Reuse and Salvage For 3500 Engine Cylinder Blocks

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Reuse and Salvage for 3500 Engine Cylinder Blocks {0672, 0705, 0762, 1201, 1217} (SEBF8255-51)
SMCS - 0672, 0705, 0762, 1201, 1217 i09732903

Caterpillar Products
All 3500 Engines
PIP
All G3500 Engines
-
202 1046
Revision History:
Table 1
4 4
Revision Summary of Changes in SEBF8255
12: 01/3 666

/
51 Added cylinder block 525-1805 to Table 5.
2
50 Corrected the Dichtol dry time in the "Dichtol WFT 1532 Sealer Application Process" Section.
SEB 9:18+ 0
Replaced C175 Damaged Head Bolt Threaded Repair information with 3500 Damaged Head Bolt Threaded Repair
information in the "Cylinder Block Top Deck Salvage Options for 3500 Series Engines" Section.
Updated Table 11 to include Radius (H).
© 2 F825 03:00
49 Updated Loctite ®in Table 3.
Removed the Crack Detection Methods Section and added a reference to SEBF1848 Reuse and Salvage Guidelines ,
"General Salvage and Reconditioning Techniques" to Table 2.
Added the "Preparation Recommendations" section.
48
0
Cat 4 C2 5
Corrected the Summary of Changes Table.
Added the "3500 Series Engine Non-sealed Insert" Section.
47
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Added part numbers for G3500B.
Updated part numbers in Tables 5, and 6.
Added new serial number prefixes.
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Note: This document is the result of the combination of documents SEBF2120, SEBF2121, SEBF2122, SEBF8219, SEBF8226,
Inc
SEBF8291, SEBF8437, SEBF9203, and SELD0458.
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© 2023 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the
llow
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 Caterpillar 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 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).
Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning additional repair options or modifications to reuse
and salvage techniques and/or methods.
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 include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service
Information System website 2.0 (SIS web 2.0) for information about canceled part numbers and replaced part numbers. NPR will
provide the current part numbers for replaced parts.
Important Safety Information

https://sis2.cat.com/#/print-preview/service/91c86027-4cf4-4f7c-b9bd-fd8bb952ee7a 1/96
1/30/24, 3:29 PM SIS 2.0
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.
Ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or the repair procedures that
are used. Ensure that the product will not be damaged or made unsafe by any operation, lubrication, maintenance, or the repair
procedures used.
Improper operation, lubrication, maintenance or repair of this

product can be dangerous and could result in injury or death.
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”. Refer to Illustration 2 for an example of a “WARNING” Safety Alert Symbol.
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
1/30/24, 3:29 PM SIS 2.0
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 provides the procedures necessary to determine the reusability of the 3500 series engine cylinder blocks. Life will vary
depending on application, load, lubrication, and environment.
This guideline contains the latest standards of engineering, which will help minimize owning and operating costs. Parts are expected to
reach the next Planned Component Rebuild (PCR) if the parts meet the specifications within this guideline and are intended for similar
applications. Use this guideline to determine whether a part should be reused. Do not install a part that is not reusable. During
reconditioning, correct any condition that might have caused the original failure.
The dimensions and tolerances provided are to return a part / component to specification. The dimensional information alone is not
solely used to condemn a part from reuse.
References
Note: Refer to the appropriate Remove and Install (R&I), Disassembly and Assembly (D&A), and Operation and Maintenance Manual
(OMM) for the part or machine of focus before initiating this inspection or procedure.
Table 2
References
Media Number Publication Type & Title

"Why Reuse and Salvage Parts"
Channel1
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z (1)
M0080689 Reuse & Salvage Guidelines , "Cylinder Block Cleaning and Audit Procedure"
SEBF8068 Reuse & Salvage Guidelines, "Inspection and Reuse Guideline of Cylinder Liners in Cat Engines"
SEBF8148 Reuse and Salvage Guidelines , "General Salvage and Reconditioning Techniques"
SEBF8301 Reuse & Salvage Guidelines, "Inspection and Reuse of Critical Fasteners Used in All Engines"
SEBF8357 Reuse & Salvage Guidelines, "General Cleaning Methods"
SEBF9238 Reuse & Salvage Guidelines, "Fundamentals of Arc Spray for Reconditioning Components"
SEBF9240 Reuse & Salvage Guidelines, "Fundamentals of Flame Spray for Reconditioning Components"
SEHS8792 Special Instruction, "Using Caterpillar Replacement Thread Inserts"
SEHS8869 Reuse & Salvage Guidelines, "Cylinder Block Salvage Procedure Using Belzona 1311 (Ceramic R Metal)"
SEHS8919 Reuse & Salvage Guidelines, "Reuse and Salvage for Cast Iron Cylinder Blocks"
SEHS9031 Special Instruction, "Storage Procedure for Caterpillar Products"
SENR1126 Disassembly and Assembly, "3500 and 3500B High Displacement Engines for Caterpillar Built Machines"
SMHS7606 Special Instruction, "Use Of 1P-4000 Line Boring Tool Group"
SMHS7697 Special Instruction, "Installing Heli-Coil Inserts in Caterpillar Cylinder Heads"
SMHS7727 Special Instruction, "Use of 8T-0455 Cylinder Liner Projection Indicator Group"
SMHS8839 Special Instruction, "Using 5P-4175 Boring Tool Group and 5P-1618 Tool Arrangement"
(1)
Service Advisories, Service Letters, and Technical Service Bulletins

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NOTICE
The most recent Service Advisories, Service Letters, and
Technical Service Bulletins that are related to this component
should be reviewed before beginning work. Often Service
Advisories, Service Letters, and Technical Service Bulletins
contain upgrades in repair procedures, parts, and safety
information which pertain to the components being repaired.
Tooling and Equipment

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 Number Part Description

— (1) Personal Protective Equipment (PPE)
— (2) Clevis/ Shackle
— (2) Lifting Eye Assemblies
— (2) Tool (Cribbing)
1P-3537 Dial Bore Gauge
2S-0115 (3) Hard Washer
4C-3845 Grinding Wheel
4C-6329 Flex-Hone
— Loctite ® 620Retaining Compound - Slip Fit/High Temp
5P-0333(6) Crowfoot Socket
5P-4175 (2)(4) Counterboring Tool Group (5)
6V-2012(6) Depth Micrometer
8H-0707 1/4 - 20 Thread Hex Head Bolt
8H-8559 Modified Extension Assembly
8T-0455 (2) Liner Projection Tool Group (6)
9U-5271 Glass Beads
— Loctite ® 263 High Strength Threadlocker (7)
— Loctite ® 270 High Strength Threadlocker (8)
— Loctite ® (SF) 7649 Primer N
178-2351 Reamer
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
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178-2502 3508 Main Bearing Threaded Insert

178-2503 3516 Main Bearing Threaded Insert
263-9070 Steel File
587-2328 Impact Wrench
607-8035 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 (9)
441-3674 (2) Water Ferrule Driver Group
448-3698 Profilometer
473-0493 (10)
Insert Kit (Standard Diameter)
473-0494 (10)
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
473-8691
2-6 inch
473-8692
6-12 inch
489-0635 Insert Driver Tool
486-1526 Degreaser Cleaner
PT-2801 Basic Kit (Jig fixture)
PT-2801-3 Service Kit
PT-8760 Threaded insert used in 3500 series engines current cylinder block style, 53.3 mm (2.10 inch) long]
PT-8762 Threaded insert used in3500 series engines old cylinder block style, 69.9 mm (2.75 inch) long]
— Brake Cleaner
— Impact Socket
— End Mill
— Isopropyl Alcohol
— Loctite ® Retaining Compound 640 High Temp
— Loctite® 5127 Flexible Anaerobic Gasket Flange Sealant
— Loctite ® Viperlube Clear High-Performance Synthetic Grease
— Loctite ®Dielectric Grease
— Loctite ® 290 Threadlocker - High Strength Wicking Grade
Automatic Tape Measure
1U-9367
1.00 in. x 26.00 ft. (25.40 mm x 8.00 m)
8S-2257 Magnifying Glass
9U-6182 Telescoping Mirror
9U-7231 Flashing Lights Conversion Kit
4C-9442 Light
— (2) Bright Incandescent Light
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— Reflective Surface for Inspection

Microscope (40-Power)
262-8390
Pocket
288-4209 Paper Towel
Brush
1U-9915
Curved Handle Wire
— Developer
— Penetrating Oil
— Solvent Cleaner
(1) Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location
and local safety standards.
(2) Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for suitable tooling.
(3) Use with the tools for the water ferrules
(4) Additional information about this tool group can be found in Tool Operating Manual, NEHS1022 .
(5) Specific counterbore tooling can be found in Table 28
(6) Use with the counterboring tool
(7) In North America, Australia, Asia Pacific, and South America.
(8) In Europe, Africa, and the Middle East.
(9) Used with 4C-7158 pneumatic hose fitting.
(10) 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.
Preparation Recommendations
Personal injury can result when using cleaner solvents.
To help prevent personal injury, follow the instructions and

warnings on the cleaner solvent container before using.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure.

