Cylinder Liner Page 1 of 16
001-028 Cylinder Liner
General Information
with Mechanically Actuated Injector
The design of the cylinder liner has changed since the introduction of the K38 and K50
engines.
The cylinder liner inside diameter is the same on all designs. The installed liner
protrusion is the same for all designs. The liner protrusion for the K38 and K50
engines was changed. Refer to Procedure 001-064 in Section 1. The depth of the
counterbore on new blocks was changed to obtain the correct protrusion.
Revised brass seal rings with three locating tabs on the inside diameter were released
in May, 1995. The tabs will hold the seal ring in the correct position on the cylinder
liner during installation of the liner in the cylinder block, preventing incorrect assembly
that can lead to coolant leaks at the liner counterbore.
The tabs are manufactured to have an interference fit to the lower press fit diameter of
the cylinder liner, so the tabs will be positioned in the small radius immediately under
the liner flange, holding the seal ring in position.
A revised rectangular sealing ring (crevice seal) was released for K38 and K50
engines in September, 1994, starting with Engine Serial Number (ESN) 33128708.
The crevice seal is manufactured from nitrile material and provides improved durability
with increased resistance to nibbling and erosion.
The revised and previous seals can be intermixed.
with Electronically Actuated Injector
Nitride hardened cylinders liners were introduced for engines with electronically
actuated injectors, and these liners have the same dimensions as the liners used on
engines with mechanically actuated injectors, but offer increased durability. They are
gray in color as opposed to black.
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Preparatory Steps
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal
injury, always ventilate the
compartment before servicing the
batteries. To reduce the possibility of
arcing, remove the negative (-) battery
cable first and attach the negative (-)
battery cable last.
WARNING
This component or assembly weighs
greater than 23 kg [50 lb]. To prevent
serious personal injury, be sure to
have assistance or use appropriate
lifting equipment to lift this component
or assembly.
• Disconnect the batteries. Refer to
Procedure 013-009 in Section 13.
• Remove the cylinder head. Refer to
Procedure 002-004 in Section 2.
• Remove the piston and connecting
rod. Refer to Procedure 001-054 in
Section 1.
Remove
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Use the cylinder liner puller, Part Number
3163745, and puller plate, Part Number
3162886, to remove the cylinder liner.
Wind down the threaded rod to extend
the arm. Turn the arm to the side to
enable passage through the liner.
Install the cylinder liner puller, Part
Number 3163745, in the cylinder liner.
The puller feet must not touch the top of
the liner. The puller arms must be
positioned firmly on the bottom of the
liner.
Turn the puller screw until the liner
loosens in the block.
Remove the tool and the liner.
Use a liquid metal marker to mark the
cylinder number on each liner.
If sealing rings were used:
• Use a tag to mark the cylinder
number.
• Measure in several places and
record the thickness of the sealing
rings used in each cylinder.
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The thickness of the sealing ring is one
factor in determining liner protrusion.
This information must be known when
the liners are installed in the engine.
Clean and Inspect for Reuse
Remove and discard the two d-rings (2
and 3).
Remove and discard the crevice seal (1).
WARNING
Wear appropriate eye and face
protection when using a wire brush.
Be sure the wire brush is rated for the
correct rpm if the brush is motor
driven. Flying debris and dirt can
cause personal injury.
CAUTION
Do not use a hone, aluminum oxide
cloth, or sandpaper to clean the
cylinder liners. Abrasives can damage
the finish and the pattern, and can
contaminate the liner.
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Use a high quality steel wire brush. Clean
the liner flange seating area and the
secondary press fit below the liner flange.
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
When using a steam cleaner, wear
safety glasses or a face shield, as well
as protective clothing. Hot steam can
cause serious personal injury.
WARNING
Wear appropriate eye and face
protection when using compressed air.
Flying debris and dirt can cause
personal injury.
Use a brush that is not metallic,
detergent soap, and warm water. Clean
the inside diameter
Clean the liners with solvent or steam.
Dry with compressed air.
NOTE: See Parts Reuse Guidelines,
Bulletin 3810303, for examples of liner
condition.
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Check the liners for cracks on the inside
diameter and outside diameter.
Any liner containing cracks must be
replaced.
Check for cracks under the flange.
NOTE: Cracks can also be detected by
either magnetic inspection or the dye
method.
Any liner containing cracks must be
replaced.
Check the outside diameter for excessive
corrosion or pitting. Pits must not
exceed 1.6 mm [0.0625 in] in depth.
Replace the liner if the pits are too deep
or if it is not possible to remove the
corrosion with a fine emery cloth.
NOTE: If a liner that contains
minimum pitting is installed again, it
must be installed so that the pitting is
in line with the centerline of the
crankshaft.
Check the inside diameter for vertical
scratches deep enough to be felt with a
fingernail.
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NOTE: If the scratch is felt with a
fingernail, the liner must be replaced.
Check the inside diameter for scuffing or
scoring.
