1.20 CYLINDER LINER
Contents
1. 19 Cylinder Liner Protrusion 12 Remove the cylinder liner tool 13 With all of the cylinder liners installed and the liner protrusion measurements within specifications install the piston and connecting rod assemblies Refer to section 1 18 5 All information subject to change without notice Rev 12 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 23 60 03 1 392a 1 20 CYLINDER LINER This page intentionally left blank Rev 12 03 All information subject to change without notice 1 392b From Bulletin 23 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION2. 483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 23 60 03 1 387 1 20 CYLINDER LINER NOTICE Erosion is due to poor cooling system maintenance If uncorrected it will eventually make holes through the liner This can result in combustion gases blowing water out of the radiator oil in the coolant or when the engine is stopped will allow water to flow into the cylinder and result in major engine damage due to water in the oil or hydraulic lockup c Check the cylinder liner for cavitation erosion See Figure 1 316 1 Cracks 3 Erosion 2 Cylinder Liner Figure 1 316 Cylinder Liner Cavitation Erosion d If cavitation erosion occurs replace with a new part Refer to section 1 20 3 NOTICE Series 60 cylinder liners are honed at the factory with a process that cannot be duplicated in the field For this reason honing of used liners should not be attempted 2 Inspect the outside diameter of the liner a Check liner for fretting b If any fretting is found remove it from the surface of the liner with a coarse flat stone Rev 12 03 All information subject to change without notice 1 388 From Bulletin 23 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 3 Inspect the liner flange a Check the liner flange for cracks smoothness and flatness on both the top and bottom surfaces b If these are detected replace with a new part 4 Ins
3. Damage to the liner and the cylinder block may occur if the proper tools and procedures are not used 1 Remove the piston and connecting rod as an assembly Refer to section 1 18 2 All information subject to change without notice Rev 12 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 23 60 03 1 385 1 20 CYLINDER LINER 2 Remove the cylinder liner with cylinder liner remover J 45876 See Figure 1 315 gt AS yf f M aa 2 R q Fi y DERES Figure 1 315 Cylinder Liner Removal Tool J 45876 a Ease the liner removal tool down into the liner b Turn the nut on tool J 45876 in a clockwise direction to remove liner from the block NOTE After removing liners from an engine and prior to installing liners always store them in an upright position until ready for use Liners left on their side for any length of time can become egg shaped and distorted making installation in cylinder bores difficult or impossible If the cylinder liners are to be reused they should be marked for cylinder location and engine orientation a paint mark can be used to indicate the front of engine so they may be installed to the same cylinder from which they were removed c Remove the tool from the liner Rev 12 03 All information subject to change without notice 1 386 From Bulletin 23 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MAN
4. SERIES 60 SERVICE MANUAL 1 20 CYLINDER LINER The cylinder liner is of the replaceable wet type made of alloy cast iron and is slip fit in the cylinder block See Figure 1 309 1 Crevice Seal 4 O ring Grooves 2 Crevice Seal Groove 5 D ring Seals 3 Cylinder Liner Figure 1 309 Cylinder Liner and Related Parts Coolant in the cylinder block water jacket surrounds the liner and cools it directly A cooling channel is also cut into the liner immediately below the flange Coolant flow through this channel and around the rest of the liner controls critical ring and liner temperatures for long cylinder component life All information subject to change without notice Rev 12 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 23 60 03 1 379 1 20 CYLINDER LINER The liner is inserted in the cylinder bore from the top of the cylinder block The flange at the top of the liner fits into a counter bore in the cylinder block See Figure 1 310 Figure 1 310 Cylinder Liner to Block Positioning NOTE The cylinder liner piston and connecting rod must be installed as a assembly in 14L engines and 12 7L EGR On Highway engines Refer to section 1 18 Rev 12 03 All information subject to change without notice 1 380 From Bulletin 23 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL NOTICE The crevice seal prevents coolant from being pumped in and out of the
5. UAL d Remove the seals all three from the liner and discard them 1 20 2 1 Cleaning of the Cylinder Liner Clean the cylinder liner prior to inspection as follows 1 a SY et If cleaning a new or used liner wash the liner with a strong detergent and warm water solution scrubbing with a non metallic bristle brush Rinse with hot water or steam To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 40 psi 276 kPa air pressure Dry the liner with compressed air NOTICE If the liners are not to be installed at this time oil them lightly with clean engine lubricating oil and store them upright in a clean dry area Do not allow the liners to rest on their sides and do not store anything on top of the liners Coat the bore of the liner with clean engine lubricating oil Allow the liner to sit for 10 minutes to allow the oil to work into the surface finish Wipe the inside of the liner with clean white paper towels If a dark residue appears on the towels repeat the oiling and wiping procedure until residue no longer appears 1 20 2 2 Inspection of Cylinder Liner Inspect the cylinder liner as follows 1 Inspect the cylinder liner a Check the cylinder liner for cracks or scoring b If any of these are detected replace with a new part All information subject to change without notice Rev 12 03 6SE
