NUMBER: 2 1–10 S.M. REF.

: Listed in Table ENGINE: Series 60 DATE: February 2010

SUBJECT: CYLINDER LINER PROTRUSION & INSTALLATION

ADDITIONS, REVISIONS, OR UPDATES

Publication Number Platform Section Title Change Page Number(s)
DDC-SVC-MAN-0004 EPA04 Series 60 Section 1.23.3 Cylinder Liner
Installation of Cylinder Installation procedure
Liner has been updated
NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.
CHECKING CYLINDER LINER PROTRUSION
Check the cylinder liner as follows:
1. Wipe the inside and outside of the liner clean. Be sure the block bore and counter bore are clean,
so the liner flange will seat properly. The block counter bore depth must be 8.9255-8.9662 mm
(0.3514 -0.3530 in) and must not vary more than 0.04 mm (0.0016 in) in depth around the
circumference. Variation between two adjacent block counter bores may not range in depth
more than 0.0508 mm (0.002 in) when measured in the center line of block.

1. Cylinder Block A. Counterbore Depth Measurement

Figure 1 Measuring Counterbore Depth

NOTE:
Thoroughly clean the cylinder block liner counter bores to remove any foreign material. Foreign
material in the cylinder liner counter bores can cause the liner to seat improperly.

2. Install the cylinder liner into the engine block without any seals.

NOTE:
It is necessary to leave the cylinder liner installation tool in place until after the liner protrusion is
measured.
 3. Install J–35597–A , over the liner. See Figure 2.

Figure 2 Cylinder Liner Installation Tools

4. Thread three cylinder head bolts through the tool and into a head bolt hole so that the round
shoe of the tool is centered over the liner.

NOTE:
It is not necessary to torque the bolts.

5. Tighten the bolts.

6. Turn the threaded center bolt in a clockwise direction. As the round shoe of the tool reaches the
liner, ensure that the shoe is properly positioned into the cylinder liner.
7. Continue turning the bolt until the liner bottoms in the cylinder counterbore. Apply a tightening
torque of 60 N·m (44 lb·ft) to the installation tool center bolt.
8. Install a dial indicator sled gage. See Figure 2.
9. Measure the distance from the top of the liner flange to the top of the block. See Figure 3.

Figure 3 Cylinder Liner Protrusion

[a] Allowable liner protrusion is -0.0127-0.0762 mm (-0.0005-0.003 in) with no more than
0.0508 mm (0.002 in) variation between any two adjacent cylinders.
[b] If the liner protrusion exceeds the maximum allowable, remove the liner and check for
debris under the liner flange. If there is no debris, machine the liner counterbore.
INSTALLATION OF CYLINDER LINER
Install the cylinder liner as follows:

NOTE:
Refer to section "Installation of the Piston and Connecting Rod" for 14L liner, piston and connecting
rod procedure.

1. Wipe the inside and outside of the liner clean.

2. Lubricate the seal rings and crevice seal with clean petroleum jelly.
3. Install two new seal rings and a new crevice seal into their respective grooves in the liner.
4. Install the cylinder liner, piston and rod assembly into the cylinder bore. Refer to section
"Installation of the Piston and Connecting Rod."

NOTE:
It is necessary to leave the cylinder liner installation tool in place until after the liner protrusion is
measured.

5. Install J–35597–A over the liner. See Figure 4.

Figure 4 Cylinder Liner Installation Tools

6. Thread three cylinder head bolts through the tool and into a head bolt hole so that the round
shoe of the tool is centered over the liner.
7. Tighten the bolts.

NOTE:
It is not necessary to torque the bolts.

8. Turn the threaded center bolt in a clockwise direction. As the round shoe of the tool reaches the
liner, ensure that the shoe is properly positioned into the cylinder liner.
9. Continue turning the bolt until the liner bottoms in the cylinder counterbore. Apply a tightening
torque of 60 N·m (44 lb·ft) to the installation tool center bolt.
10. Install a dial indicator sled gauge. See Figure 4.
11. Measure the distance from the top of the liner flange to the top of the block. To verify that the
liner protrusion has not changed. See Figure 5.
[a] Allowable liner protrusion is -0.0127-0.0762 mm (-0.0005-0.003 in) with no more than
0.0508 mm (0.002 in) variation between any two adjacent cylinders.
[b] If the liner protrusion exceeds the maximum allowable, remove the liner and check liner
protrusion.

Figure 5 Cylinder Liner Protrusion

ADDITIONAL SERVICE INFORMATION
Additional service information is available in Power Service Literature.

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