Cylinder Liner: Service and Repair
CYLINDER LINER KITS
Kits contain cylinder liners, pistons, piston pins and piston rings and connecting rods. The components of the kits are pre-measured and matched to each other ensuring correct clearances. Each kit contains one of each component.
CAUTION: All parts of the kits are coated with a preservative that can be removed with approved cleaner. Do not scrape the coating oft of any component in the kit.
Mark the components of each kit with the same letter so that they are not mixed with another kit. For example, if ten kits are used mark all components of the first kit with an A, the second kit with a B.
REMOVAL
1. Mark the liners with a marking pen for liner position in the block.
2. Loosen the nuts of both connecting rods at each journal before removing either one of the connecting rod-piston-liner assembly. It will be necessary to rotate the crankshaft to provide access to all of the connecting rod nuts.
CAUTION: When removing the piston-liner, care must be taken so that the connecting rod bolts do not nick the crankshaft journal. Make bolt protectors out of the rubber hose to fit over the connecting rod bolts once the cap is removed. Then remove the piston-liner assembly.
3. For each piston-liner assembly, turn the crankshaft until the connecting rod cap is at the bottom of its travel (piston at the bottom of the liner).
4. Remove the liner clamp(s) Special Tool 6629 holding the liners in place.
5. Remove the connecting rod nuts and cap.
6. Install rubber insulators over the connecting rod bolts.
7. Remove the piston-liner assembly.
8. Repeat the procedure on all other assemblies that are to be removed.
9. Remove and discard liner 0-rings.
10. Remove the piston-connecting rod assembly from the bottom of the liner.
INSTALLATION (LINER PROTRUSION)
When the cylinder liner and liner 0-rings are installed into the cylinder block, the top of liner protrudes above the cylinder block deck. The protrusion specification is 0.15 mm (.004 in.) maximum across the cylinder block.
CAUTION: When installing cylinder liner assembly into the position be sure that the connecting rod nut clearance notch is facing toward the outside of the engine.
If the original cylinder liner-piston-connecting rod are being reused. Install new 0-ring on the bottom of liner, then position the liners in the same bore from which they were removed. Align the marks that were made on the cylinder block and liner when the engine was disassembled.
CAUTION: Cylinder Liner assemblies are packaged for left or right side applications be sure the correct liner is being installed on the correct side.
If new cylinder liner-piston assemblies are being used, place the new liners with new 0-rings into the cylinder block. Check the liner protrusion. Since the liners are new, it is not necessary to place the liners in any particular order when installing.
Check the liner protrusion using a dial gauge at positions (A) and (B). The liner protrusion specification is between 0.05 mm and 0.12 mm (.002 in. and .004 in.) with 0.04 mm (.0015 in.) maximum across the cylinder head.
The difference in protrusion between any two adjacent cylinder liners is not to exceed 0.04 mm (0.0015 in.) within the range of 0.05 mm and 0.12 mm (0.002 in. and 0.004 in.).
Once the correct protrusions have been obtained, group the assemblies (kits) together and then number the cylinder liners, pistons assemblies from 1 to 10. If the original cylinder liner-piston-connecting rod assemblies are being reused, place the cylinder liner with the corresponding piston assembly.