Guideline for Proper Gasket Handling and Installation {0599, 0648, 0681, 1000, 7555} Caterpillar

Caterpillar Products

All Cat Engines

Introduction

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

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

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables 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). To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

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

Important Safety Information

Illustration 1	g02139237

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

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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. The "WARNING" safety alert symbol is shown below.

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

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

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

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

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

Summary

This document describes the procedures to be used for assembling gasketed joint parts and liquid gaskets.

Service Letters and Technical Information Bulletins

Tooling and Equipment

Background

Proper sealing in gasketed joints is dependent upon:

• Proper gasket design/material selection for the application.

• Appropriately rigid flange design.

• Sufficient initial and retained clamping force supplied by bolts to create proper sealing.

• Appropriate bolt spacing.

• Proper assembly and handling techniques.

• Proper localized use of gasket adhesive, RTV silicone, and sealants.

• Sealing material and sealing surfaces free of solid or liquid debris and contamination.

All the above factors must be designed appropriately and controlled to ensure a leak-free joint.

Note: RTV (Room Temperature Vulcanization) silicone is a type of silicone rubber made from a base plus a curing agent. Room temperature and exposure to air cures the rubber.

Storage of Flanges

Gasket joints are sensitive to the quality of the flanges. Flange surfaces shall be checked for the presence of defects that may compromise sealing. Flanges should not be used if such defects are found. All flanges must be stored such that these surfaces are protected from damage such as scratches, nicks, and gouges.

Flanges should never be stored or stacked on the sealing face.

Flanges must never be slid or moved across a table or other surface on the sealing face.

Clean separators (cardboard or plastic) are recommended to prevent damage during the transportation and storage of finish-machined flanges.

Flanges must be stored in clean covered containers, cabinets, shelves, racks, or a similarly enclosed environment. This storage is to avoid the settling of debris on the sealing surface.

Storage of Gaskets

Gaskets must be stored flat in an unstressed condition. Gaskets must never be stored in a manner that would cause deformation of the gasket. Avoid folding, hanging, or deforming the gasket during storage. If stored properly gaskets may be stored for no more than 5 years. If stored incorrectly this risks damage and degradation to the gasket. Be sure that all surfaces of the gasket are free from material cracks or cuts due to improper packaging.

Manufacturer packaging will provide the best storage and contamination practices.

Illustration 3	g03217962

Special care shall be given to rubber coated metal gaskets. Rubber coated metal gaskets are highly susceptible to coating damage. Damage to the coating can affect sealing ability.

Cleanliness

Seal/Gasket Cleanliness

The storage, handling, or assembly process must not compromise seal cleanliness.

Flange Cleanliness

Gaskets must be assembled to clean and dry flanges. Any debris within the joint can cause leakage in the field. Dry flanges can become oily due to previous assembly procedures that drip oil across the flanges.

If necessary, wipe flanges with a clean, lint free wipe immediately before gasket assembly. Replace the wipes frequently to prevent contamination of flanges with a dirty wipe. If necessary and allowable, isopropyl alcohol can be used to clean the flanges.

Recommended Cleaning Cloths

• 169-5420 Cleaner

• 265-2256 Lint Free Wipes

• New Pig - Low Lint Wipes, Part Number WIP230, or WIP232 from New Pig Corporation

Field Service

Consider using degreasers or cleaners on joints with severe cleanliness problems. Soft bristle discs can be used for cleaning provided the disk does not cause damage.

Prior to reassembly the flanges must be clean and undamaged from either service or the cleaning process. Recommended discs include: 165-3945 Abrasive Disc, 165-3946 Abrasive Disc, and 165-3947 Abrasive Disc.

Handling

Handling of Flanges

Gasketed joints are sensitive to the quality of the flanges. Flange surfaces must be checked for the presence of defects that would compromise sealing. Flange surfaces must not be use if particular defects are found. These defects can include the following:

• Burrs

• Nicks or large scratches

• Paint contamination

• Metal shavings or machining chips

• Dirt

• Liquid contamination such as grease

• Other debris

• Poor surface finish or porosity

• Out of flat problems

Clean cardboard or plastic separators are recommended to prevent damage during transportation and storage of finish machined flanges.

