N14 Base Engine Troubleshooting and Repair Manual – 001-028   Cylinder Liner

Preparatory Steps

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 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.
 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.

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Remove the lubricating oil pan. Refer to Procedure 007-025 in Section 7.

Remove the piston cooling nozzles. Refer to Procedure 001-046 in Section 1.

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Remove

TOC

 CAUTION 

The liner puller must be installed and used as described to avoid damage to the cylinder block.

The following steps use liner puller, Part Number 3376015.

  • Insert the liner puller into the top of the cylinder block.
  • The liner puller must be centered on the top of the cylinder block.
  • The feet on the extension arms must be extended below the bottom of the liner.

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Turn the puller jackscrew clockwise .

Use both hands to remove the liners.

Remove and discard the o-rings and the crevice seals.

Do not discard the sealing rings which are located under the cylinder liner flange. Sealing rings can be used again.

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Use a liquid metal marker to mark the cylinder number on each liner.

If the sealing rings were removed, do the following:

  • Use a tag to mark the cylinder number.
  • Measure in several places and record the thickness of the sealing rings used in each cylinder. The thickness of the sealing ring is one factor in determining liner protrusion. This information must be known when the liners are installed in the engine.

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 CAUTION 

The liner puller must be installed and used as described to avoid damage to the cylinder block.
 CAUTION 

The puller plate must not overlap the liner outside diameter.

The following steps use liner puller, Part Number 3375629.

  • Insert the liner puller into the top of the cylinder block.
  • The liner puller must be centered on the top of the cylinder block.
  • The puller plate must be parallel to the main bearing saddles.

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Turn the puller jackscrew clockwise.

Use both hands to remove the liner.

Remove and discard the crevice seals and the o-rings.

Do not discard the sealing rings which are located under the liner flange. Sealing rings can be used again.

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Use a liquid metal marker to mark the cylinder number on each liner.

If the sealing rings were removed, do the following:

  • Use a tag to mark the cylinder number.
  • Measure in several places and record the thickness of the sealing rings used in each cylinder. The thickness of the sealing ring is one factor in determining liner protrusion. This information must be known when the liners are installed in the engine.

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Clean and Inspect for Reuse

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 WARNING 

Wear eye protection. Make sure the wire brush is rated for the RPM being used if the brush is motor driven.
 CAUTION 

Do not use a hone, deglazing, or pre-brushing to clean the cylinder liners. Abrasives can damage the finish and the crosshatch pattern and can contaminate the liner.

Use a high quality steel wire brush to clean the liner flange seating area.

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 WARNING 

When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.
 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 appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Use a non-metallic bristle brush, detergent soap, and warm water to clean the inside diameter.

Use a steam cleaner or solvent tank to clean the liners.

Dry with compressed air.

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

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Inspect for cracks under the flange.

Cracks can also be detected by using either magnetic inspection or the dye method. Reference the N14 Shop Manual, Bulletin 3810487.

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Inspect the outside diameter for excessive corrosion or pitting. Liners with pitting generally can not be used again. However, if the pitting is light (the bottom is easily seen), the liner can be turned 90 degrees from its original position and used again. The liner pitting must not be orientated on the intake or the exhaust side of the block.

Replace the liner if the pits are too deep or if the corrosion can not be removed with a fine emery cloth.

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Inspect the inside diameters 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.

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Inspect the inside diameter for liner bore polishing.

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

Reference the Generic Service Literature Reuse/Repair Practices, Bulletin 3810303, for further information on liner bore polishing.

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Replace the liner if:

  • A heavy polish is present over 20 percent of the piston ring travel area.
  • Thirty percent (30%) of the piston ring travel area has both moderate and heavy polish, and one-half (15 percent) is heavy polish.
 
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Use a dial bore gauge to measure the liner inside diameter in four places 90 degrees apart at the top and the bottom of the ring travel area.

Cylinder Liner Inside Diameter

mm in
139.694 MIN 5.499
139.827 MAX 5.505

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Measure the upper press fit liner flange diameter.

Upper Press Fit Liner Flange Diameter

mm in
Standard 166.72 MIN 6.564
  166.77 MAX 6.566
Oversize 167.74 MIN 6.604
  167.79 MAX 6.606

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The liner design incorporates a press fit between the upper liner bore and the area of the liner directly below the liner flange. This is referred to as the lower press fit design.

Cylinder liners with standard and oversize press fit diameters are available.

Lower Press Fit Liner Flange Diameter

mm in
Standard 159.91 MIN 6.296
  159.96 MAX 6.298
Oversize 160.93 MIN 6.336
  160.98 MAX 6.338
 
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Measure the liner flange thickness.

Lower Press Fit Design Liner Flange Thickness

mm in
Standard 9.01 MIN 0.355
  9.04 MAX 0.356
Oversize 9.52 MIN 0.375
  9.55 MAX 0.376

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Measure the lower press fit diameter.

