32802 2 Mercury PIPE PLUG

Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.
Table 1
Dimensions for Acceptable Cylinder Liner Projection with the 362-8264 Cylinder Head Gasket
Part Dimension Value
454-9920 Cylinder Liner flange 12.650 0.020 mm (0.4980 0.0008 inch) Z
519-7297 Spacer Plate 12.338 to 12.388 mm (0.48575 to 0.4877 inch) X
144-5692 Plate Gasket 0.170 to 0.230 mm (0.0067 to 0.0091 inch) Y
Allowable projection 0.050 to 0.120 mm (0.0020 to 0.0047 inch) References
Reference: Refer to Reuse And Salvage Guidelines, "Procedure to Salvage Top Decks of Cylinder Blocks of 3500 Engines" for additional information about reuse and/or salvage of the cylinder block.Introduction
Use this procedure to check the cylinder liner projection out of the cylinder block and installed in the cylinder block.Required Tools
Table 2
Required Tools
Item Qty Part Number Part Name
T1 4 1A-0075 Bolt (3/4-16 thread, 44.45 mm (1.750 inch) long
T2 1 1U-9895 Crossblock
T3 4 3B-1925 Washer (COPPER)
T4 2 3H-0465 Push-Puller Plate
T5 1 6V-7059 Micrometer
T6 2 8F-6123 Bolt (3/4-16 thread, 139.7 mm (5.5.50 inch) long
T7 1 8T-0455 Liner Projection Tool Group
T7a 1 1P-2402 Gauge Body
T7b 1 1P-2403 Dial Indicator
T7c 1 1P-5507 Gauge Block
T7d 1 5S-2671 Bolt
Illustration 1 g06512241
8T-0455 Liner Projection Tool Group
(T7a) 1P-2402 Gauge Body
(T7b) 1P-2403 Dial Indicator
(T7c) 1P-5507 Gauge Block
(T7d) 5S-2671 BoltPreparation
For checking the cylinder liner projection with the liner out of the cylinder block, ensure that the following surfaces are clean prior to measuring:
Cylinder liner flanges
Spacer plate
Spacer plate gasketFor checking the installed cylinder liner projection, ensure that the following surfaces are clean prior to measuring:
Top surface of the cylinder block
Cylinder liner bores
Cylinder liner flanges
Spacer plates
Spacer plate gasketCylinder Liner out of the Cylinder Block - Check
Illustration 2 g02247495
Use micrometer (T5) to measure the thickness of the following items:
(X) Spacer Plate
(Y) Spacer Plate Gasket
(Z) Cylinder Liner FlangeNote: To determine the cylinder liner projection, subtract the thickness of the spacer plate and gasket from the thickness of the cylinder liner flange.
Refer to Table 1 for the correct value of your cylinder liner projection.Cylinder Liner Installed in the Cylinder Block - Check
Illustration 3 g06512258
Measuring the cylinder liner projection
(T1) 1A-0075 Bolt
(T2) 1U-9895 Crossblock
(T3) 3B-1925 Washer (COPPER)
(T4) 3H-0465 Push-Puller Plate
(T6) 8F-6123 Bolt
(T7a) 1P-2402 Gauge Body
(T7b) 1P-2403 Dial Indicator
(1) Spacer plate
Install a new gasket and spacer plate (1) on the cylinder block.
Install the cylinder liner in the cylinder block without seals or bands.
Hold spacer plate (1) and the cylinder liner in position according to the following procedure:
Install four bolts (T1) and four washers (T3) around spacer plate (1). Tighten the bolts evenly to a torque of 95 N m (70 lb ft).
Install the following components: crossblock (T2), two pusher-puller plates (T4), and two bolts (T6). Ensure that crossblock (T2) is in position at the center of the cylinder liner. Ensure that the surface of the cylinder liner is clean. Tighten the bolts evenly to a torque of 70 N m (50 lb ft).
Check the distance from the bottom edge of crossblock (T2) to the top edge of spacer plate (1). The vertical distance from both ends of the crossblock (T2) must be equal.
Use liner projection tool group