Handling of Gaskets

All gaskets must be handled carefully to minimize the chance of damage. Tearing, bending, and creasing of soft fiber gaskets must be prevented to ensure proper sealing performance. Scratches in the thin coating on rubber coated metal (RCM) gaskets will also lead to failures.

Gaskets must not be slid across tables or other surfaces as sliding can cause scratches.

Assembly Aids

Adhesives

Occasionally it may be impossible or impractical to restrain large flexible gaskets with just dowels and guide pins. Restraining large gaskets especially on vertical surfaces such as the front housing can be difficult. In such cases where sagging gaskets are a serious concern 3M'sAdhesive No. 4224 may be used sparingly.

Note: Currently there is no Caterpillar part number for the adhesive.

Adhesive Applicators

Illustration 4	g03132896
Brush applicator

Illustration 5	g03132976
Square sponge applicator

Do not apply gasket adhesive using large bristled brushes. Adhesive shall be applied using a thin/small width brush or sponge applicator.

Appropriate dispensing equipment shall be provided to ensure that the correct amount of adhesive is used.

Adhesive Application

Adhesive should only be applied to the flange on one side of the joint, never directly to the gasket and never on both flanges. This application is especially critical in any joint with shear motion (such as bimetallic joints). For bimetallic joints, adhesive should be applied to the iron or steel flange, not the aluminum.

Adhesive shall be applied in a thin layer enough to be tacky. The adhesive will have a shine or sheen, but shall not be visible to the naked eye when viewed directly. The adhesive shall not be applied in such quantity as to cause a run on the flange surface.

Illustration 6	g03217977
Examples of adhesive application. (1) Properly applied adhesive is shiny but not easily visible. (2) Improperly applied adhesive is dull and easily visible.

There are five primary reasons for minimizing and controlling the amount of adhesive used:

1. The adhesive is detrimental to the gasket properties and causes softening resulting in loss of bolt torque. However, if used sparingly deterioration is minimized.

2. Adhesives can reduce the sealing ability of the gasket by interfering with the gasket-to-flange interface.

3. Excessive amounts can cause the gasket to adhere to both surfaces, increasing the risk of tearing. This risk is especially critical in bimetallic joints.

4. Flange surface damage may occur when removing strongly adhered gasket material during service. This damage defeats the purpose of intentionally applied anti-stick coatings.

5. Adhesives that are incompatible with the fluid system can enter the system undissolved and cause premature plugging of the filter.

The assembly aid compounds are to be stored in a clean, closable container that is kept closed between uses.

Pre-Assembly Inspection

Complete a quick visual inspection of all components before the assembly process. A brief inspection is a quick visual review of the part and the mating component for damage or debris. This inspection is to help identify part issues before assembling the parts to the components.

Assembly

RTV

Cat utilizes many types of RTVs to meet the specific need and temperature of the application. When using an RTV product, reference Table 3 to obtain the proper product for use. Application of the RTV shall be applied, when needed, as a thin bead approximately 3 mm - 5 mm (0.12 inch - 0.2 inch) in width. Refer to Illustration 7 for an example.

Note: Acetoxy cure RTV materials must not be used. The curing process can cause degradation of flanges and gaskets.

Illustration 7	g03240796
Proper RTV bead size.

RTV shall always be applied in a stable, controlled, consistent manner. RTV shall be applied in a 3 mm - 5 mm (0.12 inch - 0.2 inch). The bead shall be applied on a stable stationary surface, for example: not while the component is moving down the assembly line.

To help ensure a 3 mm - 5 mm (0.12 inch - 0.2 inch) diameter bead, a uniform tube cutter is highly recommended. Refer to Illustrations 8 and 9.

Illustration 8	g03246103

Illustration 9	g03246119

Do not use RTV silicone or any other sealant as a full-coverage surface dressing for a gasket. The only exception to this rule is when silicone Types: J, K, L, M, and N RTV is used as a sealing aid for a T-joint. Refer to Table 3.

