NUMBER: S.M. REF.: Listed in Table ENGINE: Series 60 DATE: February 2010

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1 NUMBER: S.M. REF.: Listed in Table ENGINE: Series 60 DATE: February 2010 SUBJECT: CYLINDER LINER PROTRUSION & INSTALLATION ADDITIONS, REVISIONS, OR UPDATES Publication Number Platform Section Title Change Page Number(s) DDC-SVC-MAN-0004 EPA04 Series 60 Section Installation of Cylinder Liner Cylinder Liner Installation procedure has been updated Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.

2 CHECKING CYLINDER LINER PROTRUSION Check the cylinder liner as follows: 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 mm ( in) and must not vary more than 0.04 mm ( in) in depth around the circumference. Variation between two adjacent block counter bores may not range in depth more than mm (0.002 in) when measured in the center line of block. 1. Cylinder Block A. Counterbore Depth Measurement Figure 1 Measuring Counterbore Depth 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. Install the cylinder liner into the engine block without any seals. It is necessary to leave the cylinder liner installation tool in place until after the liner protrusion is measured.

3 3. Install J A, over the liner. See Figure 2. Figure 2 Cylinder Liner Installation Tools 4. 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. It is not necessary to torque the bolts. 5. Tighten the bolts. 6. 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. 7. 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. 8. Install a dial indicator sled gage. See Figure 2.

4 9. Measure the distance from the top of the liner flange to the top of the block. See Figure 3. Figure 3 Cylinder Liner Protrusion [a] [b] Allowable liner protrusion is mm ( in) with no more than mm (0.002 in) variation between any two adjacent cylinders. If the liner protrusion exceeds the maximum allowable, remove the liner and check for debris under the liner flange. If there is no debris, machine the liner counterbore.

5 INSTALLATION OF CYLINDER LINER Install the cylinder liner as follows: Refer to section "Installation of the Piston and Connecting Rod" for 14L liner, piston and connecting rod procedure. 1. Wipe the inside and outside of the liner clean. 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. Install the cylinder liner, piston and rod assembly into the cylinder bore. Refer to section "Installation of the Piston and Connecting Rod." It is necessary to leave the cylinder liner installation tool in place until after the liner protrusion is measured. 5. Install J A over the liner. See Figure 4. Figure 4 Cylinder Liner Installation 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. 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.

6 10. Install a dial indicator sled gauge. See Figure Measure the distance from the top of the liner flange to the top of the block. To verify that the liner protrusion has not changed. See Figure 5. [a] Allowable liner protrusion is mm ( in) with no more than mm (0.002 in) variation between any two adjacent cylinders. [b] If the liner protrusion exceeds the maximum allowable, remove the liner and check liner protrusion. Figure 5 Cylinder Liner Protrusion

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8 ADDITIONAL SERVICE INFORMATION Additional service information is available in Power Service Literature. Detroit Diesel, DDC, Series 60 and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. Copyright 2010 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.