Special Instruction

Use Of 8T0455 Cylinder Liner Projection Indicator Group{0760, 1216}

Media Number -SMHS7727-01 Publication Date -30/04/1986 Date Updated -13/10/2001

   

Use Of 8T0455 Cylinder Liner Projection Indicator

Group{0760, 1216}
SMCS - 0760; 1216

Reference: Service Manual

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NOTE: Liners must be installed without O-ring seals and filler band to check liner projection.

Measuring Cylinder Liner Projection

NOTE: In the procedure that follows, the crossbar from a puller assembly is one of the tools
used to clamp a liner in position. After the bolts or nuts are tightened, the distance from the
bottom edge of the crossbar to the top face of the cylinder block, or spacer plate, must be the
same on both sides of the liner. If it is not, do the tightening procedure again.

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(1) Clean the liner flange, block surface, liner counterbore, and top plate (where used). Remove
any nicks on the top of the block or plate. Install liner (1).

(2) Seat the liner in the block using the appropriate liner puller adapter (2), two 3H465 Plates or
washers (3), crossbar (4) from the 8B7548 Puller Assembly, and two bolts (5) to fit the block
bolt holes. Tighten bolts (5) according to the procedure given in the specific Service Manual.

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(3) If the engine has a spacer plate (6), install a new gasket between the spacer plate and the
cylinder block. Use four bolts (7), with two 2F126 Seals under each bolt head, to hold down
plate (6). If studs are in the block, use four 8S7219 Spacers (8) and nuts (9). Tighten bolts (7) or
nuts (9) according to the procedure given in the specific Service Manual.

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(4) Loosen bolt (10) until dial indicator (11) can be moved. Place gauge body (12) and dial
indicator (11) on the long side of gauge (13).

(5) Slide dial indicator (11) down until the point contacts gauge (13) and moves the needle 1/4
revolution clockwise to a vertical position. Tighten bolt (10) and zero indicator (11).

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(6) Put gauge body (12) on the cylinder block or spacer plate, with the indicator point on the
liner flange. Read the dial indicator to find the amount of liner projection. Check projection at
four equidistant locations around each cylinder liner. If projection varies more than the high and
low specification given in the specific engine Service Manual, remove that liner; turn it to a
different position and again install it in the cylinder bore. After installation, again check the
projection. If projection is still not within specifications, remove the liner and install it in a
different bore. When the projection of each liner is within specifications, mark the liner for radial
location and cylinder bore location in the block. (This information will be needed when the liners
are removed for installation of the seals and the filler band.)

(7) After the projection of each liner is within specifications, average the projection readings of
all liners under each cylinder head. Two additional dimensions must be checked; they are as
follows:

1. Average difference in projection of any two cylinder liners that are next to each other,
under the same cylinder head.
2. Average difference in projection between all cylinder liners under the same cylinder
head.

See the Service Manual for the maximum permissible difference, for each of these dimensions.

(8) If the average projection of the cylinder liners under each cylinder head is not within the
specifications given in the Service Manual, remove those cylinder liners and check the liner
counterbore depth. Rework the counterbores if necessary.

Measuring Liner Counterbore Depth

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(1) Install long point (1) on indicator (2). Loosen bolt (3) so indicator can be moved. Place gauge
body (4) and the indicator on gauge (5) with the point over the step closest to counterbore depth.

(2) Slide indicator (2) down so the point touches gauge (5) and moves the needle 11/4 turns
clockwise to a vertical position. Tighten bolt (3) and zero the indicator.

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(3) Thoroughly clean the block face and counterbore. Place gauge body (4) on the block with the
contact point on the liner ledge. Check counterbore depth at several locations and compare the
readings with Service Manual specifications.

NOTICE

Do not slide the contact point onto the counterbore face; this can
damage the contact point.
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