M11 Series – Service Manual – 001-064   Cylinder Liner Protrusion

To measure the cylinder liner protrusion, the cylinder head
must be removed. If the cylinder head is
not removed, Refer to Procedure
for instructions on how to remove the cylinder head.

Reference the L10 Alternative Repair Manual, Bulletin 3810310.

Use 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.

Put 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).

Check for correct protrusion.

Use a depth gauge, Part Number 3823495, to measure the liner protrusion at four points 90-degrees apart.

If the liner protrusion varies more than 0.025 mm [0.0010 in] for each 180 degrees:

• Remove the liner.

NOTE: It will be necessary to remove the piston and connecting rod assembly, if this has
not already been done, before removing the cylinder liner.

Refer to Procedure
001-054 in Section 1.

Reference the L10 Alternative Repair Manual, Bulletin 3810310.

• Inspect the liner sealing edge for burrs, dirt, or damage.
• Replace the liner if it is damaged.

• Install the liner again.
• Inspect the liner protrusion.

If the liner protrusion still does
not meet the specifications, cut the cylinder block liner bore for shims.

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

If the clearance is less than 0.25 mm [0.010 in]:

• Remove the liner.

• Inspect the liner and cylinder block for dirt or damage.

• Replace the liner if it is damaged.
• Install the liner again.

Measure the liner bore for out of roundness at points “C,” “D,” “E,” “F,” and “G.” Measure each point in the direction “AA” and “BB”. The bore
must not be more than 0.10 mm [0.004 in] out-of-round.

If the liner bore is more than 0.10 mm [0.004 in] out-of-round:

• Remove the liner so the cylinder block liner bore can be measured.

NOTE: The block counterbore diameters above and below the cylinder block counterbore area are
not critical dimensions, and do
not need to be measured.

Measure the cylinder block upper liner bore (A).

Measure the cylinder block liner seal seat bore (B) 8.0 to 13.5 mm [0.32 to 0.53 in] below the counterbore.

Measure the liner outside diameter (A).

NOTE: The cylinder block liner counterbore flange diameter is
not a critical dimension and does
not need to be measured.

Measure the cylinder liner seal seat outside diameter (C).

Inspect the cylinder block liner bore and liner for burrs, dirt, or damage.

Replace the liner if it is damaged.

Inspect the liner bore (A) and protrusion again (B).

Replace the liner if it does
not meet the specifications.