When using pressure air, wear a protective face shield and
protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa
(30 psi) for cleaning purposes.
Note: Clean exterior of all parts prior to disassembly to minimize cross-contamination.
Before you inspect a part, clean the part thoroughly to ensure that all components are free from rust, oil, burrs, and debris prior to
inspection. A surface irregularity can hide the indication of an unacceptable defect.
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Use a proper lifting device to provide safety to the operator. Also, use a proper lifting device to prevent damage to the part when
you lift the part.
During cleaning, do not damage machined surfaces.
Do not use pressurized air to dry internal components. Compressed air has moisture and contaminants that can cause premature
failure of internal components.
Put hydraulic oil on all machined surfaces to prevent rust or corrosion if inspection is not done immediately after cleaning.
Carefully store the parts in a clean container.
Inspect all flange mating surfaces for fretting. Ensure that flange mating surfaces are true and free from raised material resulting
from rust, nicks, and dents.
Use appropriate thread taps to chase all threaded holes.
Refer to SEBF8148 Reuse and Salvage Guidelines , "General Salvage and Reconditioning Techniques" for available Crack Detection
Methods.
Measurement Techniques
NOTICE
Precise measurements shall be made when the
component and measurement equipment are at 20 °C
(68 °F). Measurements shall be made after both the
component and measurement equipment have had
sufficient time to soak at 20 °C (68 °F). This will ensure
that both the surface and core of the material is at the
same temperature.
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
Cap all machined surfaces and plug all the hoses and fuel lines.
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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 486-1526 Cleaner (Degreaser).
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
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: Caterpillar recommends replacing 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 , M0080689 Reuse 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 cylinder block, spacer plates, and cylinder head
surfaces.
Specifications for 3500 Series Engine Cylinder Blocks

Specifications
Refer to Table 4 and Illustration 4 for dimensions and nomenclature of 3500 series engine specifications.
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PIP
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12: 01/3 666
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2
SEB 9:18+ 0
Illustration 4
© 2 F825 03:00 g06687400
0 5
A typical cylinder block for3500 series engines . Refer to Table 4 for specifications and dimensions.
Cat 4 C2
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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
Specifications for the Cylinder Block

Table 4
3500 Series Engine Cylinder Block Specifications
Part
Location Description Minimum Maximum
Number
Specifications of the Camshaft Bore (A)
Diameter of the bores of the cylinder block. (A 91.980 mm
N/A 92.020 mm (3.6228 inch)
Series) (3.6213 inch)
85.94 mm 86.06 mm
N/A Installed bearing bore diameter A Series
(3.383 inch) (3.388 inch)
A
97.980 mm
N/A Diameter of the bore of the cylinder block B Series 98.020 mm (3.8590 inch)
(3.8575 inch)
91.980 mm
N/A Installed bearing bore diameter B Series 92.100 mm (3.6260 inch)
(3.6213 inch)
Specifications of the Crankshaft Bore (B) After Torquing the Main Bearing Cap Bolts
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Diameter of the Bore of the cylinder block

169.722 mm
N/A Standard bore 169.762 mm (6.6835 inch)
(6.6820 inch)
170.352 mm
N/A 0.63 mm (0.25 inch) oversize bore 170.392 mm (6.7083 inch)
(6.7068 inch)
ID of the Installed Bearing
160.142 mm
149-6031 Standard ID of the bearing 160.211 mm (6.3075 inch)
(6.3048 inch)
B
159.507 mm
149-6032 0.63 mm (0.025 inch) undersized ID 159.576 mm (6.2825 inch)
(6.2798 inch)
158.872 mm
149-6033 1.27 mm (0.050 inch) undersized ID 158.941 mm (6.2575 inch)
(6.2548 inch)
160.142 mm
149-6034 0.63 mm (0.025 inch) oversize OD 160.211 mm (6.3075 inch)
(6.3048 inch)
0.63 mm (0.025 inch) undersized ID and oversize 159.507 mm
149-6035 159.576 mm (6.2825 inch)
OD (6.2798 inch)
Surface texture of the main bore of the cylinder 0.63 µm 2.5 µm
C N/A
block (24.803 µinch) Ra (98.42 µinch) Ra
585.40 mm
N/A New cylinder block
Dimension from the top deck of the cylinder block to (23.047 inch)(1)
D
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 center line of crankshaft 229.65 mm
E N/A 230.35 mm (9.069 inch)
bearing bore to bottom of cylinder block (9.041 inch)
Refer to "Specifications and Salvage for Spacer
F Thickness of the spacer plate
Plates"
N/A Shaded area (9) 0.00 0.05 mm (0.002 inch)
Flatness of the top deck
G Full length of cylinder
N/A Refer to Illustration 5. 0.00 0.15 mm (0.006 inch)
block
Angle of the top deck
H Angle 30°
N/A
Tolerance ±0.13°
N/A
Distance from center line of dowel hole to center
J 226 ± 0.06 mm (8.898 ± 0.002 inch)
line of 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 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.
Top Deck Surface Texture and Waviness Specifications

Table 5
Top Deck Surface Texture and Waviness Specifications
Part
Sales Model Description Dimension
Number
3500B cylinder 350-1392 Top Deck
block 350-1413 2.5 µm (98.43 µinch) Ra
354-5236 Roughness Sampling Length or Cutoff - 2.54 mm (0.10000 inch)
Surface Texture
383-2089
456-7076
484-5413
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515-3612
525-1801 Minimum Waviness Height
Top Deck
Waviness
0.0127 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing (1)
456-6317 Top Deck

2.5 µm (98.43 µinch) Ra
462-7209 Roughness Sampling Length or Cutoff - 2.54 mm (0.10000 inch)
525-1805 Surface Texture
G3500B
525-1815 Minimum Waviness Height
525-1816 Top Deck
609-6652 Waviness
0.0127 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing (2)
2.5 µm (98.43 µinch) Ra
Roughness Sampling Length or Cutoff - 2.54 mm (0.10000 inch)
Top Deck Average Roughness Peak
456-6313
3500E cylinder 525-1811 Surface Texture to Valley Height
block 525-1812
579-9677 19.0 µm (748.03 µinch) Rz
Top Deck Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm
Waviness (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.
(2) 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.
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.
Top Deck (Angle) Specification
Angle of the top surface of the top 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
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 top deck must meet two requirements for this specification.
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 cylinder blocks Specification

Refer to Table 6 for length dimensions of the cylinder blocks and Illustrations 7 and 8 for examples.
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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 cylinder block. The G3520 cylinder block is
measured from the rear thrust face to each end of the cylinder block.
3508, 3512, 3516 Cylinder Blocks
G3520 Cylinder Block
Table 6
Cylinder Block Lengths and End Face Surface Texture
Engine Model Dimension Description Value

576 ± 0.2 mm
A Front thrust face to front face of cylinder block
(22.7 ± 0.010 inch)
3508
624 ± 0.2 mm
B Front thrust face to rear face of cylinder block
(24.570 ± 0.010 inch)
846 ± 0.2 mm
(33.3 ± 0.010 inch)
3512
894 ± 0.2 mm
(35.197 ± 0.010 inch)
1116 ± 0.2 mm
3516 (43.937 ± 0.010 inch)
G3516 1164 ± 0.2 mm
(45.827 ± 0.010 inch)
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4.5 ± 0.2 mm
C Front thrust face to rear face of cylinder block
(0.178 ± 0.010 inch)
G3520
2810.5 ± 0.2 mm
D Front thrust face to front face of cylinder block
(110.650 ± 0.010 inch)
0.08 mm
Surface Flatness of Cylinder Block Ends
(0.003 inch)
Surface Texture of Cylinder 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.
Cracks extend from bolt holes (1) and coolant passages (2) into the bore of the cylinder block.
Do not use the cylinder block again.
Cracking that extends from a head bolt hole into a coolant passage cannot be salvaged.
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Crack extends from bolt hole into a coolant passage of the cylinder block.
Do not use the cylinder 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.
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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Example of pitting on 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 cylinder 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 102 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 top deck.
Liner Bore Inspection Tool
1/30/24, 3:29 PM SIS 2.0
(5) Sealing Region (less than 4.50 mm (0.1772 inch) from the top deck):
(6) Non-Sealing Region (more than 4.50 mm (0.1772 inch) from the top deck)
1. Non-Sealing Region (more than 4.50 mm (0.1772 inch) from the top 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 4.50 mm (0.1772 inch) 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 or salvage of the cylinder block.
Currently, insert installation is the best salvage option available. Dealers must consider their own experience and aptitude for inserting
when considering salvaging the cylinder block.
Location: Below the Cylinder Block Top Deck
Example of moderate to severe pitting that approaches liner bore chamfer.
(A) 4.5 mm (0.17 inch)
Pitting as shown in Illustration 15 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.
Severity: Depth of Liner Bore Pitting into Cylinder Block
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Illustration 16
Examples of pitting severity.
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(7) Severe Pitting: Salvage repair needed
(8) Moderate Pitting: Salvage repair needed.
(9) Minimal Pitting: Salvage repair not needed.
Illustration 16 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 16 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 cylinder 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.
Minimal Pitting Examples

