ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 001-028   Cylinder Liner

The cylinder block has a replaceable cylinder liner. A mid-stop design is used to locate the liner in the block. A press fit between the liner and the block provides coolant sealing at the top of the liner. A rectangular ring seal (liner seal) is used for sealing at the mid-stop portion of the liner.

NOTE: Cummins Inc. does not recommend removing the cylinder liners to repair an oil consumption problem if the inside diameters of the liners are within the inspection limits included in this procedure. Careful analysis of the condition of the liner bores, piston rings, and pistons can result in the restoration of cylinder sealing with a minimum replacement of parts.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

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  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.

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Remove the cylinder head. Refer to Procedure 002-004 in Section 2.
• Drain the lubricating oil. Refer to Procedure 007-037 in Section 7.
• 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 piston and connecting rod assemblies. Refer to Procedure 001-054 in Section 1.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

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  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.

CAUTION  Use caution when disconnecting or removing fuel lines and replacing filters that fuel is not spilled or drained into the bilge area. Do not drop or throw filter elements into the bilge area. The fuel and fuel filters must be discarded in accordance with local environmental regulations.

CAUTION  Use caution when draining the coolant. Do not spill coolant into the bilge area. Coolant must not be pumped overboard. The coolant must be disposed in accordance with local environmental regulations.

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Shut off the sea water supply. Refer to the OEM service manual.
• Drain the engine coolant system. Refer to Procedure 008-018 in Section 8.
• Drain the lubricating oil. Refer to Procedure 007-037 in Section 7.
• Shut off the fuel supply to the engine. Refer to the OEM service manual.
• Remove the engine from the vessel. Refer to Procedure 000-001 in Section 1.
• Remove the valve cover. Refer to Procedure 003-011 in Section 3.
• 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 piston and connecting rod assemblies. Refer to Procedure 001-054 in Section 1.

NOTE: Before removing the cylinder liners, inspect the condition to determine reuse.

Inspect the inside diameters of the liners for cracks, scuffing, and scoring.

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

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

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.

Do not reuse liners exhibiting heavy polish or any indications of particle embedment from a failure. Severely worn liners will have a ridge near the top of the liner bore.

If the wear pattern indicates the liner bore is not straight or not round, use a dial bore gauge to measure the liner inside diameter in four places 90 degrees apart at the top and bottom of the piston travel area.

Cylinder Liner Dimensions

NOTE: If a liner bore is not acceptable for reuse, it must be replaced. Damaged liners can not be honed or deglazed. This would destroy the cross-hatch pattern needed for oil control.

NOTE: Do not remove or disturb the liner seals for liners which pass the inspection criteria.

Liner protrusion is the distance the liner protrudes above the block face. Before removing the liners, check the protrusion in the “unclamped” stage. Use liner protrusion gauge, Part Number 3164438, to measure the liner protrusion.

Cylinder Liner Protrusion

If the liner was installed correctly and the liner protrusion is out of limits, it will be necessary to machine the counterbore and add shims to restore to the original specifications.

Use clean shop rags to cover the crankshaft to prevent debris from falling into the main journal area or into the connecting rod journal oil drilling.

CAUTION  The liner puller must be installed and used as described to avoid damage to the cylinder block. The puller must not contact the block casting at points (1), (2), (3), and (4).

Universal Cylinder Liner Puller Method

Cylinder Liner Puller, Part Number 3376015

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

NOTE: 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.

CAUTION  The liner 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 liner outside diameter.

Standard Liner Puller Method

Liner Puller, Part Number 3163745, may be used as an alternative to the standard puller. The universal puller must be used with remover plate, Part Number 3822786.

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

NOTE: 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.

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 or a fine fibrous abrasive pad such as abrasive pad, Part Number 3823258 or equivalent, to clean the flange seating area.

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  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

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 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.

NOTE: 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 does not show gray or black residue.

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

Inspect for cracks under the flange.

Inspect the outside diameter and seat area for excessive corrosion or pitting.

NOTE: Pits must not be more than 1.6 mm [0.06 in] deep.

