Machining of The Cylinder Block to Convert from Wet Cylinder Liners to Dry Cylinders Liners{1201} Caterpillar

Engine:

3606 (S/N: 8RB1-UP)

3608 (S/N: 6MC1-UP)

3612 (S/N: 9RC1-UP)

3616 (S/N: 1PD1-UP)

Introduction

Do not perform any procedure that is outlined in this Special Instruction until the entire Special Instruction has been read and understood.

This Special Instruction provides the procedure that is necessary for the machining of the holes for the coolant passage in the cylinder blocks on 3600 Engines. The machining of the holes for the coolant passage is required for some cylinder blocks when a dry flange cylinder liner is installed.

Note: The holes for the coolant passage in the cylinder block were machined at the factory if the cylinder block was manufactured after 1989.

Explanation of the Required Machining

The holes for the coolant passage are required for flow of engine coolant from the cylinder block to the cylinder head when a dry flange cylinder liner is installed. The coolant passage consists of two intersecting holes that are drilled four places at each cylinder. One of the intersecting holes is drilled downward from the mounting face for the cylinder head. The other hole is drilled from the side of the cylinder liner bore. Cylinder blocks that have machined holes from the factory do not require machining. Some cylinder blocks that were manufactured do not have any holes that are drilled for the coolant passage. Some cylinder blocks that were manufactured will have the holes that are drilled from the side of the liner bore.

Required Tools and Supplies

A "Milwaukee Magnetic Base Drill Catalog Number 4231 base and a 4262-1 drill motor" is recommended for holes that are drilled from the mounting face of the cylinder head. A "Milwaukee Hole-Hawg Drill Catalog Number 1854-1 or 1675-1" that is equipped with a 12.700 mm (0.500 inch) drill chuck is recommended for holes that are drilled from the side of the liner bore.

Machining Procedure

In order to machine the holes for the coolant passage, it is necessary to remove the cylinder heads, the piston and connecting rod, and the cylinder liners. Refer to Disassembly and Assembly. It is not necessary to remove the studs for the cylinder heads. If you are using a magnetic base drill, the center line of the drill spindle must be no more than 47.625 mm (1.875 inch) from the front surface of the drill or the cylinder head studs must be removed. The removal of the studs for the cylinder heads may help facilitate the drilling of the holes in some installations.

Cylinder Blocks with Neither of the Holes Drilled for the Coolant Passage

1. Before you begin the machining process, lower the protective plug into the lower area of the cylinder liner bore of the cylinder block that is being machined. Use duct tape along the flange of the protective plug in order to help seal off the lower end of the bore for the cylinder liner. This will prevent large particles of debris from falling onto the crankshaft and into the oil sump. The mounting face for the cylinder head must be clean and free of scale and of dirt particles.

2. Lay out the location of the four holes that are drilled from the mounting face of the cylinder head. Refer to Illustrations 4 and 2.

3. Drill the holes on the mounting face of the cylinder head. Ensure that the drill bit is perpendicular with the mounting face of the cylinder head while you drill. All the holes that are drilled to a measured depth from the mounting face for the cylinder head 42.0 mm (1.654 inch). Refer to Illustration 2. While you drill the holes use the following drills in sequence. This will reduce the force that is required to drill.
   • 9.525 mm (0.375 inch) two flute drill

   • 12.70 mm (0.500 inch) four flute drill

   • 19.05 mm (0.750 inch) four flute drill

   • 22.0 mm (0.866 inch) four flute drill

4. Lay out the location of the four holes that are drilled from the side of the liner bore. Refer to Illustration 2. The holes will intersect with the holes that are drilled from the mounting face for the cylinder head.

5. Drill the holes on the side of the liner bore. Ensure that the drill bit is perpendicular with the side of the liner bore while you drill. All the holes that are drilled to a measured depth from the side of the liner bore 40.0 mm (1.575 inch). Refer to Illustration 2. Use the drills that were used in Step 3 in sequence.

6. Use a shop vacuum cleaner to remove any metal chips and dirt from the holes for the coolant passage, from the cylinder liner bore, and from the protective disc in the bottom of the cylinder bore. When the drilling of the holes for the coolant passage is complete, move to the next cylinder and repeat the procedure.

Cylinder Blocks that have Existing Holes Drilled for the Coolant Passage from the Side of the Liner Bore

1. Before you begin the machining process, lower the protective plug into the lower area of the cylinder liner bore of the cylinder block that is being machined. Use duct tape with the protective plug in order to help seal off the lower end of the bore for the cylinder liner. This will prevent large particles of debris from falling onto the crankshaft and into the oil sump. The mounting face for the cylinder head must be clean and free of scale and of dirt particles.

2. The four existing holes from the side of the liner bore are drilled to a depth of 40 mm (1.575 inch) from the factory. It is necessary to drill the existing holes to an additional depth of 12 mm (0.472 inch). Drill the holes from the side of the liner bore to a depth of 52.0 mm (2.047 inch). Ensure that the drill bit is perpendicular with the side of the liner bore while you drill. Refer to the Illustration 3. While you drill the holes use the following drills in sequence. This will reduce the force that is required to drill.
   • 9.525 mm (0.375 inch) two flute drill

   • 12.70 mm (0.500 inch) four flute drill

   • 19.05 mm (0.750 inch) four flute drill

   • 22.0 mm (0.866 inch) four flute drill

3. Lay out the location of the four holes that are drilled from the mounting face of the cylinder head. Refer to Illustrations 4 and 2. The holes that are drilled from the mounting face of the cylinder head must intersect with the holes from the liner bore.

4. Drill the holes from the mounting face of the cylinder head to a depth of 30.0 mm (1.181 inch). Ensure that the drill bit is perpendicular with the mounting face of the cylinder head while you drill. Use the drills that were used in Step 2 in sequence.

5. Use a shop vacuum cleaner to remove any metal chips and dirt from the holes for the coolant passage, from the cylinder liner bore, and from the protective disc in the bottom of the cylinder bore. When the drilling of the holes for the coolant passage is complete, move to the next cylinder and repeat the procedure.

Illustrations and Dimensions

Illustration 1	g01074625
Top view of the mounting surface for cylinder head on the cylinder block

Illustration 2	g01074629
Section J-J View of the coolant passage (1) 22 MM hole diameter that is drilled to a depth of 42 mm (1.6535 inch) (2) Dimension 30 mm (1.1811 inch) (3) 22 MM hole diameter that is drilled to a depth of 40 mm (1.5748 inch)

Illustration 3	g01077493
Section view of required drilling of the coolant passage with an existing hole for coolant passage from the side of the liner bore (4) Dimension 40 mm (1.5748 inch) (5) Dimension 52 mm (2.0472 inch) (6) Dimension 30 mm (1.1811 inch)

Illustration 4	g01074630
Top view of the mounting surface for cylinder head on the cylinder block (7) Dimension 28 mm (1.102 inch) (8) Hole for the coolant passage (9) Dimension 157 mm (6.181 inch) (10) Dimension 27.2 degrees (11) Dimension 95 mm (3.740 inch) (12) Dimension 62 mm (2.441 inch)