The following are three examples of minimal pitting. These photographs are examples of acceptable pitting. These bores will not need
to be salvaged.
1/30/24, 3:29 PM SIS 2.0
Minimal pitting depth. Pitting in non-sealing region around entire bore.
Reuse
Minimal pitting depth. Pitting in non-sealing region in few locations around liner bore.
Reuse
Minimal pitting depth. Pitting in non-sealing region and in few locations around liner bore.
Reuse
Moderate Pitting Examples

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 or salvage of the cylinder block.
1/30/24, 3:29 PM SIS 2.0
Moderate pitting depth. Pitting in non-sealing region and continuous around liner bore.
Reuse
Moderate pitting depth. Pitting on edge of sealing region and continuous around liner bore.
Salvage
Moderate pitting depth. Pitting in both sealing and non-sealing region and continuous around entire liner bore.
Salvage
Severe Pitting Examples

The following of severe pitting illustrate damage that is more visually obvious. Usually of such severe pitting, salvage would be
required.
1/30/24, 3:29 PM SIS 2.0
Severe pitting depth. Pitting in non-sealing region and continuous around liner bore.
Salvage
Severe pitting depth. Pitting in sealing region and continuous around liner bore.
Salvage
Severe spotted pitting depth. Pitting within sealing region and continuous around liner bore.
Salvage
Cylinder Block Top Deck Salvage Options for 3500 Series 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
1/30/24, 3:29 PM SIS 2.0
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)
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).
1/30/24, 3:29 PM SIS 2.0
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 28.
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 28
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.
Position drill jig (6) over damaged bolt hole.
1/30/24, 3:29 PM SIS 2.0
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 29.
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.
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.
1/30/24, 3:29 PM SIS 2.0
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.
Remove installing bolt (13).
Reconditioning the Cylinder Block

The following table will help direct what type of rework is needed on 3500 series cylinder blocks.
Table 7
Cylinder Block Inspection
Defect
Top Deck Location Defect Inspection Defect Limits Rework Type
Type
Under the Liner Flange Wear 8T-0455 Liner Projection No Rework
Depth < 0.013 mm (0.0005 inch)
(1)
Tool Group Required
1/30/24, 3:29 PM SIS 2.0
Surface Remilling
Twin Wire Arc Spray
Depth ≥ 0.013 mm (0.0005 inch) (TWAS)
Stainless Steel
Insert
Visual Surface Remilling
8T-0455 Liner Projection
Pitting Tool Group No Pitting Allowed TWAS
Profilometer/Surface
Insert
Texture Gauge
Visual Surface Remilling(2)
Cracks Magnaflux No Cracks Allowed TWAS(3)
Dye Penetrant Insert

Visual
Caliper From top deck ≥ 4.5 mm No Rework

(0.17 inch)and/or minimal pitting Required
In Liner Bore Pitting Liner Bore Inspection
Tool(4)
Caliper
From top deck < 4.5 mm
Insert
(0.17 inch)and/or severe pitting
No Rework
Depth < 0.13 mm (0.005 inch)
Visual Required(5)
Surface Remilling
8T-0455 Liner Projection
Water Ferrule Sealing Areas
Pitting Tool Group Depth ≥ 0.13 mm (0.005 inch) or TWAS
and Gasket Sealing Areas
completely around the cooling SS Insert
Profilometer/Surface passage. (6)
Texture Gauge Belzona® 1311
(Ceramic R Metal)
Visual
Between Water Ferrule and Pitting smaller than 0.8 mm (0.03 inch) No Rework
Pitting
Liner Flange 8T-0455 Liner Projection acceptable Required
Tool Group
(1) Wear step created by fretting under the liner flange
(2) Reuse after milling, if top deck meets all specifications.
(3) Spray allowance not to exceed 2.54 mm (0.100 inch). If crack cannot be removed completely within this measurement, an insert must be used.
(4) Refer to Figure 102 for tool print specifications.
(5) If surface meets surface texture requirements to ensure water ferrule sealing.
(6) Max-Defined by rework type
It is critical to maintain the correct compression ratio of 3500 series 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 cylinder
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 cylinder block salvage method. Applied properly, arc spray can salvage the
cylinder 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
1/30/24, 3:29 PM SIS 2.0
Light machining of the top deck and/or arc spray is the preferred repair options for Cat cylinder 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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A cylinder block with minor pitting near the smaller water seals can also be repaired with Belzona® 1311 (Ceramic R Metal).
fide r: llar
Note: The following areas must be covered or plugged during the repair: cylinder bore, inlet port, exhaust port, and cylinder head bolt
Inc
openings. These areas could become contaminated if not properly protected.
ntia .
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.
l Ye
The water port opening is the pilot on the small seal.
llow
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.
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.
1/30/24, 3:29 PM SIS 2.0
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 cylinder 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 air 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 2 to 3 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 series cylinder blocks with pitting around the water passages can be repaired with stainless steel inserts.
NOTICE
Water ferrule inserts must be installed prior to the liner
seat insert counterbore being cut. If the water ferrule
inserts are installed after the counterbore is cut, then
the counterbore 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 cylinder block material remaining between the water ferrule and the liner bore inserts.
1/30/24, 3:29 PM SIS 2.0
(1) Pitting around water passages
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.
Water Ferrule Inserts

Table 8
Water Ferrule Inserts
Part Number 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
cylinder 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 counterbore 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.
1/30/24, 3:29 PM SIS 2.0
(1) Fabricated driver for small water ferrule inserts
(2) Fabricated driver for large water ferrule inserts
Table 9
Fabricated Driver Adapter
Location Dimension
19 mm
Diameter A
(0.75 inch)
B Passage for bolt
10 mm
Diameter C
(0.40 inch)
28 mm
Diameter D
(1.10 inch)
E counterbore for bolt head
Water Ferrule Insert Repair Procedure

1. Clamp the cylinder block in place.
1/30/24, 3:29 PM SIS 2.0
A template refers to Table 27 for fabrication specifications.
Dimensions for counterbore
Refer to Illustration 10 for specifications.
(F) counterbore diameter
(G) counterbore depth
(H) counterbore radius
2. Use an end mill to machine a counterbore in the water passage. The end mill that is used on the small counterbore should be
20.637 ± 0.013 mm (0.8125 ± 0.0005 inch). The end mill that is used on the large counterbore should be 30.162 ± 0.013 mm
(1.1875 ± 0.0005 inch). Refer to Table 10 and Table 11 for the dimensions of the counterbore.
If the top deck is not machined after insert installation, then the insert thickness must be measured and the counterbore depth
adjusted. The counterbore 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 counterbore in the Coolant Passage(1)
Location Dimension
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 40
(2) If top deck machining is not performed, then depth can be adjusted. Refer to Step 2 above.
Table 11
1/30/24, 3:29 PM SIS 2.0
Dimensions for the Large counterbore in the Coolant Passage
Location Dimension
30.162 ± 0.013 mm
Diameter (F)
(1.1875 ± 0.0005 inch)
Radius (H) 0.63 ± 0.13 mm (0.0250 ± 0.005 inch)
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 counterbore and use isopropyl alcohol to clean the counterbore 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 counterbore depth and insert thickness. The
difference should result in a uniform insert projection of 0.02540 mm (0.001 inch)
5. Apply Loctite ® Retaining Compound 640 High Temp to the counterbore 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 counterbore.
7. Drive the insert into the counterbore 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.
1/30/24, 3:29 PM SIS 2.0
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 6 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 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 top deck meet. Spray the entire circumference of the insert.
4. Inspect for bubbles around the outer diameter of the insert seam on the top deck.
If bubbles are present, then remove the insert and investigate the root cause. Do not reuse the removed insert.
Upper Liner Bore Inserts
NOTICE
Water ferrule inserts must be installed prior to
Machining of the liner seat insert counterbore. If the
water ferrule inserts are installed after machining, the
counterbore will distort.
3500 Series Engine Non-sealed Insert

