ENGINE - Continued
Cylinder Block Pressure Test Inspection
(1) Clean seal ring grooves thoroughly. Install new seal rings in grooves. Apply light coating of antifreeze (item
2, Appendix B) to seal rings.
(2) Place liner inserts in cylinder counterbores. Slide cylinder liners into block. Be careful not to roll or damage
(3) Install new compression gaskets and water hole seals in counterbores in the block.
(4) Make steel plates of 1/2 in. thick stock to cover each cylinder bank on block.
Secure plates to block using 11/16 in. - 11 bolts and flat washers. Tighten to 250 ft lb (339 Nm).
Seal off water inlet and outlet holes using rubber gaskets and steel plates bolted in place. Drill and tap one
cover plate for air inlet connection.
Install adapter J29592 to seal the aftercooler water inlet adapter plug in air box floor.
Immerse block for twenty minutes in a heated tank of water at 180 - 200 deg. F (82 - 93 deg. C).
Apply 40 psi (276 kPa) air pressure to water jacket.
(10) Observe the water in tank for bubbles which, if present, indicates the presence of a leak or crack in block. A
cracked block must be replaced.
(11) Remove block from tank. Remove plates, gaskets, liners and inserts.
Death or serious injury could occur is compressed air is directed against the skin. Do not use
compressed air for cleaning for drying unless the pressure is/has been reduced to 30 psi (2.11 kg/cm2) or
less. When working with compressed air always use chip guards, eye protection and other personal
(12) Blow out all passages in block and dry liners and inserts using compressed air.
(13) Coat all components with engine oil (item 17, Appendix B) to prevent rusting before final assembly.
Cylinder Block Bore Inspection
(1) Clean seal ring grooves. If grooves are eroded, or pitted, block must be replaced.
(2) Measure bore of each cylinder with bore gage J5347-01. Use master setting tool J23059-01 to set up bore