Series 60 – Testing the Cylinder Block (Immersion Pressure Method)

Use cylinder block pressure test kit (J–36223–D) for immersion method pressure testing as follows:
1.Install cylinder liners with new seal rings and crevice seals. Refer to section 1.23.3. Seat the liners firmly in the block counterbores with cylinder liner installation tool (J–35597–A).
2.Install two metric eye bolts (J–35595) in the head bolt holes at opposite ends of the block. See Figure 1-10.

3. Install the cylinder block test strips and rings. See Figure 1-10.
4. Install the bolts through the strips and into the cylinder block. Torque the bolts on the ring strips to 230-237 N·m (170-175 lb·ft). Torque the bolts on the outside strips to 14 N·m (10 lb·ft).
5. Install the water inlet cover plate (J–36223–7A, part of tool set J–36223–D). See Figure 1-11. Use the bolt supplied with the tool to secure it to the cylinder block.

At the base of each liner, the space between upper and lower liner seals is vented to the block surface on the left side. Any coolant leakage past the upper seal is drained to the outside rather than into the crankcase, and is easily detected by a visual inspection.

6. With a suitable lifting device and spreadable bars, immerse the cylinder block for twenty minutes in a tank of water heated to 82-93°C (180-200°F).
7. Attach an air line to the water inlet cover plate and apply 138 kPa (20 psi) air pressure to the water jacket. Observe the water in the tank for bubbles that will indicate cracks or leaks. A cracked cylinder block must be replaced by a new block.
8. Remove the block from the water tank. Remove the plates and gaskets and blow out all of the passages in the block with compressed air.
9. Install the cylinder block to the engine overhaul stand (J–29109). See Figure 1-6.

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