Procedure For Sealing Cracks In The Air Plenum That Are On The Top Surface Of The Cylinder Block{1201} Caterpillar

Procedure For Sealing Cracks In The Air Plenum That Are On The Top Surface Of The Cylinder Block{1201}

Usage:

3616 1FN

Engines:: 3612 (S/N: 9RC; 9FR; 2NZ); 3616 (S/N: 1PD; 1FN)

Introduction

This Special Instruction identifies the material and procedures that are needed to seal a crack in the air plenum that is on the top surface of the cylinder block of one of the above engines. This crack runs between a hole (A) and the hole (B) for an adjacent cylinder. Illustration 1 shows the location of a typical crack (X). Hole (A) is 100 mm in diameter and the hole (B) is 120 mm in diameter.

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Illustration 1	g00861658
This illustration shows the location of a typical crack (X) .

Parts Needed

Table 1, Illustration 2 and Illustration 3 identify the components that are required to seal a typical crack (X).

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Illustration 2	g00861839
This illustration shows some of the parts that are required to seal a crack (X) in the top surface of the cylinder block (Y) .

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Illustration 3	g00861844
VIEW A-A This illustration shows some of the parts that are required to seal a crack (X) in the top surface of the cylinder block (Y) .

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Table 1
Item	Qty	Part Number	Description
1	1	135-8828	Seal Retainer Plate
2	1	135-0830	Block Cover
3	1	4H-1225	Washer ⁽¹⁾
4	3	3V-3308	Washer ⁽²⁾
5	1	0S-1588	Bolt ⁽²⁾
6	2	0S-1594	Bolt
7	1	9X-7442	O-Ring Seal
8	1	8L-2777	O-Ring Seal
9	2	6V-4314	O-Ring Seal ⁽³⁾

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^( 1 )	One 4H-1225 Washer is required for use between cylinder 6 and cylinder 8 on twelve cylinder engines. One 4H-1225 Washer is required for use between cylinder 8 and cylinder 10 on sixteen cylinder engines. The use of this component helps provide clearance between the lines for the oil mister and the plate (2) .
^( 2 )	This component is required for use between cylinder 6 and cylinder 8 on twelve cylinder engines. This component is required for use between cylinder 8 and cylinder 10 on sixteen cylinder engines. The use of this component helps provide clearance between the lines for the oil mister and the plate (2) .
^( 3 )	The location of these O-ring seals are not shown in the illustrations. These O-ring seals fit in grooves in the top and the bottom of the 135-8828 Seal Retainer Plate (1) .

Installation Procedure

Use Disassembly and Assembly Module, SENR3594, "3612 and 3616 Diesel Engine" as a reference for this procedure. Use Illustrations 1, 2, and 3 as references for this procedure.

Remove the cylinder head that is associated with the hole (B) that is located at one end of the crack (X) .

Remove the 114-4302 Seal Plate . Remove the 7E-0729 Top Face Cover that is located at the other end of the crack (X) .

Thoroughly clean the sealing surfaces on the cylinder block and the cylinder head.

Put the new O-ring seals (7) and (8) in position on the new 135-0830 Block Cover (2) .

Put the new block cover (2) and seals in position on the cylinder block. The hole in the new block cover that is 120 mm in diameter should be concentric with hole (B) in the cylinder block. Install the bolts (6) and washers (4) that fasten the block cover to the cylinder block. Tighten the bolts (6) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).

Install a new 6V-4314 O-Ring Seal (9) in the groove on each side of the new 135-8828 Seal Retainer Plate (1). Put the new seal retainer plate in position on the cylinder block.