Cylinder Block Cleaning Procedure{1201} Caterpillar

All new, used, and reconditioned cylinder blocks should be cleaned as described in the following procedure before assembly. Any debris or residue (like metal chips, carbon deposits or sludge) that remains in the cylinder block oil passages can cause early engine failure.

Brushes For Cleaning Procedure

Good quality brushes are necessary to do the cleaning procedure. The following chart lists the part number and size of brushes that are available from the Caterpillar Parts Department. These brushes all have stiff nylon bristles.

Flushing (Cleaning) Equipment

1 Complete removal of all debris or residue is generally not possible when only a high pressure wash or a high pressure nozzle is used. Therefore the use of a a nozzle with high aerated flow or with high pulsating flow is recommended. One aerated nozzle that can be used is the "Jumbo Jiffy Gun" with "Air Boost" from the Elliott Company. The following chart lists all necessary parts for use with this tool.

For more information about these cleaning tools, contact:

2 Install a 20 micron filter for filtration of the cleaning solution. [An 8J8850 Filter Group (with 8J1600 Filter Assembly) can be installed as a filter for the cleaning solution.]

Operation

1 Use an alkaline cleaning solution (detergent) in a 2 to 3% concentration (by volume) with the Jumbo Jiffy cleaning gun. The cleaning solution should be at a temperature between 43° and 66°C (110° to 150°F). The closer the temperature of the cleaning solution is to the top of the temperature range, the better will be its cleaning action. The air pressure to the cleaning gun should be about 860 kPa (125 psi), and should be supplied at a flow rate of approximately 114 liters (30 U.S. gallons) per minute. Adjust the cleaning gun pressure to 620 kPa (90 psi).

2 All oil passages must also be thoroughly cleaned with a brush to make certain that all sludge, carbon deposits and debris are removed. A list of brushes is provided on page 2. The use of these brushes for correct cleaning of the cylinder block is also explained on pages 5 and 6.

NOTE: Do not use brushes together with a Jumbo Jiffy cleaning gun. If a Jumbo Jiffy cleaning gun is available, clean with brushes first, then flush the cylinder block with the cleaning gun.

3 All cleaning must be complete and thorough, because incomplete cleaning will only loosen debris or sludge, allowing it to break free after the engine is put into service. This will damage bearings and other components.

4 When the main oil passage in the cylinder block is cleaned, a 3 mm (.125") mild steel rod must be welded to the end of the brush handle, as shown in the illustration. Make sure the rod is long enough to let the brush go all the way through the cylinder block.

Cleaning Procedure

Use the following procedure to make sure that all oil passages in the cylinder block are free of debris, sludge and carbon deposits.

1 Remove as much external debris and deposits as possible before the engine is disassembled. This will help to avoid contamination of the final cleaning solution and wash tanks.

2 While the engine is disassembled, protect the block from dirt and debris accumulations by installing covers and plugs in all oil passage openings, until the block is ready for cleaning.

3 When the cylinder block is ready for final cleaning, remove all oil passage plugs. These plugs can usually be removed with a screwdriver or cut in half with a cold chisel.

Show/hide table

Always wear protective clothing and eye protection when removing and installing plugs, cleaning oil passages with a brush and electric drill, or when using the cleaning gun with the hot cleaning solution. Sludge, metal chips and/or other foreign materials that are forced from the oil passages under pressure can cause injury if the proper protective measures are not taken.

4 Position the cylinder block upside down, with the oil pan rail up, as shown in the illustration. Clean all oil passages with the correct size brush (use a brush with a diameter that is slightly larger than the diameter of the oil passage) that fits tight enough to provide thorough cleaning.

5 Use a petroleum base solvent, and a brush with a variable speed drill, to loosen any debris, sludge or carbon deposits in all oil passages in the cylinder block. Each oil passage must be thoroughly cleaned from every possible direction. Make sure the brush goes all the way to the end of the oil passage. Operate the drill at approximately 300 rpm.

Show/hide table

Do not operate the drill unless the end of the brush is inside the oil passage. Personal injury and damage to machined surfaces can result if the drill is operated with the brush out of the oil passage.

6 After most of the debris and deposits have been removed with the solvent, use a clean brush and a solution of water and detergent to clean out all remaining debris and deposits. When all visible foreign matter has been removed and flushed away, continue cleaning in the areas that are not visible. Clean vigorously and flush repeatedly with the water/detergent solution and the Jumbo Jiffy cleaning gun.

7 Flush all auxiliary oil passages toward the main oil gallery, then flush the main oil gallery from one end. Flush all main oil galleries, such as the camshaft bores, in the same manner. Always flush the main galleries last; this will wash away debris and deposits which have been flushed from the auxiliary oil passages.

8 Small metal particles that are created when pipe plugs and other plugs are installed are a major source of debris and deposits. Follow the procedure shown below to reduce contamination from this often overlooked source of debris and deposits.

a. Remove all plugs and clean all oil passages with a brush and a solution of water and detergent.

b. Clean all threads of each tapped hole with a small brush and water/detergent solution. If the threads have burrs and are damaged, use a tap thread chaser to clean the threads; then clean the threads and oil passages again with a brush and the water/detergent solution.

c. Install all plugs where possible. Use a thread sealant. This will help to hold some of the metal particles created during installation of the plug.

d. Repeat the flushing of all main oil galleries with the water/detergent solution to remove any particles created by the installation of the plugs. Even though auxiliary passages can only be flushed from one direction, this operation is usually adequate and much better than not flushing after any plugs have been installed.

9 Flush away remaining water/detergent solution from all oil passages with clean, clear water (do not use any detergent). After all oil passages have been flushed with clear water, dry the cylinder block with pressure air from an air hose.

10 Prevent damage to the cylinder block from rust or corrosion. Put a corrosion inhibitor on the cylinder block. For long-term storage, use VCI (Volalite Corrosion Inhibited) storage bags. Install all permanent plugs that can be installed. Install temporary plastic plugs in all other openings. More information on rust and corrosion inhibition can be found in Form SEBF4554 (Bulletin R-6 from the Engine and Component Reconditioning Guide).

11 Before an engine is assembled, all rust and corrosion inhibitor, and all temporary plastic plugs, must be removed from the cylinder block (and all other engine parts as applicable). Clean the cylinder block again with a solution of water and detergent to remove all traces of rust and corrosion inhibitor. Then flush the cylinder block again with clear water without detergent. Dry the cylinder block again with pressure air and lubricate all surfaces as needed.