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

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

NOTE: 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.

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.

Replace the liner if:

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

Dial Bore Gauge, Part Number 3376619

Measure the 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 outside diameter of the liner top press fit area.

Cylinder Liner Out Diameter (Top Press Fit)

Cylinder Liner Bore in Block (Press Fit Bore)

CAUTION  Clean all deposits and debris from sealing surfaces A, B, and C. Use abrasive pad, Part Number 3823258 or equivalent, and cleaning solvent to polish the surfaces. Due to the critical machined tolerances, care should be taken not to remove any additional material.

If surface C has cracks or signs of extreme wear, the counterbore will require machining and the installation of shims for the correct liner protrusion.

Using the Counterbore Cutter, Part Number 3163785, machine the counterbore to the proper depth.

NOTE: Part Number 3823567, cutter plate, and Part Number 3823570, cutter bit, must be used with the counterbore machining tool.

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  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

Clean the combustion deck with a gasket scraper or abrasive pad, Part Number 3823258 or equivalent, and diesel fuel or solvent.

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  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

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

Thoroughly flush the block with mineral spirits or cleaning solvent.

Remove the shop rags and clean the crankshaft with a cleaning solvent.

Blow the cylinder bores and crankshaft dry and wipe them clean with a lint-free cloth.

Lubricate surfaces A and B with clean 15W-40 engine oil.

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

Install new o-ring seals on the liners.

When reusing liners, install them in the same cylinder from where they were removed and rotate them 45 degrees (1/8 turn) from their original position. When correctly installed, any liner pitting must be positioned as illustrated so the pitted surface is rotated away from the location where pitting occurs.

Install the liner into the bore of the cylinder block, use liner driver, Part Number ST-1229.

Use two (2) cylinder head capscrews and position the two (2) liner clamps, Part Number 3822503, as illustrated.

Tighten the capscrews.

Remove the clamps and repeat this procedure until all liners have been clamped and released.

Liner protrusion is the distance the liner protrudes above the block face.

Measure the liner protrusion at four points 90 degrees apart using gauge, Part Number 3164438.

Cylinder Liner Protrusion

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

• Install and tighten the liner clamps again.

• Measure the liner protrusion again.

NOTE: If the protrusion still varies more than 0.025 mm [0.0010 in]:

• Remove the liner
• Inspect the liner sealing edge for burrs, dirt, or damage
• Replace the liner if it is damaged
• Install the liner again
• Measure the liner protrusion.

Service Tip: If the out-of-limit condition is minimal, tolerance stack-up may allow the protrusion limits to be obtained by installing other new liners in the out-of-limit bore.

NOTE: If the liner protrusion still does not meet the specifications, machine the cylinder block liner bore for shims using the following tools:

• Drive unit, Part Number 3163785
• Cutter plate, Part Number 3823567
• Cutter bit, Part Number 3823570

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

Cylinder Liner to Block Clearance

NOTE: If the clearance is less than 0.229 mm [0.009 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 0.04 mm [0.002 in] out-of-round.

NOTE: If the liner bore is more than 0.04 mm [0.002 in] out-of-round:

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

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the pistons and connecting rods. Refer to Procedure 001-054 in Section 1.
• Install the lubricating 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.
• Install the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Fill lubricating oil system. Refer to Procedure 007-037 in Section 7.
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Operate the engine and check for leaks.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the piston and connecting rod assemblies. Refer to Procedure 001-054 in Section 1.
• Install the lubricating 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.
• Install the valve cover. Refer to Procedure 003-011 in Section 3.
• Install the engine into the vessel. Refer to Procedure 000-002 in Section 1.
• Fill the lubricating oil system. Refer to Procedure 007-037 in Section 7.
• Fill the engine coolant system. Refer to Procedure 008-018 in Section 8.
• Open the sea water supply. Refer to the OEM service manual.
• Open the fuel supply to the engine. Refer to the OEM service manual.
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Operate the engine until the coolant temperature reaches 82°C [180°F] and check for leaks and proper operation.