This section contains the procedures to install 335-8971, 353-5617, and 353-5618 (oversize) inserts in 3500 series cylinder blocks.
These liner seat inserts are used to repair erosion, fretting, and cracks in the liner seat area of the top deck. The 353-5617 insert is
used to repair cracks up to 5.10 mm (0.2008 inch). The 353-5618 insert is used to repair cracks deeper than 5.10 mm (0.2008 inch).
If the 5P-4175 Counterboring Tool Group is used to machine the counterbore, refer to the "Counterbore Tool Group" Section for use
and adjustment instructions.
Cylinder blocks with the non-chamfered 7W-5949, 120-4334, and 120-4337 inserts, must be replaced with chamfered inserts to
accommodate the 352-6061 Liner Seal. The other option is to machine the previously inserted cylinders in accordance with the
process in the "Procedure to Chamfer Liner Bores" Section.
The 353-5617 and 353-5618 inserts include a machined chamfer to accept the 352-6061 Liner Seal. 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. This chamfer can be
1/30/24, 3:29 PM SIS 2.0
machined on previously inserted cylinders and, cylinders that have not been inserted. Refer to the "Procedure to Chamfer Liner Bores"
Section for the procedure.
Note: The 7W-5949 insert is not compatible with the 352-6061 Liner Seal. The insert is too thin to provide an adequate sealing
surface.
Note: Do not coat the 352-6061 Liner Seal in engine oil for installation. Loctite ®Viperlube Clear High-Performance Synthetic Grease
is used for lubrication. Refer to the appropriate Disassembly and Assembly for further instruction.
Table 12
Inserts that can be chamfered Inserts that cannot be chamfered
Part Number (1) Part Number (1)
120-1344 7W-5949
353-5617 335-8971
120-1347
—
353-5618
General Repair Information for the Cylinder Block

The liner seat inserts are made from stainless steel and provide maximum wear life for the cylinder block. Stainless steel decreases
the possibility of fretting or erosion. Inserts made from other materials have a greater possibility of fretting or erosion.
Complete removal of all cracks is required then inserts at to be used to repair the cylinder block. Cylinder blocks that have cracks
deeper than 7.6 mm (0.2992 inch) must be replaced.
Note: Reworking cylinder blocks that were formerly repaired using 7E-2866 inserts may result in failure of the cylinder liner flange.
If a cylinder block was repaired with 7E-2866 inserts, the cylinder block should not be used again.
Obtaining the correct projection of the insert
Machining of the top deck is strongly recommended when the entire cylinder block is being salvaged. This ensures that the projection
of the insert is within the correct specifications.
Inserts installed in the field do not require machining of the top deck.
Note: Before insert installation, measure top deck height to verify adequate height for machining.
Advantages to machining the top deck:
1. Machining ensures that the correct flatness is obtained
2. Increased tolerances of counterbore depth reduce machining costs.
3. Machining removes pitting from the water ferrules and the liner flange.
Make sure that each top deck has a flatness of 0.05 mm (0.002 inch). The surface texture of each top deck must be 2.5 µm
(98.43 µinch) or less.
Remove as little material from the top deck as possible. Do not exceed the specification of the top deck to the center line of the
crankshaft when the top deck is resurfaced. Refer to the "Specifications for 3500 Series Engine Cylinder Blocks" Section for
specifications.
Note: The correct insert projection before machining is 0.00 - 0.10 mm (0.00 - 0.0039 inch). If the correct insert projection is obtained,
the 353-5617 and 353-5618 inserts will allow for a skim cut and still have enough chamfer to install the liner with the 352-6061 Liner
Seal.
Verify that the inserts do not lift during the machining process. All inserts should be inspected for this condition after the machining
process.
1/30/24, 3:29 PM SIS 2.0
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Table 13
Acceptable Dimensions and Tolerances

e
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3500 Series Engine Non-Sealed Inserts
Part Number (1) H (2) J K L
120-1344
ntia
5.08 ± 0.025 mm
Inc
.
353-5617 Ø 212.115 ± 0.013 mm (0.20 ± 0.001 inch) 6.528 ± 0.032 mm
120-1347
353-5618
(8.3510 ± 0.0005 inch)
l Ye
7.62 ± 0.025 mm
(0.2570 ± 0.0013 inch) 0.90 ± 0.13 mm
(0.0354 ± 0.0051 inch)
7W-5949
335-8971 (3) (8.3610 ± 0.0005 inch) llow
Ø 212.370 ± 0.013 mm (0.30 ± 0.001 inch) 6.655 ± 0.032 mm
(0.2620 ± 0.0013 inch)
(1) The most current part number is identified in bold font when multiple part umbers are in a cell.
(2) Do not measure this dimension.
(3) Non-chamfered insert.
Counterbore detail.
Table 14
Counterbore for Series 3500Series Engine Non-Sealed Inserts
Part
M N P R S
Number
1/30/24, 3:29 PM SIS 2.0
335-8971
Ø
Sprayed R 0.63 ± 0.13 mm Ø 199.0 + 0.04 - 0.025 mm 6.72 ± 0.025 mm
212.238 ± 0.025 mm N/A
Cylinder (0.0248 ± 0.0051 inch) (7.8346 +0.0016 -0.001 inch) (0.2646 ± 0.001 inch)
(8.3558 ± 0.001 inch)
Blocks
335-8971
Non- Ø
R 0.63 ± 0.13 mm Ø 199.06 ± 0.05 mm 7.62 ± 0.025 mm
Sprayed 212.238 ± 0.025 mm N/A
(0.0248 ± 0.0051 inch) (7.837 ± 0.002 inch) (0.30 ± 0.001 inch)
Cylinder (8.3558 ± 0.001 inch)
Blocks
Ø
R 0.63 ± 0.13 mm Ø 199.06 ± 0.05 mm 5.08 ± 0.025 mm
353-5617 211.989 ± 0.025 mm N/A
(0.0248 ± 0.0051 inch) (7.837 ± 0.002 inch) (0.20 ± 0.001 inch)
(8.3460 ± 0.001 inch)
Ø 578.38 ± 0.025 mm
R 0.63 ± 0.13 mm Ø 199.06 ± 0.05 mm
353-5618 211.989 ± 0.025 mm N/A (22.7708 ± 0.001 inch)
(0.0248 ± 0.0051 inch) (7.837 ± 0.002 inch)
(8.3460 ± 0.001 inch) (1)
(1) From center line of crank bore.
The 385-4007 Liner Seat Installation Tool is used to install the liner seats.
1. Measure and record the height of all inserts.
2. Machine a counterbore into the cylinder block. Refer to the "Cylinder Block" Section for the correct dimensions. Measure and
record the counterbore depth and diameter.
Note: It is recommended that the height of the insert is greater than the depth of the counterbore.
1/30/24, 3:29 PM SIS 2.0
3. Remove all nicks and high spots on the top deck and around the counterbore.
4. Clean and the insert and counterbore with a lint free towel and isopropyl alcohol.
5. Verify that the insert and counterbore are dry.

Note: There should be no foreign material in the counterbore or on the insert.
1/30/24, 3:29 PM SIS 2.0
6. Apply Loctite ® Retaining Compound 640 High Temp around the entire counterbore.
Note: Install the insert and ensure that the insert is fully seated, Step 14, within 5 minutes of applying the Loctite ® Retaining
Compound 640 High Temp to ensure the Loctite ® does not harden.
a. Ensure that the nozzle tip of the Loctite ® is clean.
b. Use a single pass and apply a 1/8 inch bead of Loctite ® ® around the counterbore fillet.
c. Make a second pass to spread the Loctite ® ® evenly with the nozzle around the counterbore fillet.
7. Install the liner seat insert with the chamfer on the outside diameter toward the cylinder block. The part number of the insert will be
facing up.
Inserts must be installed concentric to the bore or liners may not install correctly. Subsequent machining to true up non-concentric
bores is not recommended as it may lead to the bore exceeding diameter specifications.
8. Push the insert into the counterbore until the insert is piloted by the counterbore.
Mock up of 385-4007 Tooling Assembly.
9. Install 385-4007 Tooling Assembly in to the cylinder bore.
10. Orient the plate.

Hand tighten all four bolts before finish tightening to standard torque.
11. Remove the four bolts and 385-4007 Tooling Assembly.
12. Loctite ® should extrude from the inner circumference of the bore between the insert and the bottom of the counterbore.
Note: If Loctite ® does not extrude from the inner circumference, the insert must be removed and the installation procedure
repeated with a new insert.
13. Remove excess Loctite ® using a clean, lint free towel.
1/30/24, 3:29 PM SIS 2.0
Example of improperly installed liner seat.
14. Ensure that the insert is fully seated against the cylinder block. Use a 0.025 mm (0.00098 inch) feeler gauge to check for space
between the bottom of the counterbore and the insert. Check around the entire circumference. If the feeler gauge goes into the
joint, the insert is not properly installed.
If the feeler gauge can be inserted at any point along the circumference;
Remove the insert.
Investigate the cause for poor seating.
Correct the cause. (Cleaning, foreign material removal, or excessive Loctite ® removal)
1/30/24, 3:29 PM SIS 2.0
Note: The cylinder block can be resurfaced to machine the liner inserts level with the top deck. Measuring the projection is not
required if the cylinder block is going to be resurfaced after the installation procedure.
Check the projection of the liner insert to make sure that the insert meets the following specifications;
The projection of the liner insert above the cylinder block must be between 0.00 to 0.025 mm (0.00000 to 0.00098 inch). If the
projection of the insert is greater or less than 0.00 to 0.025 mm (0.00000 to 0.00098 inch), remove the liner insert and investigate
the root cause.
Measure the projection of the insert at the 2, 4, 8, and 10 o'clock positions.
Note: Negative insert projections can cause a low load on the head gasket combustion seal.
3500Series Engine Sealed Insert

