M11 Series – Service Manual – 001-028   Cylinder Liner

NOTE: Cummins® Engine Company, Inc. does not recommend removing the cylinder liners to repair an oil consumption problem unless the cylinder liners are damaged and must be replaced.

Remove the cylinder head. Refer to Procedure 002-004.

Drain the lubricating oil pan. Refer to Procedure 007-037.

Remove the lubricating oil pan. Refer to Procedure 007-025.

Remove the piston cooling nozzles. Refer to Procedure 001-046.

Remove the pistons and connecting rods. Refer to Procedure 001-054.

The cylinder liners can be removed by using universal liner puller, Part Number 3375629.

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

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

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

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

Use both hands to remove the liner.

When the liner is removed from the cylinder block, use Dykem®, or equivalent, to place a mark on the camshaft side of the liner to show liner orientation.

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

CAUTION  Do not use any abrasives in the ring travel area of the liner. The 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 a steam cleaner, wear protective clothing, as well as, safety glasses or a face shield. Hot steam will cause serious personal injury.

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

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

Allow the oil to soak in the liner for 5 to 10 minutes.

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

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

Inspect the liners for cracks on the inside and outside diameters.

Inspect for cracks under the liner flange.

Cracks can also be detected using either magnetic inspection or the dye method. Refer to the M11 Shop Manual, Bulletin 3666075.

Inspect the outside diameter for excessive corrosion or pitting. Liners with pitting generally can not be reused. However, if the pitting is light and can be removed with fine emery cloth, the liner can be reused.

Pits must not be more than 1.60 mm [0.060 in] deep.

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

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

Inspect the inside diameter for scuffing or scoring.

Inspect the inside diameter for liner bore polishing.

NOTE: M Series cylinder liners are not lubricated.

A moderate polish (A) produces a bright 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 liner if:

• A heavy polish is present over 20 percent of the piston ring travel area.
• 30 percent of the piston ring travel area has both moderate and heavy polish and one-half (15 percent) is heavy polish.

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

Measure the liner top press fit area outside diameter.

The current 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 liners must be installed within 30 seconds after being lubricated with oil. If the liners 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 liners are installed, rotate the liner 90 degrees from their original position 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. Refer to Procedure 001-064 for measuring the cylinder liner protrusion.

Install the pistons and connecting rods. Refer to Procedure 001-054.

Install the piston cooling nozzles. Refer to Procedure 001-046.

Install the lubricating oil pan. Refer to Procedure 007-025.

Install the cylinder head. Refer to Procedure 002-004.

Fill the engine with lubricating oil. Refer to Procedure 007-037.

Operate the engine to normal operating temperature and check for leaks.