Detroit Diesel — Cylinder Block Liner Installation

A Detroit Diesel service procedure — check it applies to your exact model before use.

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Procedure

1. Perform the Measurement of Cylinder Liner Protrusion procedure.
2. Install new O-rings, clean and dry, in the cylinder block.
3. Install Liner Seat D-Ring to Cylinder Liner. Be sure the D-ring is installed with the flat surface of the ring against the liner. Be careful not to over-stretch the ring as it is installed over the liner flange.
4. Install a new seat insert, clean and dry, into the block counterbore.
5. Apply a light coating of engine oil to the lower part of the cylinder liner, from where it contacts the O-rings up to the bevelled area.
6. When installing a new cylinder liner, make sure that the diameter tolerance code corresponds to the one marked on the piston. For tolerance codes location refer to the edge of the cylinder liner.
7. Install two opposing cylinder head bolts with the washers and spacers through the base plate of the tool. Tighten securely to 41 N·m (30 lb·ft).
8. Raise the tapered cutter head from the block and install the depth set spacer provided. While there is no load, extend the cutting tool outward (using a clockwise rotation of the cutting screw) until it just touches a 0.15mm feeler gauge or shim placed next to the vertical wall of the counterbore. Tighten the Allen head hold-down screws.
9. Lower the cutting plate and cutter tool into the counterbore until it just touches the lower surface of the counterbore. Rotate the lock collars downward until they touch the bronze bushing of the tool.
10. Set the depth of cut by adjusting the top collar upwards to allow the liner shim to be inserted between the two collars. Tighten the thumb screw of the top collar. Remove the shim.
11. Lubricate the tool bushing. Back off the lower collar by two graduations 0.0254 mm (0.001 in. each). Rotate the T-handle clockwise with a moderate, constant pressure. Stop at random positions to prevent creating a ridge in the counterbore. Continue backing off the adjustment in 0.0508 mm (0.002 in.) increments for the balance of the cutting operation until the collars come together.
12. Raise the handle and insert the spacer block under the lower collar. Remove the hold-down bolts and spacers to remove the tool from the block.
13. Retract the cutter bit into the cutter plate to protect during storage.

Source: manual:08MBE40001.EPA04Rev - Cylinder Block Liner Service Procedure.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.