Use Of 6V4840 Tool Group To Install Water Ferrules{1201} Caterpillar

When a cylinder block counterbore is made for installation of a cylinder liner seat insert, it is possible that the outer diameter of the counterbore will come very near, or break into, some of the water (coolant) holes in the top of the cylinder block. When these conditions exist, it will be necessary to install water ferrules with seals in those cylinder block coolant holes, to prevent coolant leakage at those specific locations. The 6V4840 Tool Group, a 6V4841 or 6V6021 Fixture Assembly and the information in this instruction are needed for the installation procedure for the new 5N8868 and 5N8869 Ferrules. The tools needed are given on page 2 of this instruction.

Tools Needed

Parts of the 6V4840 Tool Group are:

1 - 6V4842 Core Drill6V4845 Core Drill

2 - 6V4851 Drill Bushing6V4853 Drill Bushing6V4854 Drill Bushing6V4855 Drill Bushing6V4856 Drill Bushing6V4866 Drill Bushing

3 - 1D4610 Bolt (2)

4 - 6V4846 Reamer - Ø 12,19 mm (0.480")6V4847 Reamer - Ø 13,49 mm (0.531")6V4848 Reamer - Ø 18,72 mm (0.737")6V4849 Reamer - Ø 19,84 mm (0.781")

5 - 5P8248 Washer (2)

6 - 6V4859 Case6V4861 Block6V6044 Block

Also needed for the ferrule and seal installation procedure will be either the 6V4841 Fixture Assembly (7) or the 6V6021 Fixture Assembly (8). The 6V4841 Fixture Assembly (7) is for use on 158.8 (6.25") bore, Vee engines, while 6V6021 Fixture Assembly (8) is for use on 146.1 (5.75") bore, 4 cylinder engines and 158.8 (6.25") bore, 6 cylinder engines. See the instructions that follow, for tool usage.

Recondition The Water Holes

(1) Install the correct fixture assembly (1) on the cylinder block. (Illustration above shows 6V6021 Fixture Assembly.) To put the fixture assembly in the correct position, put the fixture assembly dowel holes over dowel pins (A). [Dowel pins (A) are used to keep the cylinder head in correct position.

(2) Use 1D4610 Bolts (2) with washers to hold fixture assembly (1) in position.

NOTE: The illustrations that follow show which coolant holes, according to engine model, must be changed to a new size.

(3) For 158.8mm (6.25") bore, 6 cylinder engines, all coolant holes at locations (B) must have their size changed. Any holes at locations (C) that are 2 mm (.080") or nearer to the liner seat insert, must also have their size changed.

(4) For 146.1 mm (5.75") bore, 4 cylinder engines, all coolant holes at locations (D) must have their size changed.

(5) For 158.8 mm (6.25") bore Vee engines, all coolant holes at locations (B) must have their size changed. Any holes at locations (C) that are 2 mm (.080") or nearer to the liner seal insert, must also have their size changed.

(6) For all holes at locations (B):

1. Use a 6V4842 Core Drill (3) 11.91 mm Ø (.469"Ø) and a 6V4853 Bushing to drill through the top deck of the cylinder block.

2. Use a 6V4846 Reamer (4), 12.19 mm Ø (.480"Ø) and a 6V4854 Bushing, to ream through the same holes.

3. Use a 6V4847 Reamer, 13.49 mm Ø (.531"Ø) and a 6V4855 Bushing to make a chamfer at each of the holes (B). The chamfer must be the full diameter of the reamer, but it must not be more than .76mm (.030") deep in each hole.

NOTE: If the chamfer is too small, it will be difficult to install a ferrule correctly.

(7) For those holes (C), where necessary, and all holes (D);

1. Use a 6V4845 Core Drill (5), 18.26 mm Ø (.719"Ø) and a 6V4856 Bushing to drill through the top deck of the cylinder block.

2. Use a 6V4848 Reamer (6), 18.72 mm Ø (.737"Ø) and a 6V4866 Bushing to ream through the same holes.

3. Use a 6V4849 Reamer, 19.84 mm Ø (.781"Ø) and a 6V4851 Bushing to make a chamfer at each of the holes. The chamfer must be the full diameter of the reamer, but is must not be more than .76 mm (.030") deep in each hole.

NOTE: If the chamfer is too small, it will be difficult to install a ferrule correctly.

(8) Use emery cloth to remove any sharp edges around the coolant holes (B), (C) or (D) that have a diameter change.

Installation Of The Ferrules

(1) Put a 6L7814 Seal (1) and a 6D7128 O-ring (2) on each 5N8868 Ferrule (3).

(2) Put a 6L7813 Seal (4) and a 6V5138 O-ring (5) on each 5N8869 Ferrule (6).

(3) Put a coat of petroleum jelly on O-rings (2) and (5). Install ferrules (3) and (6) as shown, O-ring first, in the holes where needed.

NOTE: Do not turn the ferrule or use force to install it. If a ferrule will not install easily, check the hole and the ferrule and make any necessary corrections. It is permissible to use a gentle rocking (movement back and forth or side-to-side) motion of the ferrule to help in installation.