Do not use RTV silicone or any other sealant as a gasket adhesive. If necessary, use the approved gasket adhesive such as 3M's Adhesive No. 4224.

All joints using RTV must be assembled within 10 minutes of RTV application. After 10 minutes, the material will start to skin over and sealing performance will be compromised.

Sealants, in general, anaerobic sealants most never be used in the same joint as a gasket. Certain anaerobic compounds, such as polyacrylate anaerobic materials, may be an exception.

T-Joints

A T-joint occurs when one joint abuts perpendicularly to another joint. Such as where the oil pan spans across the joint formed between a housing and the block. The three-way joint forms a "T" shape when viewed from the side.

There are two varieties of T-joints. The first most common type, the leg joint is assembled first. All block-housing-oil pan joints are this type. In the second, and less common type, the crossbar joint is assembled first. This joint is common with multi-piece oil pan joints.

Silicone Types: J, K, L, M, and N must be applied to the T-joint to aid in sealing as described below. Refer to Table 3 for Silicone Types. RTV must be applied in the T-joint area at each interface between the seal/gasket and a flange. For a typical block-housing-oil pan joint, this means within the leg joint (block to housing) at each interface and again across the leg joint before assembly of the cross bar joint (oil pan).

Note: All surfaces that RTV will be applied to must be wiped clean and dry.

Note: All joints using RTV must be assembled within 10 minutes of RTV application. After 10 minutes, the material will start to skin over and sealing performance will be compromised.

If a fiber gasket or other soft sealing material is used in the leg joint, then the gasket should be designed approximately 10 mm (0.40 in) longer than the mating flange so that it sticks out conspicuously.

The gasket should be trimmed flush to the bottom of the flanges using a soft metal scraper or a putty knife. Ensure that damage is not done to the flanges prior to assembling the crossbar. Ensure that the trimmed materials are properly disposed of and does not contaminate the component.

Note: Only integral seals with specially designed trimmable rubber extensions should be trimmed flush. Integral seals with only the rubber sealing bead extending out of the flanges must NOT be trimmed. Trimming the rubber sealing bead can result in the bead tearing.

If a metal or untrimmable gasket is used in the leg of the "T", then it should be designed such that it is cut back and does not extend into the T-joint. In this case, no gasket trimming is necessary, although the excess sealant must still be removed.

Type 1 T-Joints

The following section contains specific examples of assembling Type 1 T-Joints using different types of sealant and gasketing technologies.

In the case of a trimmable gasket or integral seal, RTV must be applied at the T-Joint area on each side of the gasket during joint leg assembly. After assembly any gasket material or excess RTV protruding from the joint is trimmed. After trimming, a new bead of RTV is applied across the flush leg joint. After fresh RTV is applied, the crossbar joint is then assembled.

For example, the steps to assemble a C15 cylinder block, front plate, front housing, and oil pan is as follows:

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Illustration 10	g03247463
RTV applied to block.

1. Apply RTV at the end of the block flange in the T-Joint area.
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   Illustration 11	g03247466
   Integral seal installed.

2. Install the integral seal.
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   Illustration 12	g03247467
   RTV applied to integral seal.

3. Apply RTV to the T-Joint area on the exposed face of the integral seal.
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   Illustration 13	g03247497
   Front plate installed.

4. Install the front plate.
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   Illustration 14	g03247498
   RTV applied to front plate.

5. Apply RTV to the end of the front plate in the T-Joint area.
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   Illustration 15	g03249002
   Gasket installed on front plate.

6. Install the gasket.
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   Illustration 16	g03247499
   RTV applied to gasket.

7. Apply RTV to the T-Joint area on the exposed face of the gasket.
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   Illustration 17	g03249006
   Gear train installed.

8. Install the front gear train.
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   Illustration 18	g03247500
   Front housing installed.

9. Install the front housing.
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   Illustration 19	g03247516
   RTV and gasket trimmed flush to bottom of block.

10. Trim the excess gasket and RTV flush with the bottom of the block/plate/housing intersection.
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    Illustration 20	g03250196
    RTV applied across T-Joint.

