PLUG AS 3893733 - Caterpillar

(1) Put the disassembled cylinder block in position on the jig mill as shown. Make sure the front face of the block is perpendicular to the spindle of the jig mill by obtaining the same dial indicator reading at a minimum of three locations on the face of the block as shown. (2) The center of bore (A) for the fuel injection pump can be obtained by first locating the center of the camshaft bearing bore (B), then measuring 146.04 mm (5.750 in) vertically to locate the center of bore (A). Machine bore (A) to a diameter of 126.900 .013 mm (4.9960 .0005 in).(3) Put a thin coat of 6V1541 Quick Cure Primer on the machined bore of the cylinder block and on the outside diameter of the 4W6143 Sleeve. Lower the temperature of the sleeve to -84°C (-120°F), and put a coat of 9S3265 Retaining Compound on the machined bore of the cylinder block. (4) Use the 1P520 Driver Group and a hammer to install sleeve (1) flush with rear face (C) of the bore. If the sleeve is driven past face (C) of the bore, incorrect location of the fuel injection pump will result. Drill three equally spaced 2.80 mmØ (.110"Ø) holes (D) 12.7 mm (.5") deep. Put 6-32-2B threads 10 mm (.40") deep in the three holes. Use three 5H8548 Screws to fasten the sleeve in place. (5) Machine the inside diameter of sleeve (1) to 120.663 .025 mm (4.7505 .0010 in). The surface finish of the bore must not be rougher than 2.8 micrometers (110 microinches). Machine a chamfer in edge (E) of sleeve (1) to the dimension shown. Grind sleeve (1) and and the three screws flush with surface (F) of the block. Grind the lower 100° arc of sleeve (1) flush with surface (G) of the block (area between the arrows).