Engine Block Cleaning Procedure

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Product: GAS ENGINE
Model: G3512 GAS ENGINE 7NJ
Configuration: G3512 ENGINE 7NJ00001-UP
Special Instruction
Cylinder Block Cleaning Procedure{1201}
Media Number -SMHS8418-00 Publication Date -01/01/1985 Date Updated -13/10/2001
Cylinder Block Cleaning Procedure{1201}

SMCS - 1201
Reference: Engine And Component Reconditioning Guide Bulletin R-6, Form SEBF4554.
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.
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 2018-10-16
NOTICE
Do not use brushes with loose or worn bristles, NEVER use a brush
with metal bristles. Metal bristles can break off and leave debris in the
engine block oil passages. This can cause damage to engine parts and
result in early engine failure.
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:
The Elliott Company

1809 Sheridan Ave.
Springfield, OH 45505 USA
TWS: 810/452-2865
Tel: (513) 324-4191
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.
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.
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.
NOTICE
Do not let any surfaces dry by evaporation. If surfaces are allowed to

dry by evaporation only, they can form rust or corrosion.
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.
Copyright 1993 - 2018 Caterpillar Inc. Tue Oct 16 15:15:52 UTC+0330 2018
All Rights Reserved.
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G3512 ENGINE 7NJ00001-UP(SEBP2230 - 72)/Basic Search Page 1 of 7

Cylinder Block Cleaning Procedure{1201}

Brushes For Cleaning Procedure

Flushing (Cleaning) Equipment

For more information about these cleaning tools, contact:

The Elliott Company

Do not let any surfaces dry by evaporation. If surfaces are allowed to

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