D348 INDUSTRIAL & MARINE ENGINES Caterpillar

start by:

a) remove pistons

b) remove spacer plates

1. Use tooling (A) and an impact wrench to loosen the cylinder liners from the cylinder block.

2. Remove cylinder liners (1) from the cylinder block.

NOTE: See GUIDELINE FOR REUSABLE PARTS, PISTON AND CYLINDER LINERS, Form No. SEBF8001.

Install Cylinder Liners

1. Put a new gasket and the O-ring seal in position on the engine block.

2. Put spacer plate (1) in position and install the two bolts at the end of the spacer plate. Tighten the bolts to a torque of 35 ± 5 lb.ft. (45 ± 7 N·m).

3. Make sure the liners and the cylinder block are clean. Put the liners in position in the cylinder block without the O-ring seals.

4. Check the cylinder liner height (projection) as follows:

NOTE: To keep the bolts and washers so they are not moved as each liner is checked, install two bolts with washers on each side of each cylinder liner, along the complete length of the top plate.

a) Use 3/4"-10 NC bolts (2), 3 in. long [part of tooling (A) with two 2F126 Washers on each bolt to hold the spacer plate to the cylinder block]. Tighten the bolts evenly, in four steps: 10 lb. ft. (14 N·m), 25 lb. ft. (35 N·m), 50 lb. ft. (70 N·m) and then to 70 lb. ft. (95 N·m).

b) Install tooling (A) to hold the cylinder liner down. Tighten both bolts evenly, in four steps: 5 lb. ft. (7 N·m), 15 lb. ft. (20 N·m), 25 lb. ft. (35 N·m) and then 50 lb. ft. (70 N·m).

c) Use tooling (B) to check liner height (projection) as close as possible to where the liner is held in position by tooling (A) at four different locations around the liner. The liner height (projection) must be within .0020 to .0076 in. (0.05 to 0.19 mm). The difference between the four measurements must not be more than .002 in. (0.051 mm). The difference between the average height (projection) of any two cylinder liners next to each other must not be more than .002 in. (0.051 mm).

NOTE: If liner height is different from point to point around the liner, make a rotation of the liner to a new position within the bore. If it is still not within specifications, move the liner to a different bore.

6. If the liner height is not .0020 to .0076 in. (0.05 to 0.19 mm), check the thickness of the following parts: cylinder liner flange (3), spacer plate (1) and spacer plate gasket. The thickness of the liner flange is .5260 ± .0008 in. (13.36 ± 0.02 mm), spacer plate .5142 ± .0010 in. (13.06 ± 0.03 mm) and spacer plate gasket .008 ± .001 in. (0.20 ± 0.025 mm).

NOTE: The cylinder liner height (projection) can be changed by a counterbore made in the block to a minimum depth of .030 in. (0.76 mm) with a cylinder block counterboring tool. The maximum depth of the counterbore is .045 in. (1.14 mm). See SPECIAL INSTRUCTION FORM FMO55228. Shims are available for the adjustment of the liner height (projection).

7. Put a mark on the cylinder liner and spacer plate so the liner can be installed in the same position from which it was removed.

8. Remove tooling (A). Remove the cylinder liner. Install new O-ring seals on the liners. Put 7M7260 Liquid Gasket on the under side of the cylinder liner flange.

NOTE: Do not put 7M7260 Liquid Gasket material on the cylinder block. Put the .030 in. (0.76 mm) shim on top of the shim package if more than one shim is used. Put 7M7260 Liquid Gasket material on the top and bottom of the shim package.

9. Put liquid soap on the O-ring seals and on the cylinder bores. Put filler band (4) in diesel fuel, then immediately install on the cylinder liner. Put a thin layer of SAE 30 oil on the band and then immediately install the cylinder liner in the cylinder block before expansion of the band starts. Push the liners down with tooling (C).

end by:

a) install pistons