Usage:
1. Install clean liners or cylinder packs (without the filler band or the rubber seals), spacer plate gasket and clean spacer plate.
2. Install bolts and washers, as indicated previously, in the holes indicated with an X. Install all bolts or the six bolts around the liner. Tighten the bolts to a torque of ... 95 N·m (70 lb ft).
3. Use the 8T0455 Liner Projection Tool Group to measure liner projection at positions indicated with and A,B,C and D. Record measurements for each cylinder. Add the four readings for each cylinder and divide by four to find the average.
4. The cylinder liner specifications are as follows:
Liner projection ... 0.025 to 0.152 mm (0.001 to 0.006 in)
Maximum variation in each cylinder ... 0.051 mm (.002 in)
Maximum average variation between adjacent cylinders ... 0.051 mm (.002 in)
Maximum variation between all cylinders ... 0.102 mm (.004 in)
5. If the liner projections are out of specification, try rotating the liner or install the liner in another bore to see if the measurements improve.
6. If the liner projections are all below the specifications or low in the range, 0.025 mm (0.001 in) or 0.051 mm (0.002 in), try using a thinner spacer plate. These plates are 0.076 mm (.003 in) thinner than the regular plate and they will increase the liner projection, thus increasing the fire ring crush. Use these spacer plates to compensate for low liner projections that are less than 0.076 mm (.003 in) or if the inspection of the top deck reveals no measurable damage directly under the liner flanges, but the average liner projection is less than 0.076 mm (0.003 in).
NOTE: Do not exceed the maximum liner projection of 0.152 mm (.006 in). Excessive liner projection will contribute to liner flange cracking.
7. With the proper liner projection, mark the liners in the proper position and set them aside.
8. When the engine is ready for final assembly, the o-ring seals, cylinder block and upper filler band must be lubricated before installation.
If the lower o-rings are black in color, apply liquid soap on the lower o-ring seals and the cylinder block. Use clean engine oil on the upper filler band.
If the lower o-rings are brown in color, apply engine oil on the lower o-ring seals, the cylinder block and the upper filler band.
NOTE: Apply liquid soap and/or clean engine oil immediately before assembly. If applied too early, the filler bands may swell and be pinched under the liners during installation.