This section contains the procedures to install liner seat inserts in the cylinder blocks of 3500 series engines. See Table 7 for
recommended repair options.
Salvaging the 3500 series cylinder 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 cylinder block being salvaged was inserted in the past, then one of the inserts available will be applicable.
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.
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 machining a counterbore in the liner bore, cleaning the counterbore, installing the
shim and insert, machining the liner bore and machining the top deck.
1. Determine the size of the insert needed is standard or oversized. Cylinder blocks that have been salvaged previously with the
standard-size insert, can be salvaged with the 473-0494 Insert Kit (Oversize) inserts.
Table 15
1/30/24, 3:29 PM SIS 2.0
Previously Inserted Integral Seal Insert and Non-Sealed Insert Cross Reference
Non-Sealed Insert Outside Service Using

Process
Part Number Diameter Sealed Inserts
Machine counterbore to correct depth and diameter.
N/A(1) N/A 473-0493
Refer to Table 16
Yes
212.115 mm Machine counterbore to correct depth and diameter.
353-5617
(8.3510 inch) Refer to Table 16
473-0494
Yes
212.115 mm Machine counterbore to correct diameter.
353-5618
(8.3510 inch) Refer to Table 16
473-0494
Yes(2)
212.370 mm Inspect counterbore for proper size and reuse
335-8971
(8.3610 inch) counterbore if possible. Refer to Table 16-
473-0494
(1) Never previously inserted cylinder 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 A 90 °C (195 °F) difference between the cylinder
block and the insert will aid in installation to allow an easier slip fit of the insert into the counterbore.
Counter-bored3500 series cylinder block
1/30/24, 3:29 PM SIS 2.0
Cross section of counterbore
(A) counterbore Diameter
(B) counterbore Depth
(C) 0.8 mm (0.0312 inch) Radius
3. counterbore the liner bore.
counterbore the liner bore to the specifications given in Illustration 55 and Table 16. Ensure that the surface texture for the
counterbore is kept at Ra 3.2 µm (125.98 µinch).
Table 16

Series 3500Series Engine Sealed Inserts
Counterbore Diameter counterbore 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 counterbore depth can be calculated by combining the measured thickness of the insert and the thickness of the metal portion of the integral
seal.
4. Clean the bore and deburr counterbore. Remove any metal shavings from the counterbore area and use isopropyl alcohol to
remove any oil or dirt residue.
1/30/24, 3:29 PM SIS 2.0
Integrated seal installed.
5. Place the 433-4929 Integral Seal into the counterbore.
6. Retrieve the frozen insert from the freezer and set onto the counterbore.
489-0635 Tool Assembly in use.
7. Use 489-0635 Tool Assembly to orient the tooling onto the insert, and finger tighten the bolts.
Install tooling will not contact the top deck.
1/30/24, 3:29 PM SIS 2.0
8. Use an impact or socket driver with a crossing pattern tighten the four bolts evenly to press the insert squarely into the
counterbore. Torque the four bolts to 200 N·m (150 lb ft)
Note: The tooling will sit proud of the cylinder block when fully pressed in. This design is to concentrate the installation force onto
the insert and to allow room for water ferrule inserts.
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Inspect insert projection with tooling in place.
0 2 5
9. Leave the tooling in place, use the liner projection tooling to measure insert projection in the notches of the tooling. The tooling
Cat 4 C
applies pressure on top of the insert to replicate the cylinder head onto the liner.
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10. When all inserts have been installed, bore the inside diameter of the insert to be flush with the liner bore.
11. Remove the tooling.
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12. Mill inserts flush with the top deck of the cylinder block.
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13. Reinstall the tooling and using the liner projection tooling check insert projection again for each bore. This inspection ensures that
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the inserts have not shifted during the milling process.
.
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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 top deck height to verify the depth of the counterbore.
Machining of the top deck is recommended when the entire cylinder 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.
1/30/24, 3:29 PM SIS 2.0
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 top deck where the liner insert and the top deck meet. Spray the entire circumference of the insert.
4. Inspect for bubbles around the outer diameter of the insert on the top deck. If no bubbles are observed, repeat the test for the next
cylinder.
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
(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
1/30/24, 3:29 PM SIS 2.0
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 top deck 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.
4. Clamp the tool to the cylinder 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 top deck. When tightened, the cutter body will spin free.
(2) Spacer
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 top deck. 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
1/30/24, 3:29 PM SIS 2.0
(0.079 ± 0.008 inch) shim or spacer (2) from tool once depth is set.
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.
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.
(D) Angle of the chamfer
(E) Depth of the chamfer
Table 17
Chamfer Dimensions
Location Dimension
(D) 11° ± 1°
(E) 2.00 ± 0.20 mm (0.079 ± 0.008 inch)
1/30/24, 3:29 PM SIS 2.0
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 counterbore found on the 353-5617
Insert, the 353-5618 Inserts, and the 335-8971 Insert. The counterbore 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 Series
Engine
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 series 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 oversized bore completely
through the cylinder 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 cylinder block casting to accept a fabricated sleeve. Two
blind holes are drilled and tapped through the cylinder block and into the sleeve.
Step Method
1/30/24, 3:29 PM SIS 2.0
Sleeve and Step Method of salvage
(1) Cylinder block
(2) Sleeve
Machine the bore to specified dimensions.
Table 18
Cylinder Block Lower Repair Bore
Location Dimension
(A) 198.5 ± 0.25 mm (7.81495 ± 0.00984 inch). Use upper liner bore as a datum for all liner bore repairs. Probe
Diameter of Upper at least 8 evenly spaced points on bore to establish an accurate bore center line. Clean and inspect
Liner Bore beforehand to ensure that there is no debris or damage to the bore.
(B)
197.83 ± 0.12 mm (7.789 ± 0.005 inch).
Diameter of Lower
Surface texture - < 2.5 µm (98.42520 µinch Ra) and <16 µm (629.9213 µinch Rz)
Repair Bore
(C)
counterbore 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 68 and Table 18 to machine the counterbore for the lower liner sleeve into the cylinder block. Ensure that liner
bores (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 cylinder block is square on machine.
1/30/24, 3:29 PM SIS 2.0
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, and so on, 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 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. Caterpillar 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.
Lower Repair Sleeve
Table 19
Dimensions for Machining the Sleeve
Location Dimension
Actual cylinder 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)
1/30/24, 3:29 PM SIS 2.0
(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)
45° ± 1°
Angle of 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 70.
9. Measure for run out on the lathe before finish sleeve is parted from parent stock.
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.
1/30/24, 3:29 PM SIS 2.0
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Illustration 72
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Cat 024 C 5
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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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.
1/30/24, 3:29 PM SIS 2.0
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. 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.
17. Using clean gloves, install sleeve with the chamfer toward the cylinder block.
18. Ensure that sleeve is evenly pressed squarely into the counterbore 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.
1/30/24, 3:29 PM SIS 2.0
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.
1/30/24, 3:29 PM SIS 2.0
Table 20
Cylinder Block Actual Dimensions

Location Dimension
198.5 ± 0.25 mm (7.81495 ± 0.00984 inch). Print 199.0 + 0.040 – 0.025Locating on four or more
(A)Diameter of Upper
points within the upper liner bore (A), ensure runout from the upper liner bore (A) to the liner
Liner Bore
seat (P) is within 0.15 mm (0.00591 inch) max.
(K)Angle of Chamfer 30°
(L) Diameter of Lower 193.65 ± 0.05 mm (7.624 ± 0.002 inch).
Liner Bore Surface Texture 3.2 µm (125.98 µinch) Ra
(M)Diameter of 199.9 ± 0.5 mm (7.87006 ± 0.01969 inch)
Chamfer Surface Texture 5.5 µm (216.54 µinch) Ra
(N)Top Deck Surface Ensure that (P) lower bore is perpendicular with top deck within 0.03 mm (0.00118 inch).
(P)Depth of Chamfer
from Top Deck 239.0 ± 0.3 mm (9.40943 ± 0.01181 inch)
Surface.
24. Machine inside diameter of sleeve to 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 cylinder block.
25. Refer to Table 20 and Illustration 77, 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
Sleeve and Pin Method of salvage
(1) Cylinder block
(2) Sleeve
(3) Screw (pin)
1/30/24, 3:29 PM SIS 2.0
Machine the bore to specified dimensions.
Table 21
Cylinder Block Lower Repair Bore

