Cilindro c Gas Plus

8/12/2019 Cilindro c Gas Plus

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001-028 Cylinder Liner

Table of Contents

Preparatory Steps TOC

Preparatory Steps

Initial Check

Remove

Clean and Inspect for Reuse

Install

Finishing Steps
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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 firstand attach the negative (-) battery cable last.

WARNING

Do not remove the pressure cap from a hot engine. Wait until the coolanttemperature is below 50C [120F] 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, disposeof in accordance with local environmental regulations.

SMALL|MEDIUM| LARGE

Next
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WARNING

This component or assembly weighs greater than 23 kg [50 lb]. To prevent

serious personal injury, be sure to have assistance or use appropriate

lifting equipment to lift this component or assembly.

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 notreused, dispose of in accordance with local environmental regulations.

Close the fuel supply valve. Refer to the OEM instructions. Disconnect the batteries.Refer to Procedure 013-009 in Section 13.
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Drain the cooling system.Refer to Procedure 008-018 in Section 8. Remove the cylinder head. FUse the following procedure for C Series

diesel engines.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 piston and connecting rod assemblies.Refer to Procedure001-043 in Section 1.

Initial Check TOC

NOTE: Before removing the cylinder liners, inspect the condition to

determine reusability.

Inspect the inside of the liner for cracking, scuffing, or scoring.

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

NOTE: If a fingernail catches in a scratch, the liner must be replaced.SMALL| MEDIUM|LARGE
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Inspect the inside of the liner bore for polishing.

NOTE: 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.

NOTE: A heavy polish produces a bright mirror finish in the worn area

with no traces of hone marks or an etch pattern.

Do notreuse liners that have heavy polish or any indications of particle

embedment from failure.

Inspect the liners for a ridge near the top of the liner. Severely worn liners willhave a ridge near the top of the liner bore.

SMALL| MEDIUM| LARGE

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If the wear pattern indicates the liner bore is notstraight or notround, 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

mm in

Out of Round 0.04 MAX 0.002

Taper 0.04 MAX 0.002

Bore Diameter 114.04 MAX 4.490


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NOTE: If the liner bore is not acceptable for reuse, it must be replaced.

Damaged liners can not be honed or deglazed. This will destroy the

crosshatch pattern needed for oil control.

NOTE: Do not remove or disturb the liner seals for liners that pass the

inspection criteria.


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Cylinder liner protrusion is the distance the liner protrudes above the block

face. Before removing the liners, check the protrusion, use the liner protrusion

gauge, Part Number 3823495, in the unclamped state.

Cylinder Liner Protrusion

mm in

New Block and Liners 0.025 MIN 0.001

0.122 MAX 0.005

Used Block and Liners 0.000 MIN 0.000

0.122 MAX 0.005

New Block Used Liners 0.025 MIN 0.001

0.122 MAX 0.005

Used Block New Liners 0.000 MIN 0.000

0.122 MAX 0.005

NOTE: 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.


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Remove TOC
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NOTE: 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.

SMALL|MEDIUM| LARGE

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CAUTION

The liner puller must be installed and used as described to avoid damageto the cylinder block. The puller must not contact the block casting at

points (1), (2), (3), or (4).

Insert the cylinder liner puller, Part Number 3376015, into the top of thecylinder block.

SMALL|MEDIUM| LARGE

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NOTE: The liner puller must be centered on the top of the cylinder

block.

Turn the puller jackscrew clockwiseto loosen the liner from the cylinderblock.

Use both hands to remove the liner.

SMALL|MEDIUM| LARGE

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Mark the cylinder number on each liner.

SMALL|MEDIUM| LARGE

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Clean and Inspect for Reuse TOC

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 Scotch-Brite7448, Part Number 3823258, to clean the flange seating area.

SMALL|MEDIUM| LARGE

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WARNING

When using a steam cleaner, wear safety glasses or a face shield, as wellas protective clothing. Hot steam can cause serious personal injury.
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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 to clean the cylinder liners.

Dry the cylinder liners with compressed air.

SMALL|MEDIUM| LARGE

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Use clean engine oil to lubricate the inside 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 surfaces of the liners and wipe clean until thepaper towel shows no gray or black residue.

