REMOVAL & INSTALLATION
See Figures 1, 2, 3 and 48-250, 8-273 Engines Only
This procedure requires special tools; J-29775 cylinder liner holder, and J-29776 cylinder liner gauge. Also this is a complex procedure and is not recommended for the novice mechanic.
- Remove the cylinder heads and install the cylinder liner holders J-29775.
- Remove the oil pan and then remove the pistons as previously described.
Since the cylinder liners are removable it is necessary to keep the liner matched with the appropriate piston. Ink mark these assemblies as they are removed. Do not stamp liners with a punch stamp. Since it is possible (but not advisable) to install the liners without regard to orientation, liners which will be reinstalled should be ink marked with their original position so that this orientation may be maintained during installation.
- To remove the liners, remove the holder J-29775 and pull the liners from their position in cylinder block. Discard the O-ring from bottom of the cylinder liner.
- Inspect the mating surfaces of the cylinder block and liner to be sure they are clean and free of nicks or burrs. Minor blemishes should be polished out with crocus cloth (fine emery cloth).
- If liners are being installed in their original positions in the original block, it will not be necessary to gauge their height as this process was done on a select-fit basis during manufacturing. In this situation, install a new, lightly oiled O-ring seal on the liner and position the liner in its original position and with its original orientation in the block. Repeat this procedure for each liner removed. Install liner clamp J-29775.
Engines that have experienced overheating must be measured upon reassembly.
If a new piston/liner assembly is to be installed, proceed as follows:
- Position the new liner in its position in the block without the O-ring installed.
- Lay the cylinder liner gauge J-29776 on a flat surface such as the cylinder deck face or a piece of glass and zero the dial indicator. Only moderate pressure on the gauge is needed to zero the indicator. Excessive pressure will cause the gauge to bend creating a false zero.
- Measure the liner height by inserting the spring loaded guide pins into the liner so that the machined pads rest on the edge of the liner and the dial indicator pointer contacts the block's deck face. Apply moderate pressure to the gauge until the pointer stops moving.
- Read and record the dial reading. If this reading is on the (+) side of the dial, the cylinder liner is higher than the block face by the indicated amount. If this reading is on the (-) side of the dial, the cylinder liner is below the block face.
- Repeat steps C and D at two more locations as shown.
- Take the average of the three readings as the actual value for liner height. For example if reading #1 is + 5 (0.05mm), Reading #2 is + 7 (0.07mm) and Reading #3 is + 3 (0.03mm). then the total (15) divided by 3 is + 5.
- Correct liner height is +0.01mm to +008mm above cylinder deck face. If any liner is below +0.01mm (0.00 or a - value) or above +0.08mm, the liner must be replaced with another new assembly. Liners may be rotated in the block to obtain proper liner height. This orientation must be noted and re-established for final assembly.
- If liner height is within the range of +0.01mm to +0.08mm, the liner-to-liner dimension must also be established before assembly is attempted.
- To gauge liner-to-liner height, install the adjacent liner(s) in their original position and orientation without the O-ring. Using gauge J-29776 gauge between the liners while holding the second liner firmly in place with your free hand. This reading must be within plus or minus 0.05mm (plus or minus on gauge). Ink mark the liner orientation once it is established.
- Once the gauging operation is completed on all the new liner assemblies, liners should be installed in their respective positions using a new, lightly oiled, O-ring on each liner. Liners must be installed in the position and orientation in the block for which they have been gauged.
- Install liner holders J-29775.