| Tools Needed | Quantity | |
| 1U-9895 | Crossblock (1) | 1 |
| 3H-0465 | Push-Puller Plate (1) | 3 |
| 8F-6123 | Bolt (2) | 2 |
| 1P-2396 | Adapter Plate | 1 |
| 8T-4193 | Bolt | 28 |
| 2S-5658 | Hard Washer | 28 |
| 8F-1484 | Washer | 28 |
| 7K-1977 | Washer | 28 |
| 8T-0455 | Liner Projection Tool Group | 1 |
| ( 1 ) | This item is part of the 8B-7548 Push-puller . |
| ( 2 ) | Bolt size is 3/4 16 NF and 140 mm (5.5 inch). |
- Ensure that the top surface of the cylinder block is clean. Install a new plate gasket onto the cylinder block. Place spacer plate (5) onto the plate gasket.
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| Illustration 1 | g00769678 |
(1) 8T-4193 Bolt (2) 2S-5658 Hard Washer (3) 8F-1484 Washer (4) 7K-1977 Washer (5) Spacer plate (6) 1P-2396 Adapter Plate (7) 3H-0465 Push-Puller Plate | |
- Secure the spacer plate to the cylinder block with bolts (1) and gaskets (2), (3) and (4). Use two bolts on each side of each cylinder. Use three gaskets for each bolt. Tighten the bolts evenly in four steps:
- Tighten the bolts to a torque of 14 N·m (10 lb ft).
- Tighten the bolts to a torque of 35 N·m (25 lb ft).
- Tighten the bolts to a torque of 70 N·m (50 lb ft).
- Tighten the bolts to a torque of 95 N·m (70 lb ft).
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| Illustration 2 | g00770644 |
(1) 8T-4193 Bolt (2) 2S-5658 Hard Washer (3) 8F-1484 Washer (4) 7K-1977 Washer | |
Note: The 7K-1977 Washer (4) is made of a plastic material that will not damage the sealing surface of the cylinder block.
- Ensure that the surfaces of the engine block, the cylinder liner, and the spacer plate are clean. Remove any nicks from the surface of the spacer plate.
Note: Use the bare cylinder liners. Do not install the filler bands or the O-ring seals onto the cylinder liners yet.
- Place a cylinder liner into a bore. Fit adapter (6) onto the cylinder liner. Place plate (7) onto the adapter.
- Use crossblock (8), the two plates (7), and the two bolts (9) to seat the cylinder liner in the bore. Tighten the bolts evenly in four steps:
- Tighten the bolts to a torque of 7 N·m (5 lb ft).
- Tighten the bolts to a torque of 20 N·m (15 lb ft).
- Tighten the bolts to a torque of 35 N·m (25 lb ft).
- Tighten the bolts to a torque of 70 N·m (50 lb ft).
After the bolts are tightened, measure the distance from the bottom edge of the crossbar to the surface of the spacer plate. The distance must be equal on both sides of the cylinder liner. If the distance is not equal, repeat the bolt tightening.
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| Illustration 3 | g00740417 |
(7) 3H-0465 Push-Puller Plate (8) 1U-9895 Crossblock (9) 8F-6123 Bolt (10) 8T-0455 Liner Projection Tool Group | |
- Use 8T-0455 Liner Projection Tool Group (10) to measure the cylinder liner projection.
Note: Refer to Special Instruction, SMHS7727 that is provided with the tool group.
- Loosen bolt (11) until dial indicator (12) can be moved. Place gauge body (13) and dial indicator (12) on the long side of gauge block (14) .
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Illustration 4 g00770022
8T-0455 Liner Projection Tool Group
(11) Bolt
(12) Dial indicator
(13) Gauge body
(14) Gauge block
- Slide dial indicator (12) downward until the point contacts gauge block (14) and the needle of the dial indicator moves to the vertical position. Tighten bolt (11). Zero the dial indicator.
- Place gauge block (14) on the spacer plate with the point of the dial indicator on the cylinder liner flange. Read the dial indicator in order to find the amount of cylinder liner projection.
- Measure the projection of four points that are equally distant around each cylinder liner.
If the projection is not within specifications for the cylinder liner projection that is listed in Table 6, remove the cylinder liner. Turn the cylinder liner to a different position and seat the cylinder liner into the cylinder bore. Measure the projection again. If the projection does not meet the specifications, install the cylinder liner into a different bore.