11. Apply a new bead of RTV across the block/housing joint covering the seam. Some T-Joints will require a wide bead exceeding the aforementioned 3 mm - 5 mm (0.12 in - 0.2 in) or two beads to ensure full coverage over the leg joint.
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    Illustration 21	g03247537
    Oil pan and gasket installed.

12. Install the oil pan gasket and oil pan.

If using a metal or other untrimmable gasket, RTV must be applied at the T-Joint area on each side of the gasket during assembly of the leg joint. After assembly any excess RTV protruding from the joint is removed, and a new bead of RTV is applied across the leg joint. The crossbar joint is assembled following the application of the new bead of RTV. For example, the steps to assemble a C13 cylinder block, front housing and oil pan is as follows:

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Illustration 22	g03251858
RTV applied at T-Joint area.

1. Apply RTV at the end of the block flange in the T-Joint area.
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   Illustration 23	g03252017
   Gasket installed

2. Install the gasket.
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   Illustration 24	g03252856
   RTV applied to gasket.

3. Apply RTV to the T-Joint area on the exposed face of the gasket.
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   Illustration 25	g03252896
   Front housing installed.

4. Install the front housing.
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   Illustration 26	g03252899
   Excess RTV removed.

5. Remove the excess RTV on the bottom of the block/housing joint.
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   Illustration 27	g03252918
   New bead of RTV applied to bottom.

6. Apply a new bead of RTV across the block/housing joint. RTV must completely cover the seam of the leg joint.
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   Illustration 28	g03253117
   Oil pan Installed

7. Install the oil pan and the oil pan seal.

If using a K-type anaerobic sealant in the leg joint, the excess sealant should be removed by scraping or wiping after the leg joint is assembled. RTV shall only be applied across the leg joint prior to assembling the crossbar joint. For example, the joint between the C13 cylinder block, front plate, front housing, and oil pan is assembled as follows:

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Illustration 29	g03253978
Anaerobic applied to flywheel housing.

1. Apply anaerobic sealant to the flywheel housing.
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   Illustration 30	g03257277
   Flywheel housing assembled.

2. Assemble the flywheel housing
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   Illustration 31	g03257817
   Excess anaerobic removed.

3. Remove excess anaerobic from the crossbar area of the T-Joint.
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   Illustration 32	g03258056
   Ensure that RTV is applied across entire joint.

4. Apply a bead of RTV across the block/housing joint.
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   Illustration 33	g03258318
   Oil pan installed.

5. Install the oil pan seal and oil pan.

If using a press-in-place (PIP) seal, RTV must be applied at the T-Joint area on the non-grooved flange (opposite the PIP seal) during assembly of the leg joint. After assembly any excess RTV protruding from the joint is removed, and a new bead of RTV is applied across the leg joint. The crossbar joint is then assembled. For example, the joint between the C15 cylinder block, flywheel housing and oil pan are assembled as follows:

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Illustration 34	g03258377
RTV applied to block face

1. Apply RTV to the rear face of the cylinder block.
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   Illustration 35	g03258378
   Flywheel housing assembled

2. Assemble the flywheel housing with the PIP seal already in place.
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   Illustration 36	g03258384
   Excess RTV removed

3. Remove the excess RTV. Ensure the RTV even with the bottom of the block/housing joint.
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   Illustration 37	g03258386
   RTV applied across block/housing joint.

4. Apply a new bead of RTV across the block/housing joint.
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   Illustration 38	g03258389
   Oil Pan Installed

5. Install the oil pan seal and oil pan.

Some integral seals are specially designed to have the rubber bead as close to flush as possible with the surface of the crossbar joint. In these cases, RTV shall be applied across the assembled leg joint only.. No RTV is necessary within the leg joint. The crossbar joint is then assembled. For example, the joint between the CX35 transmission case, housing, and pan are assembled as follows.

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Illustration 39	g03468136
Integral seal installed in case/housing joint.

1. Assemble the case and housing with the integral seal between them.
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   Illustration 40	g03468276
   RTV Applied across case/housing joint.