Any liner that contains scuffs or scores
must be replaced.
Check the inside diameter for liner bore
polishing.
A light polish produces a bright mirror
finish in the worn area with traces of the
Lubrite coating remaining and the original
hone marks remaining.
A moderate polish produces a bright
mirror finish in the worn area with very
light traces of the original hone marks or
an indication of an etch pattern.
A heavy polish produces a bright mirror
finish in the worn area with no traces of
hone marks or an etch pattern.
Replace the liner if:
• A heavy polish is present over 20
percent of the piston ring travel
area.
• 30 percent of the piston ring travel
area has both moderate and heavy
polish, and 1/2 (15 percent) of the
area has heavy polish.
Use a dial bore gauge. Measure the
inside diameter of the liner at the:
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• Top
• Bottom
• Middle of the piston ring travel
area.
The middle of piston ring travel is
approximately 100 mm [3.94 in] down the
bore, as measured from the top of the
cylinder liner. Record the cylinder liner
inside diameter at this point, so that it
can be used for piston ring gap
measurement.
Take two measurements at each
location. The measurements must be 90
degrees from the initial measurement.
Cylinder Liner Inside Diameter
Use a micrometer. Measure the
mm
thickness of the liner flange. in
158.737 MIN 6.2495
NOTE: 158.877
To adjust theMAX 6.2550
protrusion, use
this measurement to predict liner
NOTE: The inside
protrusion. Refer todiameter of a001-
Procedure new
cylinder liner can
058 in Section 1. be 0.015 mm [0.0006
in] smaller than specification because
ofCylinder
the Lubrite
Linercoating.
Flange Thickness
mm in
Standard 13.36 MIN 0.526
13.39 MAX 0.527
0.25 mm [0.010 in] 13.61 MIN 0.536
13.64 MAX 0.537
0.51 mm [0.020 in] 13.87 MIN 0.546
13.89 MAX 0.547
0.76 mm [0.030 in] 14.12 MIN 0.556
14.15 MAX 0.557
1.02 mm [0.040 in] 14.38 MIN 0.566
14.40 MAX 0.567
NOTE: Counterbore rings that are
oversize in thickness aid the
adjustment of liner protrusion.
Counterbore Ring Thickness
mm in
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Standard 5.055 MIN 0.1990
5.067 MAX 0.1995
0.05 mm [0.002 in] 5.105 MIN 0.2010
5.118 MAX 0.2015
0.10 mm [0.004 in] 5.156 MIN 0.2030
5.169 MAX 0.2035
NOTE: Oversize liners are not
available for engines with
electronically actuated injectors. The
only method of adjusting liner
protrusion is with the use of
counterbore rings.
Use a micrometer. Measure the outside
diameter at the liner flange (1).
See the following table. Liner outside
diameter specifications are the same for
all K38 and K50 cylinder block designs.
Cylinder Liner outside diameter (1)
mm in
Standard 190.309 MIN 7.4925
190.360 MAX 7.4945
0.25 mm [0.010 190.563 MIN 7.5025
in] Oversize
190.614 MAX 7.5045
0.51 mm [0.020 190.817 MIN 7.5125
in] Oversize
190.868 MAX 7.5145
0.76 mm [0.030 191.071 MIN 7.5225
in] Oversize
191.122 MAX 7.5245
1.02 mm [0.040 191.325 MIN 7.5325
in] Oversize
191.376 MAX 7.5345
Use a micrometer. Measure the outside
diameter at the secondary press fit
location (2).
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See the following table. Secondary press
fit outside diameter is the same for all
K38 and K50 cylinder block designs.
Cylinder Liner Outside Diameter (2)
mm in
181.81 MIN 7.158
181.86 MAX 7.160
NOTE: No oversize cylinder liners are
oversize in the secondary press fit
location.
NOTE: Oversize liners are not
available for engines with
electronically actuated injectors. If the
counterbore diameter is out of
specification, a repair sleeve must be
used. Refer to Procedure 001-058 in
Section 1.
Check the liner flange for wear. Wear on
the outside diameter of the flange is
indicated by small areas that are
polished. The degree of wear is detected
visually by the absence of machining
marks.
If an area that does not have machining
marks exceeds 13 mm [0.50 in] in length,
the liner must be replaced.
NOTE: If a liner that contains
acceptable levels of small polished
areas is installed again, it must be
installed so that the polished area is in
line with the centerline of the
crankshaft.
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Wear on the bottom of the flange is
indicated by the absence of machining
marks in the polished area.
If the area that does not have machining
marks exceeds 13 mm [0.50 in] in length,
the liner must be replaced.
NOTE: If a liner that contains
acceptable levels of small polished
areas on the bottom of the liner's
flange is installed again, it must be
installed so that the polished area is
90 degrees to the centerline of the
crankshaft. That is, the not polished
area must be in line with the centerline
CAUTION
of the crankshaft.