Lower Press Fit Design Lower Press Fit Area Outside Diameter

mm in
Standard 159.91 MIN 6.296
  159.96 MAX 6.298
Oversize 160.93 MIN 6.336
  160.98 MAX 6.338
 
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Apply a thick film of clean 15W-40 oil to the bores of the liners for final cleaning. Leave the oil on for 5 to 10 minutes.

Use a clean, lint-free paper towel, not cloth, to wipe the oil from the bores until the black and gray deposits are removed.

Do not set the liners in an area where dirty air flow can contaminate the liners.

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If the block surface needs to be resurfaced, the engine must be removed from the chassis.

Reference the Alternative Repair Manual, Bulletin 3379035.

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 WARNING 

Do not smoke or allow any flame, pilot light, sparks, arcing switch or equipment in area or area sharing ventilation. Solvents may be identified by state or federal agencies as carcinogenic or cause reproductive toxicity. See manufacturer’s Material Safety Data Sheet for product warnings. Naptha and methyl ethyl ketone (MEK) are flammable. Do not use starting fluid as a cleaning agent.

When cleaning the liner counterbore in-chassis, install the chip control plug, Part Number 3823231, in the lower bore to prevent contamination of the crankshaft.

Inspect the liner counterbore as follows:

  • Clean the cylinder block counterbores with a suitable hydrocarbon solvent such as naptha, methyl ethyl ketone (MEK) or trichlorethane 1, 1, 1 (methyl chloroform).

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Check the counterbore for cracks or porosity.

 
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If there is a crack, it usually can be seen in the corner between the upper bore area and the ledge.

If any cracks of any size can be seen running horizontally around the counterbore, all the coolant passages that are close to the bore must be repaired. Reference the NH/NT Counterbore Troubleshooting and Repair Manual, Bulletin 3810450, for repair.

 
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Circumferential cracks in the counterbore ledge that do not extend more than one-half the width of the ledge are acceptable.

 
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Inspect the liner counterbore for cracks. If cracks are present, the cylinder block can be used without salvage if:

  • Circumferential cracks do not extend into a cylinder head capscrew hole or a water jacket hole.
  • Circumferential cracks do not extend beyond one-half the width of the counterbore ledge from the radius.

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Circumferential cracks that extend more than one-half the width of the ledge must be repaired with a sleeve.

Reference the Counterbore Troubleshooting and Repair Manual, Bulletin 3810450, for repair instructions.

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If there is a porous area below the counterbore ledge that is close to a capscrew hole, the hole must be repaired. Refer to Procedure 001-059 in Section 1.

If there is a porous area above the counterbore ledge that is close to a coolant passage, the passage must be repaired. Reference the Counterbore Troubleshooting and Repair Manual, Bulletin 3810450, for repair instructions.

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Cylinder blocks with vertical cracks that extend down over the counterbore ledge that can not be machined out using an 17.907 mm [0.750 in] long sleeve can not be repaired.

 
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Measure below the counterbore in two directions as shown.

A standard LPF bore must check 159.842 to 159.893 mm [6.293 to 6.295 in] in the press fit area below the counterbore.

If the bore exceeds the maximum specifications, it needs to be machined for an oversize LPF liner.

An oversize LPF bore must check 160.858 to 160.909 mm [6.333 to 6.3350 in] in the press fit area below the counterbore.

If the bore measures other than the above tolerances, it must be bored again or sleeved to the correct lower press fit.

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Use inside micrometers or the correct liner flange as a go/no go gauge to check the upper bore.

A standard LPF counterbore must check 166.88 to 166.78 mm [6.570 to 6.564 in].

The preferred dimension for an oversize LPF counterbore is between 167.39 to 167.23 mm [6.590 to 6.584 in]. If the counterbore is less than 167.23 mm [6.584 in] for oversize LPF, or 166.78 mm [6.564 in] for standard LPF, it must be machined again.

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Measure the diameter of the counterbore area as follows:

Measure the counterbore diameter from the top deck to 2.54 mm [0.100 in] below the top deck of the cylinder block.

The counterbore diameter must be measured 45 degrees to the crankshaft and measured at two places as shown.

Reference the NH/NT Counterbore Troubleshooting and Repair Manual, Bulletin 3810450, for machining instructions.

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 CAUTION 

Make sure the indicator does not contact the counterbore radius. It will not give a true indication of the ledge angle and can cause liner damage.

Use a depth gauge, Part Number 3823495. Measure the angle of the counterbore ledge at four equally spaced points.

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Measurement (2) must never exceed measurement (1) or be less than measurement (1) by more than 0.025 mm [0.001 in].

Machine the ledge again if the measurement near the counterbore edge (2) exceeds the measurement near the radius (1).

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The desired protrusion is the total sum of the thickness of the liner flange and the seal rings minus the counterbore depth.

