TUBE 3940420 - Caterpillar

Note: The following procedure alleviates the need for the crossbar to hold the cylinder liners during cylinder liner projection measurements.
Clean the cylinder liner flange and the cylinder block surface. Remove any nicks on the top of the cylinder block.
Install clean cylinder liners without the rubber seals or the filler band. Install a new spacer plate gasket and the clean spacer plate.
Table 2
Required Components    
Item     Part Number     Part Description     Quantity For One Cylinder     Quantity For Six Cylinders    
1     0S-1589     Bolt     6     36    
2     2S-0736     Washer     6     36    
3     8F-1484     Washer     6     36    
4     7K-1977     Washer     6     36    
Illustration 1 g00544054
Install the bolts and washers in the order that is shown in Illustration 1 in order to seat the cylinder liner in the block. Tighten bolts (1) evenly to a torque of 95 N m (70 lb ft).
Illustration 2 g00544478
(5) Bolt (6) Dial Indicator (7) Gauge Body (8) Gauge
Loosen bolt (5) until dial indicator (6) can be moved. Place gauge body (7) and dial indicator (6) on the long side of gauge (8) .
Slide dial indicator (6) into position until the point contacts gauge (8). Slide dial indicator (6) until the needle of the dial indicator makes a quarter of a revolution clockwise. The needle should be in a vertical position. Tighten bolt (5) and zero dial indicator (6) .
Place gauge body (7) on the spacer plate with the dial indicator point on the cylinder liner flange. Read the dial indicator in order to find the amount of liner projection. Check the liner projection at four locations (every 90 degrees) around each cylinder liner.
Table 3
Specifications    
Liner Projection    
0.033 mm (.0013 inch) to
0.175 mm (.0069 inch)    
Maximum Variation in Each Cylinder    
0.051 mm (.0020 inch)    
Maximum Average Variation Between Adjacent Cylinders    
0.051 mm (.0020 inch)    
Maximum Variation Between All Cylinders    
0.102 mm (.0040 inch)    
If the cylinder liner projection is out of specification, rotate the cylinder liner in the bore and repeat the procedure. If the cylinder liner projection measurements are again out of specification, try installing the cylinder liner in a different cylinder bore to improve the measurements.Note: Do not exceed the maximum liner projection of 0.175 mm (0.0069 inch). Cracking in the flange of the cylinder liner results from excessive cylinder liner projection measurements.
If the maximum variation between cylinder liners is greater than the recommended specification, shims must be used in order to reach the correct specification.
When the cylinder liner projection for each cylinder liner is within the recommended specification, mark each cylinder liner for the proper location in the bore and remove the cylinder liners.
Lubricate the O-ring seals, the cylinder liner, and the upper filler band before installation.Note: If the lower O-ring seals are black in color, apply liquid soap on the lower O-ring seals and the