SMALL|MEDIUM| LARGE

Previous Next

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

SMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyee_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyee_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyee_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyee_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyee_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cyee_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cyee_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cyee_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsa_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsa_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsa_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsa_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsa_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsa_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsa_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsa_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsa_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsa_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsa_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cyee_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyee_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyee_sm.png');


13/30

Previous Next

Inspect for cracks under the flange.

SMALL|MEDIUM| LARGE

Previous Next

Inspect the outside 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 notbe

removed with Scotch-Brite 7448, Part Number 3823258.

NOTE: Cylinder liner pitting is caused by poor coolant composition.SMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsa_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsa_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsa_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsa_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsa_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slsa_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slsa_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slsa_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsb_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsb_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsb_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slsb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slsb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slsb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slsb_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsb_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsb_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slsa_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsa_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2slsa_sm.png');


14/30

Refer to the Operation and Maintenance Manual, GTA8.3

CM558/CM2358, Bulletin 4021640, for coolant specifications.Previous Next

Inspect the inside surface 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 surface for scuffing or scoring.

SMALL|MEDIUM| LARGE

Previous Next

Inspect the inside surface for liner bore polishing.

NOTE: A moderate polish produces a bright mirror finish in the worn

area with traces of the original hone marks or an indication of an etchpattern.

NOTE: A heavy polish produces a bright mirror finish in the worn area

with no traces of hone marks or an etch pattern.SMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsb_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsb_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsb_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsb_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsc_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsc_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsc_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsc_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsc_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsc_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsc_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsc_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsc_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsc_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsc_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsb_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsb_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsb_sm.png');


15/30

Previous Next

Replace the liner if:

A heavy polish is present over 20 percent of the piston ring travelarea.

Both moderate and heavy polish over 30 percent of the piston ringtravel area and one half (15 percent) is heavy polish.

SMALL|MEDIUM| LARGE

Previous Next

Measure the liner inside diameter with dial bore gauge, Part Number3375072, in four places 90 degrees apart at the top and bottom of the piston

travel area.

Cylinder Liner Inside Diameter

mm inSMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsd_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsd_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsd_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsd_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsd_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsd_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsd_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsd_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slna_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slna_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slna_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slna_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slna_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slna_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slna_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slna_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slna_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slna_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slna_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/8/ck8slsd_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsd_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/8/ck8slsd_sm.png');


16/30

114.00 MIN 4.488

114.04 MAX 4.490

Previous Next

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

Cylinder Liner Outside Diameter (Top Press Fit)

mm in

130.938 MIN 5.1550

130.958 MAX 5.1558

SMALL|MEDIUM| LARGE

Previous Next

Measure the cylinder liner bore in the block.

Cylinder Liner Bore in Block (Press-Fit Bore)

mm in

130.90 MIN 5.154

130.95 MAX 5.156SMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2slna_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2slna_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slna_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slna_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slna_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slna_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slna_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slna_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck900sb_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck900sb_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck900sb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck900sb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck900sb_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck900sb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck900sb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck900sb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck900sb_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck900sb_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck900sb_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slna_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slna_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2slna_sm.png');


17/30

Previous Next

Install TOC

WARNING

When using solvents, acids, or alkaline materials for cleaning, follow the

manufacturer's recommendations for use. Wear goggles and protective


WARNING



SMALL|MEDIUM| LARGE

Previous Next
https://quickserve.cummins.com/qs3/pubsys2/xml/en/procedures/100/100-001-028.html#TOChttp://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_sm.png');https://quickserve.cummins.com/qs3/pubsys2/xml/en/procedures/100/100-001-028.html#TOC


18/30

Clean all deposits and debris from the sealing surfaces (A), (B), and (C). Use

Scotch-Brite 7448, Part Number 3823258, and cleaning solvent to polish

the surfaces. Due to the critical machined tolerances, care mustbetaken notto 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 linerprotrusion.

Cylinder liner shims are available as follows:

Measurements

mm in

Cylinder Liner

Shim Thickness -By Part Number

3924445 0.25 0.010

3924446 0.38 0.015

3924447 0.51 0.020

3924448 0.76 0.0303924449 1.00 0.040

Use a maximum of one shim.

