Engine Disassembly and Assembly
Install Cylinder Liners 1216-012
2P8260 Liner Installer Group
1P5510 Liner Projection Tool Group
8B7548 Push-Puller (Crossbar)
1P2394 Puller Plate
S1589 Bolt [5/8"-11 NC x 1. 75 in
(44. 5 mm) long]
1S379 Washer (copper)
1D4595 Bolt, 5/8"-1 1 NC x 152. 4 mm
(6. 00 in. ) long
1. Clean cylinder liners (3) and the liner bores in the
2. Install the cylinder liners in the block without the O-
ring seals or filler bands.
3. Check the cylinder liner projection as follows:
a. Install the S1589 Bolts (2) and 1S379 Washers of
tooling (B) on the cylinder block next to each liner.
Tighten the bolts evenly, in four steps: 14 N-m (10 Ib.
ft. ), 35 Nem (26 lb. ft. ), 70 N-m (50 Ib. ft. ) and 95
Nom (70 Ib. ft. ).
b. Put the adapter plate on top of the liner, and install
the remainder of tooling (B). Tighten the 1D4595 Bolts
(1) evenly in four steps: 7 Nom (5 Ib. ft. ), 20 N*m (15
Ib. ft. ), 35 N-m (26 Ib. ft. ) and 70 N-m (50 Ib. ft. ).
c. Check to be sure the distance from the bottom edge
of the crossbar to the top of the cylinder block is the
same on both sides of the liner. .
d. Check the cylinder liner projection with tool group (C)
at four locations around the liner.
e. Liner projection must be 0. 033 to 0. 175 mm (.
0013 to . 0069 in. ). Measurements on the same liner
must not be different by more than 0. 05 mm (. 002 in.
). Average measurements between liners next to each
other must not be different by more than 0. 05 mm (.
002 in. ). The maximum permissible difference between
average projection of all cylinder liners is 0. 10 mm (.
004 in. ).
NOTE: If the liner is turned in the bore, it can make a
difference in the liner projection. 4. If the liner
projection is not 0. 033 to 0. 175 mm (. 0013 to . 0069
in. ), check the thickness of the following parts: spacer
plate, spacer plate gasket and cylinder liner flange. The
thickness of the spacer plate must be 9. 970 + 0. 025
mm (. 3925 + . 0010 in. ). The thickness of the spacer
plate gasket must be 0. 208 + 0. 025 mm (. 0082 + .
0010 in. ). The thickness of the cylinder liner flange
must be 10. 282 + 0. 020 mm (. 4048 + . 0008 in. ).
NOTE: If the liner projection changes from point to point
around the liner, turn the liner to a new position in the
bore. If the liner projection is still not to specifications,