Cylinder Liner: Service and Repair

Fig. 19 Measuring liner protrusion:

1. Prepare the matched sets of pistons and liners.
2. Insert the liners without the seals.
3. Place plate .0132 (B) with its boss bearing on liner, Fig. 19. Install dial indicator onto support (C) and zero it over four spots on the same liner. Maximum deviation between spots should not exceed .0008 inch.

Fig. 20 Measuring liner protrusion deviation:

LINER PROTRUSION WITHOUT SEALS

1. Measure the liner protrusion at three points (B), Fig. 20, with respect to the calibrated level.
2. Note value of highest spot, it should not exceed .002 inch. If deviation is greater, install liner in another position in block.

Fig. 21 Selection of liner seals:

SELECTING LINER SEALS

1. Select a seal with a thickness (X) according to protrusion (Y) of liner without seal, Fig. 21.
2. The protrusion at the highest point X + Y must be .005 to .008 inch.
3. Seal thicknesses (including colored varnish) are as follows:
a. Orange yellow: .0038-.0052 inch.
b. Colorless: .0048-.0060 inch.
c. Blue: .0054-.0076.

Fig. 20 Measuring liner protrusion deviation:

LINER PROTRUSION WITH SEALS

1. Check liner protrusion at three places B, Fig. 20, with respect to the cylinder block.
2. Change seal category if necessary.

Fig. 22 Checking difference in liner protrusion between two liners:

3. Measure the protrusions of two adjacent liners at spots (a) and (b), Fig. 22. Difference in protrusion should not exceed .0002 inch.
4. If difference in protrusion exceeds .0002 inch, fit a thinner seal to the highest liner. When installing new liners, it is possible to level out differences in protrusion by switching liners.
5. Mark the final order and orientation of liners on cylinder block.