COOLER GP-EXHAUST (NRS) 3551059 - Caterpillar

some of the water (coolant) holes in the top of the cylinder block. When these conditions exist, it will be necessary to install water ferrules with seals in those cylinder block coolant holes, to prevent coolant leakage at those specific locations. The 6V4840 Tool Group, a 6V4841 or 6V6021 Fixture Assembly and the information in this instruction are needed for the installation procedure for the new 5N8868 and 5N8869 Ferrules. The tools needed are given on page 2 of this instruction.
After liner projection has been checked and adjusted as necessary, it is necessary to remove all of the liners from the cylinder block before the water ferrule installation procedure is started.
Tools Needed
Parts of the 6V4840 Tool Group are:1 - 6V4842 Core Drill6V4845 Core Drill2 - 6V4851 Drill Bushing6V4853 Drill Bushing6V4854 Drill Bushing6V4855 Drill Bushing6V4856 Drill Bushing6V4866 Drill Bushing3 - 1D4610 Bolt (2)4 - 6V4846 Reamer - Ø 12,19 mm (0.480")6V4847 Reamer - Ø 13,49 mm (0.531")6V4848 Reamer - Ø 18,72 mm (0.737")6V4849 Reamer - Ø 19,84 mm (0.781")5 - 5P8248 Washer (2)6 - 6V4859 Case6V4861 Block6V6044 Block Also needed for the ferrule and seal installation procedure will be either the 6V4841 Fixture Assembly (7) or the 6V6021 Fixture Assembly (8). The 6V4841 Fixture Assembly (7) is for use on 158.8 (6.25") bore, Vee engines, while 6V6021 Fixture Assembly (8) is for use on 146.1 (5.75") bore, 4 cylinder engines and 158.8 (6.25") bore, 6 cylinder engines. See the instructions that follow, for tool usage.Recondition The Water Holes
(1) Install the correct fixture assembly (1) on the cylinder block. (Illustration above shows 6V6021 Fixture Assembly.) To put the fixture assembly in the correct position, put the fixture assembly dowel holes over dowel pins (A). [Dowel pins (A) are used to keep the cylinder head in correct position. (2) Use 1D4610 Bolts (2) with washers to hold fixture assembly (1) in position. The illustrations that follow show which coolant holes, according to engine model, must be changed to a new size. (3) For 158.8mm (6.25") bore, 6 cylinder engines, all coolant holes at locations (B) must have their size changed. Any holes at locations (C) that are 2 mm (.080") or nearer to the liner seat insert, must also have their size changed. (4) For 146.1 mm (5.75") bore, 4 cylinder engines, all coolant holes at locations (D) must have their size changed. (5) For 158.8 mm (6.25") bore Vee engines, all coolant holes at locations (B) must have their size changed. Any holes at locations (C) that are 2 mm (.080") or nearer to the liner seal insert, must also have their size changed. (6) For all holes at locations (B): 1. Use a 6V4842 Core Drill (3) 11.91 mm Ø (.469"Ø) and a 6V4853 Bushing to drill through the top deck of the cylinder block.2. Use a 6V4846 Reamer (4), 12.19 mm Ø (.480"Ø) and a 6V4854 Bushing, to ream through the same holes.3. Use a 6V4847 Reamer, 13.49 mm Ø (.531"Ø) and a 6V4855 Bushing to make a