Location Dimension
(A)
198.5 ± 0.25 mm (7.81495 ± 0.00984 inch). Use upper liner bore as a datum for all liner bore repairs. Probe
Diameter of
at least 8 evenly spaced points on bore to establish an accurate bore center line. Clean and inspect
Upper Liner
beforehand to ensure that there is no debris or damage to the bore.
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 79 and Table 21 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
owners manual for determination of instruments, equipment, and test devices according to industrial requirement.
1. Establish X/Y/Z axis and ensure that cylinder block is square on machine.
1/30/24, 3:29 PM SIS 2.0
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
datum (A) 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 and so on, 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 21 and Illustration 79.
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 81 and Table 22.
Lower Repair Sleeve
Table 22
Dimensions for Machining the Sleeve
Location Dimension
(S)
42.00 mm (1.650 inch)
Sleeve Height
(T)
4.06 mm (0.160 inch)
Sleeve Thickness
1/30/24, 3:29 PM SIS 2.0
Actual cylinder 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)
(V)
0.80 mm (0.030 inch)
Chamfer
(W)
45° ± 1°
Angle of 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 81.
9. Measure for run out on the lathe before finish sleeve is parted from parent stock.
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.
1/30/24, 3:29 PM SIS 2.0
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.
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.
1/30/24, 3:29 PM SIS 2.0
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.
Example of installed sleeve.
17. Using clean gloves, install sleeve with the chamfer toward the cylinder block.
1/30/24, 3:29 PM SIS 2.0
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.
20. Machine the sleeve so that the sleeve is flush with the bottom of the bore.
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21. Secure the sleeve from the bottom side of the cylinder block in two places that are 180° from each other. Use two 8H-0707 Bolts
Cat 024 C 5
(1/4 - 20 Thread Hex Head) and Loctite ® 263 High Strength Threadlocker. Refer to Illustration 88.
22. Drill and tap screw holes with 2/3 of the hole into the cylinder block and 1/3 into the new sleeve. The depth of the hole should be
e a
approximately 22.0 mm (0.87 inch) deep.
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23. After screws are installed and tight, remove the screw head by cutting or grinding.
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24. Blend the surface of the screw into the cylinder block and sleeve using a blunt ended tool with a 0.79 mm (1/32 inch) diameter and
Inc
a pneumatic hammer. This will produce the appearance of a rough casting to the repaired area.
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Table 23
Cylinder Block Actual Dimensions
Location Dimension
(A)Diameter of Upper 198.5 ± 0.25 mm (7.81495 ± 0.00984 inch). Locating on four or more points within the upper
Liner Bore liner bore (A), ensure runout from the upper liner bore (A) to the liner seat (P) is within
1/30/24, 3:29 PM SIS 2.0
0.15 mm (0.00591 inch) max.
(K)Angle of Chamfer 30°
(L)Diameter of Lower 193.65 ± 0.05 mm (7.624 ± 0.002 inch).
Liner Bore Surface Texture 3.2 µm (125.98 µinch) Ra
199.9 ± 0.5 mm (7.87006 ± 0.01969 inch)
(M)Diameter of Chamfer
Surface Texture 5.5 µm (216.54 µinch) Ra
(N)Top Deck Surface Ensure that (L) lower bore is perpendicular with top deck within 0.03 mm (0.00118 inch).
(P)Depth of Chamfer
239.0 ± 0.3 mm (9.40943 ± 0.01181 inch)
from Top Deck Surface.
25. Machine inside diameter of sleeve to 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 cylinder block.
26. Refer to Table 23 and Illustration 89, 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.
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
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 24.
2. Machine the extension to rest of the dimensions in Table 24.
3. Machine three equally spaced flats (6) on the end of the extension. Refer to Illustration 90.
Table 24
Modified 8H-8559 Extension Assembly
Location Dimension
1/30/24, 3:29 PM SIS 2.0
(A) New length 127.0 mm (5.00 inch)

(B) 50.8 mm (2.00 inch)
(C) 38.1 mm (1.50 inch)
(D) 0.8 mm (0.03 inch) by 45 °C/R
(E) Ø 12.7 + 0.0 - 0.3 mm (0.50 + 0.00 - 0.01 inch)
Tooling for 3500 series engine . Refer to Table 25 and Table 26 for identification.
Table 25
Thread Repair Tooling

(Late 3500 series engine 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 26
Thread Repair Tooling

Early 3500 series engine 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
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 25 and Table 26 for the correct taps.
1/30/24, 3:29 PM SIS 2.0
1. Insert the reamer in the damaged main bearing hole.
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.
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.
1/30/24, 3:29 PM SIS 2.0
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.
Thread the hole with the thread tap.
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.
(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.
1/30/24, 3:29 PM SIS 2.0
(5) Threaded Insert
17. Start threading the threaded insert (5) onto the same main bearing bolt. Refer to illustration 97.
18. Thread the threaded insert until the insert contacts the sleeve. Refer to illustration 98.
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.
Sleeve and threaded insert
21. Coat the threads on the outside diameter of the insert with 154-9731 Thread Lock Compound.
22. Screw the threaded insert into the cylinder 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 30°.
Note: Once the insert is started in the cylinder 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.
1/30/24, 3:29 PM SIS 2.0

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 cylinder block.
Cylinder Block Salvage Tooling

Water Ferrule Template

Table 27
Water Ferrule Dimensions and Tolerances

Location Description Dimension Location Description Dimension
Press bushings flush to 4 x Ø 28.58 ± 0.03 mm 11.5 ± 0.3 mm
a E —
bottom surface (1.1252± 0.0012inch) (0.45 ± 0.01 inch)
1/30/24, 3:29 PM SIS 2.0
Ø 9.52 mm 16.7 ± 0.3 mm

A 2 Roll Pins F —
(0.3748 inch) (0.61 ± 0.01 inch)
90.0 ± 0.3 mm
2 4 Bushings ANSI P-78-12-.8125 G —
(3.54 ± 0.01 inch)
100 ± 3 mm
3 1018 Steel Plate — H —
(3.94 ± 0.11 inch)
145.5 ± 0.8 mm
4 Drill Bushing ANSI P-96-12-1.1875 I —
(5.73 ± 0.03 inch)
305.00 ± 3.00 mm 188.5 ± 0.3 mm
AA Square Plate J —
(12.0079± 0.1181 inch) (7.42 ± 0.01 inch)
12.70 mm 216.7 ± 0.3 mm
AB Plate Thickness K —
(0.50 inch) (8.53 ± 0.01 inch)
15.00 mm 32 ± 1 mm
AC Roll Pin Protrusion A1 —
(0.5906 inch) (1.26 ± 0.04 inch)
19.10 mm 35.8 ± 0.3 mm
AD Bushing Thickness B1 —
(0.7520 inch) (1.41 ± 0.01 inch)
200.00 ± 0.3 mm 132.0 ± 0.3 mm
A — C1 —
(7.87400 ± 0.01181 inch) (5.20 ± 0.01 inch)
204.5 ± 0.3 mm
B — 105.0 ± 0.3 mm (4.13 ± 0.01 inch) D1 —
(8.05 ± 0.01 inch)
230.0 ± 0.8 mm
C — 52 ± 1 mm (2.05 ± 0.04 inch) E1 —
(9.06 ± 0.03 inch)
236.7 ± 0.3 mm
D — 54.5 ± 0.8 mm (2.15 ± 0.03 inch) F1 —
(9.32 ± 0.01 inch)
1/30/24, 3:29 PM SIS 2.0
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All measurements shown are in millimeters.
Counterbore Tool Group

5P-4175
Counterboring Tool Group

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.
1/30/24, 3:29 PM SIS 2.0

Nomenclature for 5P-4175 Counterboring Tool Group
Table 28
5P-4175 Counterboring Tool Group
Location Part Number Description

1 5P-4175 Counterboring Tool Group
2 8H-3127 (1)
Bolt
3 5P-1629 (1)
Drive Group
- 5P-1628(2) Drive Assembly
- 5P-1627(2) Sprocket
- 4B-9806(2) Socket Setscrew
4 5P-1631 (1)
Chain Assembly
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

The base of the boring tool may require modification to permit clearance for the tool holder that is used on 3500 series 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.
1/30/24, 3:29 PM SIS 2.0
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 104.
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.

(1) Plate
(2) Boring tool
(3) Nut and washer
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

(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.
1/30/24, 3:29 PM SIS 2.0
5. Tighten knob (4).

(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 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 counterbore 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.

(1) Plate
(2) Boring tool
(4) Knob
1/30/24, 3:29 PM SIS 2.0
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.

(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.

(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 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.
1/30/24, 3:29 PM SIS 2.0

6. Clean slot (13) in the plate.
7. Install cutter (10) and tighten screw (14).
8. Carefully loosen knob (4) and move down the cutter until cutter (10) is against the top deck of the cylinder block.
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.
1/30/24, 3:29 PM SIS 2.0
10. Lift the plate so the cutter is approximately 1.5 mm (0.06 inch) above the top deck of the cylinder block. Close the control valve.
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.
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 counterbore.
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
1/30/24, 3:29 PM SIS 2.0
1. When the deepest location of the counterbore 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.
4. Install shims (21) between housing (19) and base adapter (20) next to the deepest point of the counterbore. 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).
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
1/30/24, 3:29 PM SIS 2.0
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Illustration 120
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(AC) Slot for clearance of cutter 12.7 mm (0.50 inch)

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
1/30/24, 3:29 PM SIS 2.0

(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 cylinder 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.
1/30/24, 3:29 PM SIS 2.0
Nomenclature

Spacer Plate for 3500 series engines.
Table 29
Spacer Plate
Location 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.
3. After cleaning the spacer plate, visually inspect the spacer plate for cracks, corrosion, erosion, and other damage.
Plate Thickness
Table 30
Plate Thickness
Part Number Thickness Minimum Thickness Surface Texture
110-6994 12.313 ± 0.025 mm (0.4848 ± 0.0010 inch) 12.288 mm (0.4838 inch) N/A
362-9677 12.333 ± 0.025 mm (0.4856 ± 0.0010 inch) 12.308 mm (0.4846 inch) N/A
1/30/24, 3:29 PM SIS 2.0
Ra 1.6 µm (62.99213 µinch)

519-7297 12.363 ± 0.025 mm (0.48673 ± 0.00098 inch) (1) 12.338 mm (0.48575 inch)
Rz 18.0 µm (708.6614 µinch)
(1) 0.025 mm (0.00098 inch) allowable thickness variation throughout a part.
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

Bent spacer plate or warped spacer plate
Do not use the part again.

