is the width of the bearing cap, and (C) is the
height of the bearing cap.

Table 36
Main Bearing Cap Specifications

Engine Model Dimension A Dimension B Dimension C


G3508, G3512,
G3512E, PM3508,
PM3512, PM3516,
PP3516, G3516, 169.742 ± 0.020 mm 340.030 ± 0.015 mm 212.750 ± 0.060 mm
G316B, G3516C, (6.6827 ± 0.0007 inch) (13.3870 ± 0.0006 inch) (8.3760 ± 0.0020 inch)
G3516E, G3520B,
G3520C, G3520E,
SPF343, SPT343 3508,

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3508B, 3508C, 3512,


3512B 3516, 3516B
3508, 3508B, 3512, 129.891 ± 0.013 mm 340.000 ± 0.015 mm 212.750 ± 0.060 mm
3512B, 3516, 3516B (5.1138 ± 0.0005 inch) (13.3860 ± 0.0005 inch) (8.3760 ± 0.0020 inch)

Part Description

Table 37
Base Metal Hardness
Cast Iron 28 - 34 Rc

Arc Spray Equipment and Procedure

Table 38
Maximum Surface Texture 1.6 µm (62.99213 µinch)
Reason for Spraying Wear and/or bearing failure

Mating Part Contact Area & Material Bearing sleeve and press fit

SmartArc by Oerlikon Metco,TAFA 8830 MHU, or TAFA


Arc Spray Equipment Type
8835 MHU

Wire TAFA 30T Wire Top Coat, TAFA 75B Wire Bond Coat
Finish Thickness As required

Spray Angle 90°

Substrate Pre-Heat Temperature 66° C (150° F) Do not direct arc on area to be sprayed
Substrate Temperature During Spraying
148° C (300° F)
Not to Exceed

Auxiliary Cooling Filtered shop air


Rotation/Traverse Device Lathe or headstock/tailstock arrangement, rotary turntable

Rotation/Traverse Speed 11 SMPM (36.00 SFPM)

Surface Preparation Method Undercut and grit blast


Machining Method Machine

Equipment Required Mill, Line boring machine


Recommended Cutting Tool ISCAR DNMG 432 TFIC507

Blast Media Recommendation Pressure Type Only (Aluminum Oxide Grit)

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Badly discolored caps (heavily burned due to bad bearing


Remarks
failure) should not be rebuilt

Table 39
Check
Arc Spray Procedure
List
Clean Part Degrease in hot caustic solution
Undercut Not required

Chamfer All edges - 45° x .76 mm (.030 inch)


Emery paper or glass beading (mating face), Flapper wheel - 60
Remove Oxide
grit (bearing sleeve)
Mask for Grit Blast Metal mask type only
Grit Blast Equipment Pressure type only

Grit Type and Size 20 mesh aluminum oxide


Blast Air Pressure 690 kPa (100.0 psi)

Blast Nozzle to Work


51 to 150 mm (2.0 to 6.0 inch)
Distance
Remove Blast Mask Make sure that surface is clean

Mask for Metal Spray Use metal mask or METCO Anti-bond


Metal Spray Equipment Smart Arc by Oerlikon
TAFA
Type Metco

Consumable
TAFA 75B TAFA 75B
(Bondcoat)

Clamp Pressure 275 kPa (40 psi)


Air Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)

Arc Load Volts 30V 30V

Amps 125 Amps 150 Amps


Gun to Work Distance
128 mm (5.0 inch) 128 mm (5.0 inch)
(Standoff)
0.038 mm (0.0015 inch) per 0.038 mm (0.0015 inch) per
Spray Rate/Bond Pass
pass pass

Consumable (Topcoat) TAFA 30T TAFA 30T


Clamp Pressure 275 kPa (40 psi)

Air Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)

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Arc Load Volts 31V 31V


Amps 150 Amps 175 Amps

Gun to Work Distance


166 mm (6.5 inch) 166 mm (6.5 inch)
(Standoff)

0.058 mm (0.00228 inch) per 0.058 mm (0.00228 inch) per


Spray Rate/Build Up
pass pass
Rotation Speed of Part
RPM varies depending on diameter
(RPM)
Rotation Speed of Part 92 SMPM (300.00 SFPM)
Traverse Rate of Gun 11 SMPM (36.00 SFPM)
Gun Fixturing Method Machine mounted or hand held

Finishing Equipment Milling machine, line boring machine


Part/Cutter Rotation
50 SMPM (150 SFPM)
(Roughing)
Part/Cutter Rotation
75 SMPM (250 SFPM)
(Finishing)
Coolant Oil based synthetic - 40:1 ratio

