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Product: GEN SET ENGINE

Model: 3512B GEN SET ENGINE 4AW
Configuration: 3512B Generator Set Engine 4AW00001-UP

Reuse And Salvage Guidelines

Cylinder Block Pitting
Media Number -SELD0458-01 Publication Date -21/11/2002 Date Updated -22/11/2002

SELD04580001

Cylinder Block Pitting

SM CS - 1201

SELD0458-01
July 2002
SMCS Code : 1201

3500 ENGINE &

COMPONENT
RECONDITIONING
BULLETIN
Cylinder Block Pitting

Summary of Revisions

Page Description

All Updated information.

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Problem
Cylinder block pitting has been noted near the 8N-6862 Seals (smaller water seals) in the
cylinder head. This problem is reported as an external water leak at the cylinder head gasket
joint.

The pitting is the result of a chemical reaction between the material in the seals and some
antifreeze solutions, which caused a small electrical voltage.

Solution:
When pitting is found around one cylinder, all the cylinder should be inspected. The pitting can be
repaired with Belzona Ceramic R Metal by using the following procedures.

Reference:

Special Instructions, SEHS8869, "Cylinder Block Salvage Using Belzona

Ceramic R Metal".

Reference:

Special Instructions packed with the Belzona.

Note:

The following areas must be covered or plugged during the repair: cylinder bore, inlet
port, exhaust port and cylinder head bolt openings. These areas could become
contaminated if not properly protected.

1. Use a ¾ inch drill bit to remove only enough metal to remove the porous material. The
depth of the cut should not exceed ¼ inch. The water port opening is the pilot on the small
seal.
2. Grind an undercut around the middle of the ¾ inch water port opening, using a Dremel
tool with a cut off wheel dressed to fit the opening. See illustration.
3. Sweat the area to be repaired. This can be accomplished by using a propane or acetylene
torch. Very little heat is required. This will remove the oil and moisture from the casting.

Caution must be used to prevent the damaging of other seals, gaskets and components in
the area.

4. Clean the prepared area with Belzona cleaner. The Belzona cleaner will dry and leave no
film residue.
5. To maintain the proper water port diameter a ½ inch diameter by 3 inch long wooden dowel
rod will be installed in the water port opening. Before the rod is installed coat the rod with
Belzona release agent and let dry.
6. Mix the Belzona material per package instructions.

Note:

Do not contaminate the product during mixing. Use a separate measuring devices or
thoroughly clean between the measuring of the two different agents.

7. Wet the area to be repaired. Apply small amounts of the Belzona with a small flat stick.
Work the Belzona into the undercut. Make sure all areas are wet.
8. Install the ½ inch dowel into the water port. This is after the release agent has been applied
to the dowel and has dried.

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9. After the dowel is in position continue applying the Belzona until the drilled area is slightly
higher than the top deck of the block.
10. After approximately 30 minutes from the original mix time, the applied material can be
smoothed. Be sure to wear rubber gloves and check to see if the surface of the repair
material has a dried film, or is somewhat sticky.
11. If the repair material sticks to the finger of the glove, it is still too wet. To get a smooth finish
for the material at the repaired area, dip the fingers of the gloves in water, and work the
surface back and forth. Use only enough water to wet the fingers. Too much water on the
Belzona repair material can have adverse effect on its mechanical strength.
12. Press firmly to force out any time that may have been trapped in the material during the
smoothing process. If this smoothing procedure is done correctly, it will reduce the time
needed for sanding once the Belzona repair material has cured.
13. Belzona repair material can be removed from non-repair areas using the Belzona cleaner
before the Belzona hardens.
14. Approximately two to three hours after the Belzona has been applied, it should be hard
enough for sanding. Remove the excess material and sand flush with the top deck of the
cylinder block. Be careful not to dish the repaired area.

Note:

Curing time. When the Belzona Ceramic R Metal is mixed and used at a temperature
of 21

ỳC (70ỳF), it will develop its full mechanical capabilities in 24 hours.

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