Do not set the liners in an area where
dirty air flow can contaminate the
liners.
Apply a thick film of clean 15W-40 oil to
the bores of the liners for final cleaning.
Let the oil remain for 5 to 10 minutes.
Use a clean, lint-free paper towel, not
cloth, to wipe the oil from the bores until
the black and gray deposits are removed.
Install
Lubricate the packing ring bores of the
cylinder block with vegetable oil.
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WARNING
Do not use starting fluid. Naptha and
methyl ketone are highly flammable
and explosive. Follow the instructions
of the manufacturer.
Use a hydrocarbon solvent, such as
naptha, methyl ethyl ketone,
tricholorethane 1,1,1 (methyl chloroform),
or equivalent to clean the counterbore.
NOTE: The counterbore ledge must be
dry. The sealant applied in assembly
will not dry if there is oil on the ledge.
NOTE: The counterbore ledge must be
dry. The sealant applied in assembly
will not dry if there is oil on the ledge.
Install the shims (1) if required. The
following table lists the part numbers and
thicknesses.
Shims with Tabs
Part Number of
mm in
Number Notches
3088385 0.46 0.018 two
3088386 0.52 0.0205 two
3088387 0.56 0.022 two
3088388 0.79 0.031 two
Due to the interference fit of the shims
with tabs, it is necessary to keep the
shim straight on the liner and push with
your fingers near the tabs to work down
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over the lower press fit diameter. Do not
push on the shim too hard or the tabs
can be deformed to the point that the
seal will not fit squarely on the bottom of
the liner flange. The thickest seal rings
can deform to a very slight angle during
installation on the liner. Some
deformation is acceptable, as long as the
tabs will still engage the radius under the
liner flange.
NOTE: Do not lubricate the crevice
seal and the d-ring seals or shims.
This prevents oil transfer to the
cylinder counterbore ledge during
assembly.
The packing ring bore must be lubricated
thoroughly.
NOTE: A new rectangular crevice seal
was introduced in September 1994,
(Engine Serial Number (ESN) first
33128708), manufactured from nitrile
material and provides improved
durability and increased resistance to
nibbling and erosion.
The beveled edge of the crevice seal (2)
must be positioned as illustrated. Install
the crevice seal.
NOTE: The ring seals have a d-shaped
cross section. This type of ring seal
must be installed with the flat side
against the cylinder liner.
Install the d-ring seals as shown. Use the
mold mark on the seals to check if the
seal is twisted.
1. Black d-ring
2. Red d-ring
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CAUTION
The parts must be installed within 5
minutes after applying the sealant. An
excessive amount of sealant can
cause engine damage.
Install a bead of gasket sealant, Part
Number 3823494, or equivalent, 1.1 to
1.6 mm [0.0468 to 0.0625 in] wide onto
the cylinder block counterbore surface.
The sealant bead must be a continuous
loop and must not contain any breaks or
voids from start to finish.
NOTE: The sealant does not change
Make sure that the end of the bead
the cylinder liner protrusion
overlaps the beginning of the bead,
measurement.
approximately 6Itmm
prevents coolant
[0.236 in].
leaks. The sealant fills the small
spaces between the liner flange and
the counterbore ring and block.
The counterbore ring must be positioned
with the curved edge as illustrated. Install
the counterbore ring (5).
Push the liner in the block by hand.
Use the liner installation tool, Part
Number 3375422, or equivalent. Install
the bridge assembly. Install two cylinder
head capscrews.
Torque Value: 47 n.m [35 ft-lb]
Install the push plate. Make sure the
plate is aligned on the cylinder liner. Turn
the push screw until it touches the push
plate.
Use a wrench. Do not apply more than
68 N•m [50 ft-lb] of torque. Turn the push
screw until the bottom of the liner flange
touches the counterbore ring.
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Remove the tool.
Check the liner protrusion. Use the
following procedure for instructions on
how to measure liner protrusion. Refer to
Procedure 001-064 in Section 1.
Finishing Steps
WARNING
This component or assembly weighs
greater than 23 kg [50 lb]. To prevent
serious personal injury, be sure to
have assistance or use appropriate
lifting equipment to lift this component
or assembly.
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal
injury, always ventilate the
compartment before servicing the
batteries. To reduce the possibility of
arcing, remove the negative (-) battery
cable first and attach the negative (-)
battery cable last.
• Install the piston and connecting
rod. Refer to Procedure 001-054 in
Section 1.
• Install the cylinder head. Refer to
Procedure 002-004 in Section 2.
• Connect the batteries. Refer to
Procedure 013-009 in Section 13.
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• Use the engine run-in procedure.
Refer to Procedure 014-003 in
Section 14.
• Use the engine run-in procedure.
Refer to Procedure 014-004 in
Section 14.
• Operate the engine and check for
proper operation.
Last Modified: 04-Sep-2012
Copyright © 2000-2010 Cummins Inc. All rights reserved.
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