2. Apply a bead of RTV across the case/housing joint.
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   Illustration 41	g03507393
   Pan installed

3. Install the transmission pan seal and transmission pan.

Type 2 T- Joints

Type 2 T-joints, most commonly encountered in multi-piece oil pans, are assembled slightly differently than the more common Type 1 joints. The principles are the same however, in that RTV must be applied in the T-joint area at each interface between the seal/gasket and a flange.

For a typical multi-piece oil pan joint, RTV must be applied across the crossbar piece at the anticipated location of the leg joint and again within the leg joint at each interface before assembly.

A template is useful for identifying the proper RTV location on the block before the pan pieces are assembled.

Regardless of the exact configuration of the T-joint, all surfaces contacting the sealant shall be as clean and dry as possible.

Instructions for applying RTV to Type 1 engine T-joints can be found within 236-5128 Instructions. The basic method and principles are applicable to other applications as well. This part number can be referenced on assembly drawings for clear, easily referenced instructions.

Multi-Section Gaskets

Use silicone types E, J, K, L, M, or N (oil resistant RTV silicone), refer to Table 3. Apply the silicone at the interfaces of all multipiece gaskets. Apply RTV to both sides of the gasket (block side and oil pan side in the case of a multi-section oil pan gasket).

Illustration 42	g03507409
RTV applied to Puzzle Gasket.

The RTV must fully cover the seam between gasket sections, and will exceed the 3 mm - 5 mm (0.12 in - 0.2 in) guideline from the section "RTV" within this document.

The RTV shall form a wide, shallow "pad" covering the seam, which may require leveling or smoothing after the bead is applied. Refer to Illustration 42. This is most common on "puzzle-piece" style oil pan and flywheel housing gaskets.

As with the previous RTV requirements regarding T-joints, all surfaces contacting the sealant shall be as clean and dry as possible. All joints using RTV must be assembled within 10 minutes of application. After 10 minutes the material will start to skin over, and sealing performance will be compromised.

Bolt Tightening

Tighten according to the Disassembly and Assembly Manual unless otherwise specified.

Do not torque higher than the specified values, especially to correct a minor leak or weep. If seepage or leakage occurs, over-tightening is not a solution and will result in joint failure. Over-tightening can crush the gasket or bow the flange, making the situation worse.

Gasketed joints should be tightened in multiple steps. Applying an intermediate load (torque) to all the fasteners, then following up with full torque will help provide more consistent joint loading.

In joints using different-sized fasteners, the larger fasteners should generally be tightened first. Small fasteners if tightened first can become loose when a nearby large fastener is tightened.

Illustration 43	g06381753
Generic head face tightening sequence.

Illustration 44	g06381756

Tighten fasteners according to the specified torque sequence, if available. If no torque sequence is specified, then tighten in a star or spiral pattern. Do not tighten adjacent fasteners in order around the perimeter of the bolt pattern.

Do not re-torque Type-K anaerobic joints because the compound begins to cure immediately after flange assembly. Re-torquing will cause the anaerobic to crack and lead to joint failure.

Fasteners must not be loosened and retightened. For example, bolts may not be removed to install a bracket, wiring harness clip, then retightened, as the gasket seal will be compromised.

Troubleshooting Leakage

There are many factors that could cause leakage to occur during testing. The following is a list of items to check that in the event leakage is detected during a test:

• Was the gasket installed?

• Is the bolt torque correct? Were any of the fasteners loosened and retightened?

• Are the mating surfaces clean, dry, flat, porosity-free, and in good condition?

• Is the gasket in proper condition (undamaged, scratch free)?

• Does the gasket fit into the joint properly? Is the gasket positioned correctly?

• Is the gasket dimensionally correct?

• Is the air test pressure appropriate for this type of gasket?

Note: Some gaskets require a "settling" period involving time, temperature, or fluid exposure to seal effectively . A failed air pressurization test during this time frame is not necessarily indicative of a bad joint. If replacing the gasket does not solve the issue, or the same joint routinely fails a pressurization test, conduct a formal root cause analysis with appropriate design groups.

Approved Suppliers and Materials

Silicone

Anaerobic Adhesives