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

Deep cut (8) between large bolt hole (4) and the hole for the clearance of the cylinder liner.
1/30/24, 3:29 PM SIS 2.0

The illustration shows a deep cut (9) around the large water port (2).
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
1/30/24, 3:29 PM SIS 2.0
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.
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).

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

The illustration shows the maximum allowable amount of erosion. The arrow points out erosion around the water port.
Use the part again.
1/30/24, 3:29 PM SIS 2.0
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.

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 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.

The arrow points to a crack without a measurable width. This kind of crack is a hairline crack.
Precautions for Measuring the Projection of the Liner
1/30/24, 3:29 PM SIS 2.0
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 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 Threadlocker - High Strength Wicking Grade, Metco 185 Sealer, or a wick type air drying sealer. These types of
sealers are simple to apply.
Dichtol WFT 1532 Sealer Application Process

1. Ensure to wear the proper Personal Protection Equipment (PPE) when handling solvents.
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.
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.
1/30/24, 3:29 PM SIS 2.0

5. Start the timer for 1 minute.
6. Apply Dichtol to only two cylinders at a time in the correct sequence order dictated in Illustration 135. 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 12 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 top deck height recovery with the use of inserts under the liner flanges.
Arc Spray Equipment and Procedure

Table 31
Minimum Surface Texture

3.2 µm (125.9843 µinch)
Before Spray
1/30/24, 3:29 PM SIS 2.0
Reason for Spraying Restore top deck height to specification

Arc Spray Equipment Type SmartArc by Oerlikon Metco, TAFA 8830 MHU, or TAFA 8835 MHU
Wire TAFA 75B Wire or equivalent Nickel Aluminum Wire
Max Spray Thickness 2.0 mm (0.08 inch) (Should Target 0.60 mm (0.024 inch) to 1.20 mm (0.05 inch) Spray Thickness)
Spray Angle 90°
PIP
Substrate Pre-Heat
Temperature
Substrate Temperature
-
202 1046
22.20 °C (72.0 °F) to 66.0 °C (150.80 °F)
Do not direct arc on area to be sprayed.
During Spraying Not to

Exceed
4 /
148.0 °C (300.0 °F)
12: 0 4 666
2 1 /3
Grit blast - If the entire mating surface is to be arc sprayed, some shops prefer to pre-machine the
SEB :18+ 0
9
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
© 2 F825 03:00
Method Precautions and care must be taken to properly mask and remove all grit from cylinder 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
Cat 024 C 5
performance.
Machining Method Milling
Equipment Required
Recommended Cutting
Tool
e
Con illa terpi
p a
Rottler 99Y or similar
r
Sandvik R245 12T 3MPM 1010
Blast Media
Recommendation
fide r: llar
Pressure Type Only (Aluminum Oxide Grit)
Finishing Equipment Type Milling

ntia Inc
Finishing Equipment
l Ye
.
llow
Table 32
Check
Arc Spray Procedure
List
Pre-machine cylinder block and degrease top 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
Chamfer All edges must have at least 0.25 mm (0.010 inch) to 0.50 mm (0.020 inch) 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
(0.010 inch) coating, reduces technique dependency in producing an even coating and can reduce
Mask for Grit Blast material cost and finish grinding time.
Precautions and care must be taken to properly mask and remove all grit from cylinder block
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
51 mm (2.0 inch) to 150 mm (6.0 inch)
Work Distance
Remove Blast Make sure that surface is clean
Mask
1/30/24, 3:29 PM SIS 2.0
Precautions and care must be taken to properly mask and remove all grit from cylinder block
performance.
Mask for Metal
Tape, Metal Shield, Rubber, Metco Antibond, and so on.
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 Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)
Arc Load Volts 30 V 30 V
Amps 125 A 150 A
Gun to Work
Distance 152.4 mm (6.0 inch) 152.4 mm (6.0 inch)
(Standoff)
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
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
Depth of Rough 0.51 mm (0.020 inch) per side max
Cut First pass should remove at least 0.178 mm (0.007 inch) to get below the peaks of the spray.
Depth of Finish Cut 0.25 mm (0.010 inch) per side max
Flame Spray Equipment and Procedure
NOTICE
Flame spray is not a validated or approved process for spraying
under top supported liner flanges.
Table 33
Minimum Surface Texture

3.2 µm (125.9843 µinch)
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)
Spray Angle 90°
1/30/24, 3:29 PM SIS 2.0
Substrate Pre-Heat
22.20 °C (72.0 °F) to 66.0 °C (150.0 °F)
Temperature
Substrate Temperature
During Spraying Not to 204.0 °C (400.0 °F)
Exceed
Grit blast - If the entire mating surface is to be flame sprayed, some shops prefer to pre-machine the
(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 cylinder block
performance.
Finishing Method Machine
Grinding Equipment Type Standard head and cylinder block grinder
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 cylinder 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 34
Flame Spray Check
Procedure
Process (6P-II) List
Pre-machine cylinder block and degrease top deck surface.
Clean Part 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
Chamfer All edges must have at least 0.25 mm (0.010 inch) to 0.50 mm (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 cylinder
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 Equipment Pressure type only
1/30/24, 3:29 PM SIS 2.0

Blast Nozzle to Work
50 mm (2.0 inch) to 150 mm (6.0 inch)
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 Spray Tape, Metal Shield, Rubber, Metco Antibond, and so on.
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)
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
Spray Rate/Build 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 Equipment Standard head and cylinder block grinder, Milling machine
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
1/30/24, 3:29 PM SIS 2.0
Part Description
Table 35
Base Metal Cast Iron

Hardness N/A

Table 36
Maximum Surface Texture 1.6 µm (62.99213 µinch)

Reason for Spraying Bearing Failure
Mating Part Contact Area & Material Crankshaft main bearing
Arc Spray Equipment Type SmartArc by Oerlikon Metco, TAFA 8830 MHU, or 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 (150.0 °F) Do not direct arc on area to be sprayed
Substrate Temperature During Spraying Not to Exceed 148.0 °C (300.0 °F)
Auxiliary Cooling Filtered shop air
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 37
Arc Spray Procedure Check 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
Blast Nozzle to Work Distance 51 mm to 150 mm (2.0 inch to 6.0 inch)
Remove Blast Mask Make sure that surface is clean
Mask for Metal Spray Antibond or Blue Layout Dye
Metal Spray Equipment Type Smart Arc by Oerlikon Metco TAFA
Consumable (Bondcoat) TAFA 75B TAFA 75B
1/30/24, 3:29 PM SIS 2.0
Arc Load Volts 30V 30V
Amps 125 Amps 150 Amps
Gun to Work Distance (Standoff) 128 mm (5.0 inch) 128 mm (5.0 inch)
Spray Rate/Bond Pass 0.038 mm (0.0015 inch)/pass 0.038 mm (0.0015 inch)/pass
Consumable (Topcoat) TAFA 30T TAFA 30T
Amps 150 A 175 A
Gun to Work Distance (Standoff) 166 mm (6.5 inch) 166 mm (6.5 inch)
Spray Rate/Build Up 0.0023 mm (0.00009 inch)/pass 0.0023 mm (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) Roughing 50 SMPM (150 SFPM)
Part/Cutter Rotation (Finishing) Finishing 75 SMPM (250 SFPM)
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
Additional Finish Method Flex hone if necessary

Table 38

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
Finishing Allowance 0.51 mm (0.020 inch) per side
Spray Angle 90° to bore
Substrate Pre-Heat Temperature 38.0 °C (100.0 °F)
Substrate Temperature During Spraying Not to Exceed 149.0 °C (300.0 °F)
Auxiliary Cooling If desired
Rotation/Traverse Speed 15 SMPM (50 SFPM)
Surface Preparation Method Grit Blast
Recommended Wheel Norton 23A30E12VBEP or SGL abrasive HSA24F13-VKP
Machining Equipment Type Line Boring Machine
Recommended Cutter Grade ISCAR DNMG 432 TFIC507
1/30/24, 3:29 PM SIS 2.0
Table 39
Flame Spray Process (6P-II) Procedure Check List

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
Blast Nozzle to Work Distance 51 mm to 150 mm (2.0 inch to 6.0 inch)
Remove Blast Mask Remove mask, make sure that surface is clean
Mask for Metal Spray Metco Anti-Bond or blue layout dye
Metal Spray Equipment Type 6P-II Hand Held Thermo Spray System by Oerlikon Metco
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)
Spray Rate/Build Up 5.5 kg (12.00 lb) per hour 0.10 - 0.15 mm (0.004 - 0.006 inch) per pass
Gun to Work Distance 230 mm (9.0 inch)
Rotation Speed of Part (RPM) N/A
Rotation Speed of Part N/A
Traverse Rate of Gun 15 SMPM (50.00 SFPM)
Bond Pass/Thickness 0.13 mm (0.005 inch)
Top Coat/Thickness As required
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)
Thermal Spray Procedures for Main Bearing Cap
1/30/24, 3:29 PM SIS 2.0

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.

