This procedure describes the correct method for measuring the cylinder liner height in the event of cavitation.
Only start with this procedure when the height of all liners is measured.
There are different service cylinder liners available to correct the cylinder liner height.
– A service cylinder liner with a 0.50 mm [0.020 in] higher collar.
– A service cylinder liner with a 0.25 mm [0.0098 in] higher collar.
– A service cylinder liner with a 0.04 mm [0.0016 in] higher collar.
Top deck condition before repair
The cylinder liner seat can only be repaired when:
– The damage of the sealing surface (A1) of the top deck is not deeper than 0.02 mm.
The fretting damage (A2) around the liner is not on a sealing surface, so no maximum depth is applicable here.
There is sealing between liner, gasket and cylinder head.
Acceptable damaged top deck
Condition before repair
1. Remove the cylinder liner from the cylinder block.
2. Inspect the liner seat and liner bore and make sure that:
– The cavitated surface of the liner seat (B) is not deeper than 0.45 mm.
– The damaged surface of the liner bore (C) must not have more cavitation or damage than shown in the pictures. If in doubt, contact your local helpdesk.
3. Remove the adjacent cylinder liner(s).
Mark the position of the cylinder liners to install them in their original orientation.
4. Machine the surface of the liner seat until it is free of cavitation according to the procedure: “Repair cylinder liner seat”.
5. Install the appropriate service cylinder liner to make sure that only the minimum amount of material has to be removed.
6. Position the special tool (1) (1809948) on the cylinder liner.
7. Check that the tool is properly centered and tighten the attachment bolts (2) in the specified sequence to the specified torque.
8. Place the special tool (4) (1903047) onto the height measurement tool (1).
9. Fit the clock gauge (3) into the cylinder liner height gauge block (4).
Use a digital clock gauge with an accuracy of 0.005 mm.
10. Position the tip of the clock gauge (3) onto the outside edge of the cylinder liner.
11.Measure the cylinder liner height according to the specified measuring sequence and note the values in the table.
Make sure not to measure the cylinder liner height on the damaged part of the top deck.
12. Remove the special tool (1) (1809948) from the cylinder liner.
13. Calculate how much supporting surface must be machined using the following calculation method:
The difference between the average of E, B, D and C, A, F from the adjacent liner must not exceed 0.03 mm.
14. Remove the service cylinder liner from the cylinder block.
15. Machine the supporting surface using this procedure: “Repair cylinder liner seat”
16. Install the service cylinder liner.
17. Repeat steps 6 to 12.
Make sure that the correct cylinder liner height is reached.
Checking the repair possibility
1. Mark the position of the cylinder liners.
To install the cylinder liner in its original orientation.
2. Position the special tool (1) (1809948) on the cylinder liner.
3. Check that the tool is properly centered and tighten the attachment bolts (2) in the specified sequence to the specified torque.
4. Place the special tool (4) (1903047) onto the height measurement tool (1).
5. Fit the clock gauge (3) into the cylinder liner height gauge block (4).
Use a digital clock gauge with an accuracy of 0.005 mm [0.0002 in].
6. Position the tip of the clock gauge (3) onto the outside edge of the cylinder liner.
7. Measure the cylinder liner height according to the specified measuring sequence and note the values in the table.
Re-zero the clock gauge before each individual measurement.
8. Remove the special tool (1) (1809948) from the cylinder liner.
9. Remove the cylinder liner from the cylinder block according to the job: (Remove 1 (one) cylinder liner)
10. Inspect the cylinder block according to the: Conditions before repair as described above.
11. Machine the surface of the liner seat until it is free of cavitation according to the procedure:
“Repair cylinder liner seat”.
12. Install the service cylinder liner.
Make sure that the cylinder block is cleaned thoroughly.
13. Repeat steps 2 to 7.
14. Calculate how much supporting surface must be machined using the following calculation method:
The difference between the average of E, B, D and C, A, F from the adjacent liner must not exceed 0.03 mm [0.00012 in].
15. Machine the supporting surface using this procedure: “Repair cylinder liner seat”