Traverse Cut 0.30 mm (0.012 inch) per revolution

Depth of Rough Cut 0.51 mm (0.020 inch) per side max


Depth of Finish Cut 0.25 mm (0.010 inch) per side max

Additional Finish Method Flex hone if necessary

Flame Spray Equipment and Procedure

Table 40
Maximum Surface Texture 1.6 µm (62.99213 µinch)
Reason for Spraying Bearing failure

Mating Part Contact Area & Material Crankshaft main bearing sleeve

Oerlikon Metco Equipment Type 6P-II by Oerlikon Metco


Metco Material Metco 453

Finish Thickness As required


Finishing Allowance 0.51 mm (0.020 inch) per side

Spray Angle 90° to bore

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Substrate Pre-Heat Temperature 66° C (150.8° F) Do not direct flame on area to be sprayed
Substrate Temperature During Spraying
148° C (298.4° F)
Not to Exceed

Auxiliary Cooling A J Unit

Rotation/Traverse Device Hand held


Rotation/Traverse Speed 15 SMPM (50.00 SFPM)
Surface Preparation Method Grit Blast

Finishing Method Machine


Machining Equipment Type Line Boring Machine
Recommended Cutter Grade C-2, 883 Carboloy, or equivalent
Badly discolored caps (heavily burned due to bad bearing
Remarks
failure) should not be rebuilt

Table 41
Check
Flame Spray Process (6P-II) Procedure
List

Clean Part Degrease in hot caustic solution


Undercut Not required

Chamfer All edges 45° x 0.76 mm (0.030 inch)


Remove Oxide Flapper wheel - 60 grit

Mask for Grit Blast Use metal mask or duct tape

Grit Blast Equipment Pressure or suction blast


Grit Type and Size 24 mesh aluminum oxide

Blast Air Pressure 690 kPa (100.0 psi)


Blast Nozzle to Work
51 to 150 mm (2.0 to 6.0 inch)
Distance

Remove Blast Mask Remove mask, make sure that surface is clean
Mask for Metal Spray Metco Anti-Bond or blue layout dye

6P-II Hand Held Thermo Spray System by Oerlikon


Metal Spray Equipment Type
Metco

Auxiliary Cooling METCO A J Siphon Air Jet

Nozzle 6P7-CK "K" Nozzle

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Air Capacity/Pressure 6P-3/Cooling Air 140 kPa (20.0 psi)


Oxygen Pressure 210 kPa (30.0 psi)

Oxygen Flow 1190 L/h (42.0 cfh)


Fuel Gas Pressure 100 kPa (15.0 psi)

Fuel Gas Flow 1415 L/h (50.0 cfh)

Carrier Gas Pressure 380 kPa (55.0 psi)


Carrier Gas Flow 1050 L/h (37.0 cfh)
Spray Rate/Build Up 5.5 kg (12.00 lb)/hr or 90 gr (3.2 oz)/min
Gun to Work Distance 230 mm (9.0 inch)

Rotation Speed of Part 91.4 m (299.869 ft)


Traverse Rate of Gun 15.24 m (50.0 ft)
Gun Fixturing Method Hand held

Bond Pass/Thickness 0.13 mm (0.005 inch)


Top Coat/Thickness As required
Finishing Equipment Line boring machine

Part/Cutter Rotation Standard


Traverse Speed Standard

Depth of Rough Cut 0.25 to 0.51 mm (0.010 to 0.020 inch) per side

Depth of Finish Cut 0.13 mm (0.005 inch) or less per side


Additional Finish Method Flex hone if necessary

-Do not direct flame on area to be sprayed.

-Excessive heat will cause cap draw in.

Storage Procedures
Proper protection of the cylinder block from corrosion is important. Corrosion will start in as little as one
hour after the cylinder block has been cleaned.

When the cylinder block will not be inspected for one hour or less the cylinder block should be coated with a
rust or corrosion inhibitor or coated with clean engine oil. The cylinder block should be individually wrapped
to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 128.

When the cylinder block will not be inspected in two days or more the cylinder block should be coated with a
rust or corrosion inhibitor or coated with clean engine oil and should be placed in a container which is clean

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and structurally solid. The container should be covered or wrapped in plastic to prevent damage and
contamination to the cylinder block. See Illustration 129.

Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.

Illustration 128 g06278538


Example of protection for a component that is stored for a shorter term

Illustration 129 g06278539


Example of protection for a component that is stored for a longer period

Copyright 1993 - 2020 Caterpillar Inc. Tue Jan 21 2020 16:46:00 GMT+0200 (Eastern European Standard Time)
All Rights Reserved.
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