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 40
Main Bearing Cap Specifications
Engine Model Dimension A Dimension B Dimension C

G3508, G3512, G3512E, PM3508, PM3512, PM3516,
PP3516, G3516, G316B, G3516C, G3516E, G3520B, 169.742 ± 0.020 mm 340.030 ± 0.015 mm 212.750 ± 0.060 mm
G3520C, G3520E, SPF343, SPT343 3508, 3508B, (6.6827 ± 0.0007 inch) (13.3870 ± 0.0006 inch) (8.3760 ± 0.0020 inch)
3508C, 3512, 3512B 3516, 3516B
129.891 ± 0.013 mm 340.000 ± 0.015 mm 212.750 ± 0.060 mm
3508, 3508B, 3512, 3512B, 3516, 3516B
(5.1138 ± 0.0005 inch) (13.3860 ± 0.0005 inch) (8.3760 ± 0.0020 inch)
Part Description
Table 41
Base Metal Hardness

Cast Iron 28 - 34 Rc

Table 42

Reason for Spraying Wear and/or bearing failure
Mating Part Contact Area & Material Bearing sleeve and press fit
Arc Spray Equipment Type SmartArc by Oerlikon Metco,TAFA 8830 MHU, or TAFA 8835 MHU
1/30/24, 3:29 PM SIS 2.0
Wire TAFA 30T Wire Top Coat, TAFA 75B Wire Bond Coat
Finish Thickness
PIP As required
-
Spray Angle 90°
202 1046
Substrate Pre-Heat Temperature 66.0 °C (150.0 °F) Do not direct arc on area to be sprayed
Substrate Temperature During Spraying Not to
4 4
148.0 °C (300.0 °F)
12: 01/3 666

Exceed
Auxiliary Cooling
/ Filtered shop air
2
SEB 9:18+ 0
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
© 2 F825 03:00
Machining Method Machine
Equipment Required Mill, Line boring machine
Recommended Cutting Tool
Blast Media Recommendation 0
Cat 4 C2 5 ISCAR DNMG 432 TFIC507
Pressure Type Only (Aluminum Oxide Grit)
e
Con rpilla aterpi
Badly discolored caps (heavily burned due to bad bearing failure) should not be
Remarks
rebuilt
fide r: llar
Table 43
Check
ntia Inc
Arc Spray Procedure
List
Clean Part
Undercut
l Ye
Not required .
Degrease in hot caustic solution
Chamfer
Remove Oxide llow

All edges - 45° x .76 mm (.030 inch)
Emery paper or glass beading (mating face), Flapper wheel - 60 grit (bearing
sleeve)
Mask for Grit Blast Metal mask type only
Blast Nozzle to Work Distance 51 to 150 mm (2.0 to 6.0 inch)
Remove Blast Mask Make sure that surface is clean
Mask for Metal Spray Use metal mask or METCO Anti-bond
Metal Spray Equipment Type Smart Arc by Oerlikon Metco TAFA
Consumable (Bondcoat) TAFA 75B TAFA 75B
Amps 125 A 150 A
Gun to Work Distance
128 mm (5.0 inch) 128 mm (5.0 inch)
(Standoff)
Spray Rate/Bond Pass 0.038 mm (0.0015 inch) per pass 0.038 mm (0.0015 inch) per pass
Consumable (Topcoat) TAFA 30T TAFA 30T
Arc Load Volts 31V 31V
Amps 150 Amps 175 Amps
1/30/24, 3:29 PM SIS 2.0
Gun to Work Distance

166 mm (6.5 inch) 166 mm (6.5 inch)
(Standoff)
Spray Rate/Build Up 0.058 mm (0.00228 inch) per pass 0.058 mm (0.00228 inch) per pass
Rotation Speed of Part (RPM) RPM varies depending on diameter
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 (Roughing) 50 SMPM (150 SFPM)
Part/Cutter Rotation (Finishing) 75 SMPM (250 SFPM)
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

Table 44
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
Finishing Allowance 0.51 mm (0.020 inch) per side
Spray Angle 90° to bore
Substrate Pre-Heat Temperature 66.0 °C (150.80 °F) Do not direct flame on area to be sprayed
Substrate Temperature During Spraying Not to
148.0 °C (298.40 °F)
Exceed
Auxiliary Cooling A J Unit
Rotation/Traverse Speed 15 SMPM (50.00 SFPM)
Surface Preparation Method Grit Blast
Machining Equipment Type Line Boring Machine
Recommended Cutter Grade C-2, 883 Carboloy, or equivalent
Badly discolored caps (heavily burned due to bad bearing failure) should not be
Remarks
rebuilt
Table 45
Flame Spray Process (6P-II) Procedure Check List
Chamfer All edges 45° x 0.76 mm (0.030 inch)
Remove Oxide Flapper wheel - 60 grit
1/30/24, 3:29 PM SIS 2.0
Mask for Grit Blast Use metal mask or duct tape

Grit Blast Equipment Pressure or suction blast
Blast Nozzle to Work Distance 51 to 150 mm (2.0 to 6.0 inch)
Remove Blast Mask Remove mask, make sure that surface is clean
Mask for Metal Spray Metco Anti-Bond or blue layout dye
Metal Spray Equipment Type 6P-II Hand Held Thermo Spray System by Oerlikon Metco
Auxiliary Cooling METCO A J Siphon Air Jet
Nozzle 6P7-CK "K" Nozzle
Air Capacity/Pressure 6P-3/Cooling Air 140 kPa (20.0 psi)
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)
Bond Pass/Thickness 0.13 mm (0.005 inch)
Top Coat/Thickness As required
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
-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 1 hour after the cylinder block has
been cleaned.
When the cylinder block will not be inspected for 1 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 139.
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 and structurally solid. The container should be
covered or wrapped in plastic to prevent damage and contamination to the cylinder block. See Illustration 140.
Refer to SEHS9031 Special Instruction, "Storage Procedure for Caterpillar Products" for more information.
1/30/24, 3:29 PM SIS 2.0

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

Example of protection for a component that is stored for a longer period
PIP-10464666
2024/01/30
12:28:46+03:00
i03196557
© 2024 Caterpillar Inc.
Caterpillar:
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1/30/24, 3:29 PM SIS 2.

SMCS - 0672, 0705, 0762, 1201, 1217 i09732903

12: 01/3 666

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Canceled Part Numbers and Replaced Part Numbers

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Do not operate or perform any lubrication, maintenance or repair

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Required Tools and Equipment

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178-2502 3508 Main Bearing Threaded Insert

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To help prevent personal injury, follow the instructions and

Personal injury can result from air pressure.

Personal injury can result without following proper procedure.

Note: Clean exterior of all parts prior to disassembly to minimize cross-contamination.

During cleaning, do not damage machined surfaces.

Use appropriate thread taps to chase all threaded holes.

Initial Cleaning of the Engine

Personal injury can result from working with cleaning solvent.

Because of the volatile nature of many cleaning solvents,

Always wear protective clothing and eye protection when

Cleaning the Cylinder Block

Specifications for 3500 Series Engine Cylinder Blocks

Specifications for the Cylinder Block

3500 Series Engine Cylinder Block Specifications

Diameter of the Bore of the cylinder block

Top Deck Flatness Specification

Top Deck Surface Texture and Waviness Specifications

Top Deck Surface Texture and Waviness Specifications

456-6317 Top Deck

Top Deck (Angle) Specification

Lengths of cylinder blocks Specification

Cylinder Block Lengths and End Face Surface Texture

Engine Model Dimension Description Value

Coolant Passage Pitting

Cylinder Block Pitting Near the Upper Liner Seal

Location: Below the Cylinder Block Top Deck

Severity: Depth of Liner Bore Pitting into Cylinder Block

Minimal Pitting Examples

Moderate Pitting Examples

Severe Pitting Examples

Top Deck Threaded Hole Repair

Reconditioning the Cylinder Block

Cylinder Block Inspection

Cracks Magnaflux No Cracks Allowed TWAS(3)

Dye Penetrant Insert

Caliper From top deck ≥ 4.5 mm No Rework

Top Deck Inserts

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