6. area adjacent to the liner lower block location which could result in cavitation and corrosion damage to the liner and the block A crevice seal fitting in the wide uppermost groove in the liner helps to stabilize the liner in the cylinder block bore This system also keeps any debris that is in the cooling system from causing abrasion damage to the upper D liner seal ring See Figure 1 311 CYLINDER LINER CREVICE SEAL Figure 1 311 Cylinder Liner Crevice Seal Cross Section All information subject to change without notice Rev 12 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 23 60 03 1 381 1 20 CYLINDER LINER Two teflon coated D shaped seal rings recessed in the lower two grooves in the cylinder liner are used between the liner and the block to prevent coolant and oil leakage See Figure 1 312 Figure 1 312 Cylinder Liner Seal Ring Cross section Rev 12 03 All information subject to change without notice 1 382 From Bulletin 23 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL A weep hole for each cylinder is drilled through the cylinder block exterior into the cylinder bore area This weep hole is located between the two D shaped seal rings It is used to determine if engine coolant is leaking past the upper liner seal or if oil is leaking past the lower liner seal See Figure 1 313 A special rubber plug prevents dirt from getting into th
7. e D seal ring areas and causing abrasive damage At the same time it allows leaking oil or coolant a path out of the engine for detection WEEP HOLES Figure 1 313 Weep Hole Plug Locations All information subject to change without notice Rev 12 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 23 60 03 1 383 1 20 1 20 1 CYLINDER LINER Repair or Replacement of Cylinder Liner To determine if repair is possible or replacement is necessary perform the following procedure See Figure 1 314 INSPECT CYLINDER LINER BLOCK BORE OR FLATNESS AND CYLINDER REPLACE REMOVE CYLINDER LINER FRETTED ON OUTSIDE DIAMETER OF LINER REPAIR CRACKED SCORED ERODED CYLINDER REPLACE ee OUT OF ROUND CAVITATION EROSION ON EXCEEDED ON CYLINDER REPLACE REPLACE Figure 1 314 1 384 From Bulletin 23 60 03 INSPECT CYLINDER LINER INSTALL Rev 12 03 Flowchart for Repair or Replacement of Cylinder Liner All information subject to change without notice 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 1 20 2 Removal and Cleaning of Cylinder Liner Precleaning is not necessary NOTICE Refer to section 1 18 2 for removal of 14L and 12 7L EGR ON Highway Cylinder Liner Piston and Connecting Rod assembly NOTICE The proper method must be followed when removing a cylinder liner
8. ntil after the liner protrusion is measured J 35597 A SLED GAGE J 22273 Figure 1 318 Cylinder Liner Instalation Tools 6 Thread three cylinder head bolts through the tool and into a head bolt hole so that the round shoe of the tool is centered over the liner 7 Tighten the bolts NOTE It is not necessary to torque the bolts 8 Turn the threaded center bolt in a clockwise direction As the round shoe of the tool reaches the liner ensure that the shoe is properly positioned into the cylinder liner 9 Continue turning the bolt until the liner bottoms in the cylinder counterbore Apply a tightening torque of 60 N m 44 lb ft to the installation tool center bolt 10 Install a dial indicator sled gage See Figure 1 298 Rev 12 03 All information subject to change without notice 1 392 From Bulletin 23 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 11 Measure the distance from the top of the liner flange to the top of the block See Figure 1 319 a Allowable liner protrusion is 0 0127 0 0762 mm 0 0005 0 003 in with no more than 0 0508 mm 0 002 in variation between any two adjacent cylinders Specifications are listed in Table 1 16 b If the liner protrusion exceeds the maximum allowable remove the liner and check for debris under the liner flange J 35597 A LINER PROTRUSION ze as CYLINDER LINER CYLINDER BLOCK Figure 1 3
9. pect the block bore and cylinder liner a Measure the block bore and the outside diameter of the liner The liner specifications are listed in Table 1 16 The block specifications are listed in Table 1 15 Refer to section 1 1 3 3 for procedures b If the liner does not meet specification replace with a new part All information subject to change without notice Rev 12 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 23 60 03 1 389 1 20 CYLINDER LINER 5 Inspect inside diameter of cylinder liners a Set the cylinder bore gage on zero in master setting fixture Use cylinder bore gage J 5347 B to measure the inside diameter of the liner of various points The maximum diameter of a used liner is 130 100 mm 5 122 in for 12 7 and 11 1 L and 133 100 mm 5 244 in for 14L at any measurement location See Figure 1 317 Also check the liner for taper and out of round J 5347 B Figure 1 317 Cylinder Liner Measurement Diagram b If the taper and out of round exceed 0 025 mm 0 001 in replace with a new part 6 Inspect the cylinder liner a Check the seal ring and crevice seal grooves for burrs or sharp edges b If any are detected smooth with an emery cloth Rev 12 03 All information subject to change without notice 1 390 From Bulletin 23 60 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 1 20 3 Installation of Cylinder Liner Ins
10. tall the cylinder liner as follows NOTE Refer to section 1 18 for 14L and 12 7L EGR On Highway liner piston and connecting rod procedure 1 Wipe the inside and outside of the liner clean Be sure the block bore and counter bore are clean so the liner flange will seat properly The block counter bore depth must be 8 9255 8 9662 mm 0 3514 0 3530 in and must not vary more than 0 04 mm 0 0016 in in depth around the circumference No two adjacent block counter bores may range in depth more than 0 025 mm 0 001 in when gaged along the longitudinal cylinder block centerline Specifications are listed in Table 1 15 and listed in Table 1 16 NOTE Thoroughly clean the cylinder block liner counter bores to remove any foreign material Foreign material in the cylinder liner counter bores can cause the liner to seat improperly 2 Lubricate the seal rings and crevice seal with clean petroleum jelly 3 Install two new seal rings and a new crevice seal into their respective grooves in the liner 4 Insert the cylinder liner into the cylinder bore NOTE Do not exert excessive force on the liner while pushing it down All information subject to change without notice Rev 12 03 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 23 60 03 1 391 1 20 CYLINDER LINER 5 Install J 35597 A over the liner to be installed See Figure 1 318 NOTE It is necessary to leave the cylinder liner installation tool in place u
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