SMALL|MEDIUM| LARGE

Previous Next
http://opensmallgraphic%28%27/rtgraphics/english/service/bp/9/bp900gf_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/9/bp900gf_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/9/bp900gf_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/9/bp900gf_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/9/bp900gf_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/9/bp900gf_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/9/bp900gf_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/9/bp900gf_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/9/bp900gf_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/9/bp900gf_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/9/bp900gf_sm.png');


19/30

Machine the counterbore with counterbore machining tool, Part Number

3823558; cutter plate, Part Number 3823567; and cutter bit, Part Number

3823570.

SMALL|MEDIUM| LARGE

Previous Next

WARNING

When using solvents, acid, or alkaline materials for cleaning, follow themanufacturer's recommendations for use. Wear goggles and protective


WARNING

SMALL|MEDIUM| LARGE

Previous Next
http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck900xa_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck900xa_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck900xa_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck900xa_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck900xa_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck900xa_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck900xa_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck900xa_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck900xa_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck900xa_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck900xa_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_sm.png');


20/30

Some solvents are flammable and toxic. Read the manufacturer'sinstructions before using.

Clean the combustion deck with a gasket scraper or Scotch-Brite 7448, Part

Number 3823258, and solvent.

WARNING

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

WARNING



Thoroughly flush the block with mineral spirits or cleaning solvent.

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

SMALL|MEDIUM| LARGE

Previous Next
http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9brek_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9brek_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9brek_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9brek_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9brek_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9brek_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9brek_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9brek_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9brek_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9brek_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9brek_sm.png');


21/30

Blow the cylinder bores and crankshaft dry, and wipe clean with a lint-free

cloth.

Lubricate surfaces (A) and (B) with clean engine oil.

SMALL|MEDIUM| LARGE

Previous Next

Use clean engine oil to coat the liner o-ring seals.

Install the new lubricated o-ring seals on the cylinder liners.

SMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2slwc_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2slwc_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slwc_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slwc_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slwc_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slwc_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slwc_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slwc_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2slwc_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2slwc_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2slwc_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9brga_sm.png');


22/30

Previous Next

NOTE: When reusing liners, install them in the same cylinder from

where they were removed, and rotate the liner 45 degrees (1/8 of a turn)

from their original position. When correctly installed, any liner pitting

can be positioned as illustrated so the pitted surface is rotated away from

the location where pitting occurs.

SMALL|MEDIUM| LARGE

Previous Next

Install the cylinder liners into the bore of the cylinder block, use cylinderliner driver, Part Number ST-1229, and a leather mallet.

NOTE: If the liner does not rest on the cylinder block counterbore seat,remove the liner. Inspect the counterbore seat and liner for nicks, burrs,

or dirt. Install the liner again.

SMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyha_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyha_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyha_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyha_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyha_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/cy/9/cy9cyha_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/cy/9/cy9cyha_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/cy/9/cy9cyha_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyha_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyha_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyha_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyha_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyha_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyha_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyha_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyha_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyha_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyha_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyha_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/cy/9/cy9cyha_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyha_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyha_sm.png');


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Previous Next

Use two cylinder head capscrews and position the two liner clamps, Part

Number 3822503, as illustrated.

Tighten the capscrews.

Torque Value: 68 n.m [50 ft-lb]

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

clamped and released.SMALL|MEDIUM| LARGE

Previous Next

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

Measure the liner protrusion with the liner protrusion gauge, Part Number

3823495, at four points 90 degrees apart.

Cylinder Liner Protrusion

SMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_sm.png');


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mm in

0.025 MIN 0.001

0.122 MAX 0.005

Previous Next

NOTE: If the cylinder liner protrusion varies more than 0.025 mm

[0.001 in] in 180 degrees:

Install and tighten the cylinder liner clamps again.

SMALL|MEDIUM| LARGE

Previous Next

Check the cylinder liner protrusion again.

SMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyjb_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/9/bp9toha_sm.png');


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Previous Next

NOTE: If the protrusion still varies more than 0.025 mm [0.001 in]:

Remove the cylinder liner.

