Centinel System – Repair Manual – 001-028   Cylinder Liner

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50° C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

WARNING  To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin.

WARNING  Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations.

• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Drain the lubricating oil. Refer to Procedure 007-037 in Section 7.
• Remove the cylinder head. Refer to Procedure 002-004 in Section 2.
• Remove the lubricating oil pan. Refer to Procedure 007-025 in Section 7.
• Remove the lubricating oil suction tube. Refer to Procedure 007-035 in Section 7.
• Remove the block stiffener plate. Refer to Procedure 001-089 in Section 1.
• Remove the piston cooling nozzles. Refer to Procedure 001-046 in Section 1.
• Remove the piston and connecting rod assemblies. Refer to Procedure 001-054 in Section 1.

The cylinder liners can be removed by using either:

• Cylinder liner puller (universal), Part Number 3163745, and puller plate (S600), Part Number 3162462.
• Cylinder liner puller (universal), Part Number 3376015.

CAUTION  The cylinder puller must be installed and used as described to reduce the possibility of damage to the cylinder block. The puller plate must be parallel to the main bearing saddles and must not overlap the cylinder liner outside diameter.

Insert the cylinder liner puller onto the top of the cylinder block.

The cylinder liner puller must be centered on the top of the cylinder block.

Turn the puller jackscrew clockwise to loosen the cylinder liner from the cylinder block.

Use both hands to remove the cylinder liner.

Remove and discard the o-ring seals.

Use Dykem™, or equivalent, to place a mark on the intake air side of the cylinder liner to show cylinder liner orientation.

Use Dykem™, or equivalent, to mark the cylinder number on each cylinder liner.

CAUTION  Do not use emery cloth or sandpaper to remove carbon from the cylinder liners. Aluminum oxide or silicon particles from emery cloth or sand paper can cause serious engine damage. Do not use any abrasives in the ring travel area. The cylinder liner can be damaged.

Use a soft wire brush to clean the flange seating area.

Use a fine fibrous, abrasive pad such as Scotch-Brite™ 7448, Part Number 3823258, or equivalent, to remove the remaining scale and rust.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Wear safety glasses or a face shield, as well as protective clothing, to reduce the possibility of personal injury when using a steam cleaner or high pressure water.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Use solvent or steam clean the cylinder liners and dry with compressed air.

Use clean 15W-40 oil to lubricate the inside circumference of the cylinder liners.

Allow oil to soak into the cylinder liner for 5 to 10 minutes.

Use lint-free paper towels to wipe the oil from the inside of the cylinder liners.

Continue to lubricate the inside of the cylinder liners and wipe clean until the paper towel shows no gray or black residue.

Inspect the cylinder liners for cracks on the inside and outside circumferences.

Inspect for cracks under the cylinder liner flange.

Cracks can also be detected by using either magnetic inspection or dye method.

Inspect the outside circumference for excessive corrosion or pitting.

Cylinder liners with pitting generally can not be used.

However, if the pitting is light and can be removed with fine emery cloth, the cylinder liner can be used.

Cylinder Liner Pitting Depth

Inspect the inside circumference for vertical scratches deep enough to be felt with a fingernail.

If a fingernail catches in the scratch, the cylinder liner must be replaced.

Inspect the inside circumference for scuffing or scoring.

Inspect the inside diameter for cylinder liner bore polishing.

A moderate polish (A) produces a mirror finish in the worn area with traces of the original hone marks or an indication of an etch pattern.

A heavy polish (B) produces a bright mirror finish in the worn area with no traces of hone marks or an etch pattern.

Replace the cylinder liner if a heavy polish is present over 20 percent of the piston ring travel area or 30 percent of the piston ring travel has both moderate and heavy polish and one half (15 percent) is heavy polish.

Use a dial bore gauge to measure the cylinder liner inside diameter in four places, 90 degrees apart at the top and bottom of the piston travel area.

Cylinder Liner Inside Diameter

Measure the cylinder liner top press fit area outside diameter.

Cylinder Top Press Fit Outside Diameter

CAUTION  Cylinder liners of different design can not be mixed within an engine. All six cylinder liners must be of the same design.

There are two different designs of cylinder liners used. The design used in a particular engine is dependent on the engine’s production vintage.

Engines assembled prior to engine serial number 14022615 have groove-top cylinder liners. They are characterized by a groove machined into the top surface of the cylinder liner flange.

Engines with serial number 14022615, and after, are assembled with flat-top cylinder liners. They are characterized by a cylinder liner flange that is flat, except for the fire dam.

Make sure the cylinder block and all parts are clean before assembly.

Lubricate the two cylinder liner o-ring seals with vegetable oil prior to assembly.

Install the two o-ring seals onto the cylinder liner.

CAUTION  Cylinder liners of different design can not be mixed within an engine. All six cylinder liners must be of the same design.

Install the cylinder liner into the cylinder block.

When acceptable and used cylinder liners are installed, rotate the cylinder liner 90 degrees from its original position in the engine. The thrust and anti-thrust surfaces must face the front and back of the cylinder block.

Use cylinder liner installation kit, Part Number 3162461, to seat the liner.

If the cylinder liner does not seat properly, remove it and inspect the cylinder liner bore seat and cylinder liner for nicks, burrs, or dirt.

Install the cylinder liner again.

Because of design differences, the cylinder liner’s position (relative to the cylinder top deck) will be different.

For groove-top cylinder liners, a recession measurement is taken. This measures the depth of the groove relative to the cylinder block deck regardless of the flange or fire dam height.

For flat-top cylinder liners, a cylinder liner protrusion measurement is taken which is the height of the cylinder liner flange above the cylinder block surface regardless of the flange or fire dam height.

Regardless of the cylinder liner design, the measurement technique will be the same.

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

The cylinder liner measurement must be made with the cylinder liners in the clamped state.

Install and tighten the cylinder liner installation tool.

Use depth gauge, Part Number 3823495, to measure the clamped state at the intake side three times and average the readings.

Measure the clamped state of the exhaust side three times and average the readings.

Cylinder Liner Recession (Groove-Top Cylinder Liners)

Cylinder Liner Protrusion (Flat-Top Cylinder Liners)

If the cylinder liner measurement on either the intake or exhaust side is not within specifications, the cylinder liner must be replaced.

For flat-top cylinder liners only:

• The difference between the lowest cylinder liner and the highest cylinder liner can not be greater than 0.102 mm [0.004 in].
• The maximum allowable difference between adjacent cylinders is 0.051 mm [0.002 in].
• The protrusion must be within 0.0381 mm [0.0015 in] around any cylinder.

Before installing the piston and connecting rod assemblies, wipe the inside of the cylinder liners.Use a clean cloth with 15W-40 oil.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

• Install the piston and connecting rod assemblies. Refer to Procedure 001-054 in Section 1.
• Install the piston cooling nozzles. Refer to Procedure 001-046 in Section 1.
• Install the block stiffener plate. Refer to Procedure 001-089 in Section 1.
• Install the oil suction tube. Refer to Procedure 007-035 in Section 7.
• Install the lubricating oil pan. Refer to Procedure 007-025 in Section 7.
• Install the cylinder head. Refer to Procedure 002-004 in Section 2.
• Fill the engine with clean lubricating oil. Refer to Procedure 007-037 in Section 7.
• Prime the lubricating oil system. Refer to Procedure 007-037 in Section 7.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Operate the engine and check for leaks.