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Cylinder Liner

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Install

The present o-ring has been produced by two distinctly different manufacturing
processes. Following are those two methods
and the installation procedures:

The molded o-ring has a symmetrical cross section. The edges are rounded. It does
not require specific care in orientation of the o-ring other than normal prevention of
rolling the o-ring.

The lathe-cut o-ring has a straight outside with sharp corners. The inside has two 45-
degree chamfers (1) so there are no
sharp corners next to the  liner . This o-ring
must be installed with the straight side (2) facing the block and the chamfered side
next to the  liner . If the o-ring is not installed this way,  liner  bore distortion can
occur.

 CAUTION 
The  liner s must be installed within 30 seconds after being lubricated with oil.
If the  liner s are not installed within this
time limit, the o-rings will swell and be
damaged when the  liner  is installed.
Make sure the  cylinder  block and all parts are clean before assembly.

Use clean 15W-40 oil to coat the  liner  o-ring seals.

Install the o-ring seal on the  liner .

Install the  liner  into the  cylinder  block.

When acceptable reused  liner s are installed, rotate the  liner s 90 degrees from their
original positions in the engine. The
thrust and anti-thrust surfaces must face the
front and back of the  cylinder  block.

Use  cylinder   liner  driver, Part Number 3824272, and a leather mallet to drive the
 liner  into the  cylinder  block bore.

If the  liner  does not seat properly, remove the  liner . Inspect the counterbore seat
and  liner  for nicks, burrs, or dirt. Install the  liner  again.

The  cylinder   liner  protrusion must be checked before installing the pistons and
connecting rods.

Use the  cylinder   liner  clamping tool, Part Number 3824272, to seat the  liner  in the
 cylinder  block.

Place the force plate (3) across the top of the  liner  with the step inside the  liner 
bore.

Place the installation tool bridge (1) across the  liner  and install the two  cylinder 
head capscrews finger-tight to hold the
bridge down. Rotate the force plate until the
areas where the protrusion measurements will be taken are exposed.

 CAUTION 

Do not use an impact wrench to tighten the  liner  force plate screw. Excessive
torque will cause damage to the  liner  installation
tool.

Tighten the forcing screw (2).

Torque Value:  136 
n•m
  
[
100 ft-lb
]

Use a depth gauge, Part Number 3164438, to measure the  liner  protrusion at four
points that are 90 degrees apart.

 Cylinder   Liner  Protrusion


mm in
0.00 MIN 0.0000
0.12 MAX 0.0047
Maximum allowable variation in  liner  protrusion for each 180 degrees is 0.03mm

[0.001 inch].

Use a feeler gauge to measure the  liner -to-block clearance at the four-block casting
points.

 Cylinder   Liner -to-Block Clearance


mm in
0.25 MIN 0.010

Last Modified:  26-Feb-2016

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