Cylinder Liner Page 1 of 8

001-028   Cylinder Liner

Install

 CAUTION 

Clean all deposits and

debris from sealing
surfaces A, B, and C. Use
abrasive pad, Part Number
3823258, or equivalent,
and cleaning solvent to
polish the surfaces. Due to
the critical machined
tolerances, care should be
taken not to 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 liner
protrusion.

Use a counterbore cutter, Part

Number 3163785, to machine
the counterbore to the proper
depth.

NOTE: Part Number 3823567, 
cutter plate, and Part Number 
3823570, cutter bit, must be 
used with the counterbore 
machining tool.

mk:@MSITStore:C:\Program%20Files%20(x86)\Cummins\QuickServeDVD\MR_D.... 16.02.2023
Cylinder Liner Page 2 of 8

 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.

Clean the combustion deck

with a gasket scraper or
abrasive pad, Part Number
3823258 or equivalent, and
diesel fuel or solvent.

 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

mk:@MSITStore:C:\Program%20Files%20(x86)\Cummins\QuickServeDVD\MR_D.... 16.02.2023
Cylinder Liner Page 3 of 8

personal injury.

Thoroughly flush the block with

mineral spirits or cleaning
solvent.

Remove the shop rags and

clean the crankshaft with a
cleaning solvent.

Blow the cylinder bores and

crankshaft dry and wipe them
clean with a lint-free cloth.

Lubricate surfaces A and B

with clean 15W-40 engine
oil.

Use clean 15W-40 oil to coat

the liner o-ring seals.

Install the new o-ring seal in

the lower groove at the mid-
stop location of each liner.

When reusing liners, install

them in the same cylinder
from where they were
removed and rotate them 45
degrees (1/8 turn) from their
original position. When

mk:@MSITStore:C:\Program%20Files%20(x86)\Cummins\QuickServeDVD\MR_D.... 16.02.2023
Cylinder Liner Page 4 of 8

correctly installed, any liner

pitting must be positioned as
illustrated so the pitted
surface is rotated away from
the location where pitting
occurs.

Install the liner into the bore

of the cylinder block, use
liner driver, Part Number ST-
1229.

Use two (2) cylinder head

capscrews and position the
two (2) 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.

Liner protrusion is the

distance the liner protrudes
above the block face.

mk:@MSITStore:C:\Program%20Files%20(x86)\Cummins\QuickServeDVD\MR_D.... 16.02.2023
Cylinder Liner Page 5 of 8

Measure the liner protrusion

at four points 90 degrees
apart using gauge, Part
Number 3164438.

Cylinder Liner Protrusion

mm in
0.026 MIN 0.0010
0.122 MAX 0.0048

NOTE: If the liner 
protrusion varies more 
than 0.025 mm [0.0010 in] 
for 180 degrees:

l Install and tighten the

liner clamps again.

Torque 
Value: 68 n.m [50 ft-lb]

l Measure the liner

protrusion again.

NOTE: If the protrusion 
still varies more than 0.025 
mm [0.0010 in]:

mk:@MSITStore:C:\Program%20Files%20(x86)\Cummins\QuickServeDVD\MR_D.... 16.02.2023
Cylinder Liner Page 6 of 8

l Remove the liner.

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

Service Tip: If the out-of-limit

condition is minimal, tolerance
stack-up may allow the
protrusion limits to be obtained
by installing other new liners in
the out-of-limit bore.

NOTE: If the liner 
protrusion still does not
meet the specifications, 
machine the cylinder block 
liner bore for shims using 
the following tools:

l Drive unit, Part

Number 3163785.
l Cutter plate, Part
Number 3823567.
l Cutter bit, Part Number
3823570.

Use a feeler gauge to

inspect the liner to block
clearance at the four block
casting points.

mk:@MSITStore:C:\Program%20Files%20(x86)\Cummins\QuickServeDVD\MR_D.... 16.02.2023
Cylinder Liner Page 7 of 8

Cylinder Liner to Block

Clearance
mm in
0.229 MIN 0.009

NOTE: If the clearance is 
less than 0.229 mm [0.009 
in]:

l Remove the liner.

l Inspect the liner and

cylinder block for dirt or
damage.

l Replace the liner if it is

damaged.
l Install the liner again.

mk:@MSITStore:C:\Program%20Files%20(x86)\Cummins\QuickServeDVD\MR_D.... 16.02.2023
Cylinder Liner Page 8 of 8

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 not be more than
0.04 mm [0.002 in] out-of-
round.

NOTE: If the liner bore is 
more than 0.04 mm [0.002 
in] out-of-round:

l Remove the liner so

the cylinder block liner
bore can be measured.

Last Modified:  21-Apr-2015

Copyright © 2000-2010 Cummins Inc. All rights reserved.

mk:@MSITStore:C:\Program%20Files%20(x86)\Cummins\QuickServeDVD\MR_D.... 16.02.2023