Cat C13 with coolant getting into the oil

I do not think that you understand the situation. I machined the counterbores perfectly, measured from the block deck. The bore in the block is machined so crooked, that when the liner is installed without clamping it down, gets against the rear side of the counterbore, while the front of the liner is still .005" from touching the front of the counterbore. So then, when the front of the liner is forced down against the counterbore, the liner gets so distorted, that it leaks coolant past the o-ring, that is .035" larger OD than the bore in the block,when installed on the liner. With out any pressure in the cooling system. Just gravity.

 

It was .005" higher than the rear.

 

I am embarrassed. I was completely wrong in my diagnosis of this problem. I should have waited until we got the block into our shop, to publish my diagnosis. It turns out that there was not a problem with the block, but the whole problem, was that the mechanic, unknown to me, was using anti-freeze as an o-ring lubricant. Apparently the o-rings were not sliding into place as they should have, causing them to buckle, as the liners were being installed into the block. He should have been using the Cat recommended "rubber lubricant". The thing that threw me off, and I have no explanation for it, is that the o-rings all buckled on the same side, which pushed all of the leaking liners, the same way. If even one of them would have pushed the opposite way, It would have thrown my "crooked bore theory" out the door. He had had a Cat mechanic examine the problem, and he thought that anti-freeze was a suitable lubricant. "IT IS NOT"!! After closely examining the o-rings that were only installed once, one of them was split halfway through. Because these are flat o-rings, they are much more critical as to what lubricant is used. Sorry for my misleading posts.