Cylinder Liner Protrusion

mm in
0.10 MIN 0.004
0.18 MAX 0.007

Cylinder liners and sealing rings are available in the following sizes:

Lower Press Fit Liners and Sealing Rings
Standard LPF Liner
Oversize LPF Liner
Part Name
Thickness mm [in]
Part Name
Thickness mm [in]
Sealing ring
0.50 [0.0195]
Sealing ring
0.46 [0.0180]
Sealing ring
0.52 [0.0205]
Sealing ring
0.51 [0.0200]
Sealing ring
0.55 [0.0215]
Sealing ring
0.56 [0.0220]
Sealing ring
0.57 [0.0225]
Sealing ring
0.79 [0.0310]
Sealing ring
0.60 [0.0235]
   
Sealing ring
0.62 [0.0245]
   
Sealing ring
0.79 [0.0310]
   
Sealing ring
1.58 [0.0620]
   

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  1. Standard Lower Press Fit (LPF)
  2. Standard flange outside diameter (1) and thickness (2)
  3. Oversize Lower Press Fit (LPF) 0.020/0.040
  4. Oversize flange outside diameter (3) (plus 0.51 mm [0.020 in])
  5. Oversize flange thickness (4) (plus 0.51 mm [0.020 in]),
  6. Oversize lower press fit diameter (5) (plus 1.02 mm [0.040 in]).

If the ledge angle is okay and a sealing ring(s) is available that will give the correct protrusion, use that sealing ring(s). If the ledge must be cut again to achieve correct protrusion or ledge angle. Reference the NH/NT Counterbore Troubleshooting and Repair Manual, Bulletin 3810450, for machining instructions. Two sealing rings can be used to achieve correct protrusion.

 
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Install

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Make sure the cylinder block and all parts are clean before assembly. If used liners are being installed again, any sealing rings removed must be installed with the same liner in the same cylinder.

Use vegetable oil to lubricate the new liner o-rings and the crevice seals.

Use vegetable oil to lubricate the o-rings. Do not use lubricating oil on the o-rings. The o-rings will increase in size after they have been lubricated with oil.

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Install the crevice seal (1) into the top groove.

Install the black o-rings (2 and 3) into the center and the bottom grooves.

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Do not apply sealant to the counterbore.

Put a sealing ring into position on the counterbore ledge.

 
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Do not get excessive oil on the counterbore or the liner flange. Excessive oil can result in a hydraulic lock condition and generate inaccurate liner protrusion. Make sure that the o-rings do not move from the grooves.

Lubricate the crevice seal and the o-rings with vegetable oil. Install the liner in the bore with a quick push.

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Liner installation tool, Part Number 3823615, is used to press the cylinder liner into the cylinder block. Protrusion can be checked while the liner is held down by the installation tool.

 
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Put the force plate (3) across the top of the liner with the step in the liner bore. Tap the top of the force plate with a soft hammer to square up and start the liner into the press fit bore.

 
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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.

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 CAUTION 

Do not use an impact wrench to tighten the liner force plate screw.

Tighten the forcing screw (2).

Torque Value:  136  n.m  [100 ft-lb]

Check for correct protrusion.

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

The protrusion must be from 0.10 to 0.18 mm [0.004 to 0.007 in].

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If correct liner protrusion is not attained, remove the liner from the cylinder block.

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The desired counterbore depth is the total sum of the thickness of the liner flange and the seal rings minus the cylinder liner protrusion.

Cylinder Liner Protrusion

mm in
0.10 MIN 0.004
0.18 MAX 0.007
 
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Check for twisted liner o-rings.

Clean the liner flange and the cylinder block liner counterbore.

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Inspect the liner flange for burrs.

Inspect the cylinder block liner counterbore for burrs.

Remove the burrs, or replace the damaged parts.

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Install the liner.

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Finishing Steps

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Install the pistons and the connecting rods. Refer to Procedure 001-054 in Section 1.

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Install the piston cooling nozzles. Refer to Procedure 001-046 in Section 1.

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Install the lubricating oil pan. Refer to Procedure 007-025 in Section 7.

Install the cylinder heads. Refer to Procedure 002-004 in Section 2.

Install the rocker lever housings. Refer to Procedure 003-013 in Section 3.

Install the injectors. Refer to Procedure 006-026 in Section 6.

Installl the rocker lever assemblies. Refer to Procedure 003-009 in Section 3.

Adjust the valves and injectors. Refer to Procedure 003-004 in Section 3.

Install and adjust the compression brakes, if equipped. Refer to Procedure 020-001 in Section 20.

Install the rocker lever covers. Refer to Procedure 003-011 in Section 3.

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 CAUTION 

The lubricating oil system must be primed before operating the engine after any internal engine repairs to avoid internal component damage. Do not prime the system from the bypass filter; the filter will be damaged.

Prime the lubricating system. Refer to Procedure 007-037 in Section 7.

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Fill the engine with lubricating oil. Refer to Procedure 007-025 in Section 7.

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Fill the cooling system. Refer to Procedure 008-018 in Section 8.

Do not overfill the cooling system.

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If new rings, liners, or pistons were installed, perform the engine run-in. Refer to Procedure 014-004 in Section 14.

Operate the engine until it reaches a temperature of 82°C [180°F], and check for coolant or lubricating oil leaks.

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Last Modified:  11-Jun-2010