Use the 8T-0455 Liner Projection Tool Group in order to
measure the flange projection of the cylinder liner. Use
the gauge block (3) in order to zero the dial indicator (1).
Measure the liner projection.
(1) 1P-2403 Dial Indicator
(2) 1P-2402 Gauge body
Position the gauge body (2) and the dial indicator (1) in
order to measure the flange projection in four locations
around the cylinder liner. Do not measure the projection
from the flame ring, if equipped.
The four measurements should not vary more than 0.03
mm (0.001 inch) from each other. The average
projection between adjacent cylinders must not vary
more than 0.03 mm (0.001 inch).
Refer to Specifications, "Cylinder Block for the
tolerance of the flange projection that is above and
below the face of the cylinder block.
Cylinder Compression Test
The cylinder compression test should only be used in order to
compare the cylinders of an engine. If one or more cylinders
vary by more than 350 kPa (51 psi), several tests should be
conducted. The tests will determine if an adjustment is
required or if replacement of components is required. Perform
the following tests If one or more cylinders vary by more than
350 kPa (51 psi):
Measure the height of the piston above the cylinder
Measure the bore of the cylinder liner.
Check the surface finish of the cylinder liner.
Measure the piston rings for wear or damage.
Perform the valve tests that are described in the
Systems Operation. Testing and Adjusting manual.
Before the performance of the compression test, make sure
that the following conditions exist:
The battery is in good condition.
The battery is fully charged.
The starting motor operates correctly.
The valve lash is set correctly.
All fuel injector nozzles are removed.
The fuel supply is disconnected.
Install a gauge for measuring the cylinder compression
in the hole for a fuel injector nozzle.
Operate the starting motor in order to turn the engine.
Record the maximum pressure which is indicated on the
Repeat Steps 1 and 2 for all cylinders.
Inspection Of The Cylinder Liner
The condition of a cylinder liner is determined by the following
The extent and the location of any polished areas that
are on the bore of the cylinder liner is a condition. If the
bore of the cylinder liner is polished, an engine can have
oil consumption that is high with very little wear on the
bore. Observe the area that is near the top of the bore
of the cylinder liner. However, the area is just below the
ring of carbon. The thrust from the top piston ring is the
maximum in this area.
The wear that is on the bore of the cylinder liner is a
condition. Refer to the Specifications manual for the
dimensions of a cylinder liner.
Damage to the cylinder liner such as cracks and deep
scratches is a condition.
If the conditions that follow exist, the cylinder liner does not
need to be replaced:
The honed finish can be clearly seen on the area of the
The engine performance and the oil consum ption are
If the cylinder liner requires replacement, refer to the
Disassembly and Assembly manual for the procedures for
removal and installation of the cylinder liner.