SMALL|MEDIUM| LARGE

Previous Next

Inspect the cylinder liner sealing edge for burrs, dirt, or damage. Replace the cylinder liner if it is damaged. Install the cylinder liner again.

Check the cylinder liner protrusion.

SMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyda_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyda_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyda_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyda_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyda_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyda_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyda_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyda_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/2/bp2cysb_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/2/bp2cysb_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cysb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cysb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cysb_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cysb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cysb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cysb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cysb_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cysb_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/2/bp2cysb_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyda_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyda_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyda_sm.png');


26/30

Previous Next

Service Tip: If the out-of-limit condition is minimal, tolerance stackup will

allow the protrusion limits to be obtained by installing other new liners in theout-of-limit bore.

SMALL|MEDIUM| LARGE

Previous Next

NOTE: If the liner protrusion still does not meet the specifications,

machine the cylinder block liner bore for shims.

SMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyga_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyga_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyga_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyga_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyga_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/cy/9/cy9cyga_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/cy/9/cy9cyga_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/cy/9/cy9cyga_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9tova_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/cy/9/cy9cyga_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyga_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/cy/9/cy9cyga_sm.png');


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Previous Next

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

casting points.

Cylinder-Liner-to-Block Clearance

mm in

0.23 MIN 0.009SMALL|MEDIUM| LARGE

Previous Next

NOTE: If the clearance is less than 0.23 mm [0.009 in]:

Inspect the liner and cylinder block for dirt or damage.

Remove the liner.

SMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2sljd_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2sljd_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2sljd_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2sljd_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2sljd_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2sljd_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2sljd_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2sljd_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/2/bp2cydb_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/2/bp2cydb_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cydb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cydb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cydb_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cydb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cydb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cydb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cydb_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cydb_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/2/bp2cydb_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2sljd_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2sljd_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2sljd_sm.png');


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Previous Next

Replace the liner if it is damaged. Install the liner again.

SMALL|MEDIUM| LARGE

Previous Next

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 notbemore than 0.08-mm [0.003-in] out of round.

SMALL|MEDIUM| LARGE
http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyhb_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyhb_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyhb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyhb_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyhb_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyhb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyhb_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyhb_lg.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyta_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyta_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyta_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyta_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyta_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cyta_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cyta_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cyta_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/bp/2/bp2cyta_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyta_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/bp/2/bp2cyta_sm.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/9/ck9cyhb_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyhb_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/9/ck9cyhb_sm.png');


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Previous Next

NOTE: If the bore is more than 0.08-mm [0.003-in] out of round:

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

SMALL|MEDIUM| LARGE

Previous Next

Finishing Steps TOC
http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2cyji_sm.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2cyji_sm.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2cyji_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2cyji_md.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2cyji_md.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2cyji_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2cyji_lg.png');http://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2cyji_lg.png');https://quickserve.cummins.com/qs3/pubsys2/xml/en/procedures/100/100-001-028.html#TOChttps://quickserve.cummins.com/qs3/pubsys2/xml/en/procedures/100/100-001-028.html#TOChttp://openlargegraphic%28%27/rtgraphics/english/service/ck/2/ck2cyji_lg.png');http://openmediumgraphic%28%27/rtgraphics/english/service/ck/2/ck2cyji_md.png');http://opensmallgraphic%28%27/rtgraphics/english/service/ck/2/ck2cyji_sm.png');


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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 firstand attach the negative (-) battery cable last.

NOTE: Do not interchange pistons from the original cylinder location.

Install the piston and connecting rods.Refer to Procedure 001-043 inSection 1.

Install the lubricating oil pan and suction tube. Refer to Procedure007-025 in Section 7.

Install the cylinder head. Use the following procedure for C Seriesdiesel engines.Refer to Procedure 002-004 in Section 2.

Fill the cooling system.Refer to Procedure 008-018 in Section 8. Fill the lubricating system.Refer to Procedure 007-037 in Section 7. Connect the batteries.Refer to Procedure 013-009 in Section 13. Open the fuel supply valve. Refer to the OEM instructions.

Operate the engine until the coolant temperature reaches 82C[180F], and check for leaks and proper operation.

SMALL|MEDIUM| LARGE

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