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Illustration 5 g00769831
Points to measure around each cylinder liner
- After the projection of the cylinder liner is within specifications, mark the radial position of the cylinder liner for the cylinder. Be sure to identify the particular cylinder liner with the corresponding cylinder.
- Record the measurements in Table 2. Add the four measurements for each cylinder. Divide the sum by four in order to calculate the average projection for each cylinder liner. Record the averages in Table 2.
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Table 2 Cylinder Liner Projection Points Measurement 1A 1B 1C 1D Sum Average 2A 2B 2C 2D Sum Average 3A 3B 3C 3D Sum Average 4A 4B 4C 4D Sum Average 5A 5B 5C 5D Sum Average 6A 6B 6C 6D Sum Average
- Record the maximum measurement and the minimum measurement for each cylinder in Table 3. Subtract the minimum measurement from the maximum measurement in order to determine the maximum variation for each cylinder liner projection.
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Table 3 Maximum Variation for Each Cylinder Cylinder 1 (maximum) Cylinder 1 (minimum) Variation Cylinder 2 (maximum) Cylinder 2 (minimum) Variation Cylinder 3 (maximum) Cylinder 3 (minimum) Variation Cylinder 4 (maximum) Cylinder 4 (minimum) Variation Cylinder 5 (maximum) Cylinder 5 (minimum) Variation Cylinder 6 (maximum) Cylinder 6 (minimum) Variation
- Record the average measurement for the adjacent cylinder liners in Table 4. Determine the variation between the adjacent cylinder liners. Record the variations in Table 4.
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Table 4 Variation of the Average Measurements for Adjacent Cylinder Liners Cylinder 1 (average) Cylinder 2 (average) Variation Cylinder 2 (average) Cylinder 3 (average) Variation Cylinder 3 (average) Cylinder 4 (average) Variation Cylinder 4 (average) Cylinder 5 (average) Variation Cylinder 5 (average) Cylinder 6 (average) Variation
- Determine the cylinder with the greatest average measurement and the cylinder with the least average measurement. Record the measurements in Table 5. Subtract the minimum average measurement from the maximum average measurement in order to determine the maximum variation of all the cylinder liner projections.
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Table 5 Maximum Variation of All of the Cylinder Liner Projections Greatest average measurement Least average measurement Variation
- Compare the results to the specifications that are listed in Table 6.
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Table 6 Specifications for Cylinder Liner Projection Cylinder liner projection
0.033 to 0.175 mm (0.0013 to 0.0069 inch)Maximum variation for each cylinder liner
0.05 mm (0.002 inch)Maximum average variation between adjacent cylinder liners
0.05 mm (0.002 inch)Maximum variation for all of the cylinder liners ( G3306 Engines)
0.10 mm (0.004 inch)
Result 1
The cylinder liner projection is correct. - The results meet the specifications that are listed in Table 6. Remove the cylinder liners and remove the tooling from the spacer plate. Install the filler bands and the O-ring seals onto the cylinder liners. Refer to Disassembly and Assembly, "Cylinder Liners - Install".
Result 2
One or more cylinder liner projections exceeds the maximum specifications. - At least one of the results exceed the specifications that are listed in Table 6.
Use any of the following methods in order to correct the condition:
- Machine the engine block. The 8S-3140 Counterboring Tool Group can be used. Refer to Instruction, FM055228. After the cylinder block is reworked, use any of the following shims in order to obtain the correct cylinder liner projection: 8S-6045 Shim (0.18 mm (0.007 inch)), 8S-6046 Shim (0.20 mm (0.008 inch)), 8S-6047 Shim (0.23 mm (0.009 inch)), 8S-6048 Shim (0.38 mm (0.015 inch)) and 8S-6049 Shim (0.76 mm (0.030 inch)).
- Obtain new cylinder liners.
- Obtain a new engine block.
Result 3
One or more cylinder liner projections is less than the minimum specifications. - At least one of the results is less than the maximum specifications that are listed in Table 6.
Use any of the following methods in order to correct the condition:
- Shim the cylinder liner. Use the shims that are listed in "Result 2" in order to obtain the correct cylinder liner projection.
- Obtain new cylinder liners.
- Obtain a new engine block.