Installation of 7C-6208 Cylinder Sleeve {1222} Caterpillar

Engines: 3114 All Engines 3116 All Engines

Introduction

The 7C-6208 Cylinder Sleeve is available for reconditioning cylinder blocks that are used for the 3114 and 3116 Engines. Check the existing cylinder walls for damage. Reconditioning of the cylinder walls is necessary if any of the following conditions exist:

• Excessive wear

• Pin holes

• Cracks

• Scoring

Note: Prior to measuring the dimensions of a cylinder or cylinders, it is necessary to install a Cylinder Head Stress Plate on the cylinder block. Refer to the section of this document ""Installation of the Cylinder Head Stress Plate" " for more information.

Carefully inspect the cylinder block in order to determine if the block is still usable.

Note: For additional information, refer to Guideline for Reusable Parts and Salvage Operations, SEBF8261.

If the cylinder block is still usable, follow the procedure that is described in this Special Instruction. The procedure includes instructions for the installation of the 7C-6208 Cylinder Sleeve .

Tooling and Equipment

The recommended boring tools, and the honing machines are in Table 1. These tools are acceptable for the procedures that are described in this instruction.

Note: For information that relates to the correct operation of the tools that are specified in the following table, refer to the literature that is provided by the OEM.

The boring and honing equipment may be purchased from the manufacturers that are listed below.

Note: It is necessary to have a cylinder head gasket of standard thickness for the 3114 and the 3116 Engine. The gasket is installed with the cylinder head stress plate prior to the measuring and honing operations. The cylinder head gasket may be reused several times with the cylinder head stress plate. When you are performing the final cylinder head installation, a new gasket must be used.

Refer to the Parts Manual in order to determine the correct part number for the cylinder head gasket for your application.

Machining Procedures and Specifications

Illustration 1	g00494966
Features of the cylinder after boring

Features of the cylinder block counterbore are shown in Illustration 1 and Illustration 2. Refer to Table 2 for specifications that are related to the dimensioning of these features.

Note: Refer to Illustrations 1 and 2 in order to find the items in Table 2.

1. Position the boring tool on the cylinder block.

   Note: The dimension (A) is the diameter of the original cylinder bore.

2. In order to machine the bore to a diameter (B) and a depth (C), use the centerline of the original cylinder bore (A).

   Note: The dimension (C) is measured from the top deck (top surface) of the cylinder block.

Show/hide table



Illustration 2	g00907061
Chamfer edge (E) at the bottom of the bore. Refer to Table 2 for the specifications of the cylinder bore.

3. Remove the sharp corners and any burrs at the bottom edge of the cylinder bore (E) .

Installation of 7C-6208 Cylinder Sleeve

Show/hide table



Illustration 3	g00906610
Tools that are required for installing the cylinder sleeve (1) 9S-6072 Adjusting Crank (2) 6V-2183 Screw (3) 1P-2329 Insert (4) 1P-0820 Hydraulic Puller (5) 9U-6008 Puller Plate (6) 7C-6208 Cylinder Sleeve (7) 9U-6007 Puller Plate (8) 5H-1504 Hard Washer (9) 1D-5119 Nut (F) 45 degree chamfer on Cylinder Sleeve

1. Remove the 9S-6074 Adjusting Screw from the 1P-0820 Hydraulic Puller (4) and install 6V-2183 Screw (2) in the correct position.

2. Use the 1P-0820 Hydraulic Puller (4) with the following items: forcing screw (2), 1P-2329 Insert (3), 9U-6008 Puller Plate (5), 9U-6007 Puller Plate (7), 5H-1504 Hard Washer (8), 1D-5119 Nut (9) and 7C-6208 Cylinder Sleeve (6) .

   Note: Install the cylinder sleeve (6) with the 45 degree chamfer at the bottom of the cylinder block. See Illustration 3.

3. Use clean diesel fuel (No. 2) to lubricate the outside diameter of the cylinder sleeve (6) .

4. Connect a hydraulic pump to the 1P-0820 Hydraulic Puller (4), and begin to press the cylinder sleeve into the bore. Continue to apply pressure to the hydraulic puller until full extension of the puller is realized.

   Note: The insert (3) will need to be readjusted several times before the sleeve is fully installed.

5. Reposition the hydraulic puller group and continue the installation until the cylinder sleeve is fully installed into the sleeve bore.

   1. Retract the 1P-0820 Hydraulic Puller (4) .

   2. Loosen the socket head screw and readjust the insert (3) .

Show/hide table



Illustration 4	g00906682
The cylinder sleeve (6) has complete contact (10) with the bottom of the bore.

6. Press the cylinder sleeve (6) into the bore until the bottom of the sleeve contacts the counterbore at location (10) .

Show/hide table



Illustration 5	g00906732
Features of the cylinder sleeve after the installation (K) 1.02 ± 0.25 mm (0.040 ± 0.010 inch) chamfer (G) 30 degree angle that is machined into the cylinder sleeve (H) Maximum height above the deck of the engine block 0.013 mm (0.0005 inch).

7. The top of the cylinder sleeve (6) should extend no more than 0.013 mm (0.0005 inch) above the top deck of the cylinder block. This should be checked after the cylinder sleeve (6) is installed in the cylinder bore. The cylinder sleeve should be flush with the top deck of the block in order to obtain the best results.

   Note: It is acceptable to machine the top of the cylinder sleeve in order to make the sleeve flush with the top deck.

Show/hide table

NOTICE
If the top of the cylinder sleeve is machined, do NOT nick or cause damage to the top deck of the cylinder block. To ensure correct seal between the bottom of the cylinder head and the top surface of the cylinder block near the cylinder sleeve, the cylinder head gasket MUST have a smooth surface to seal against.

Show/hide table



Illustration 6	g00921959
Machine chamfer (K) on the top of the cylinder sleeve (6) .

8. Machine a chamfer (K) of 30 degrees that is 1.02 ± 0.25 mm (0.040 ± 0.010 inch) deep. Refer to Illustrations 5 and 6.

9. Use the 1P-3565 Chamfer Group to remove the sharp corner at the bottom of each cylinder bore. The angle of chamfer (L) should be 15 degrees and the depth should measure approximately 2.3 mm (0.09 inch). The chamfer is necessary in order to prevent scuffing of the piston skirt.

Stress Honing

Stress honing the newly installed cylinder sleeve is necessary in order to confirm the correct cylinder sleeve bore size. The following procedure also includes instructions for honing the cylinder bore in order to provide a surface finish that will allow the piston rings to seal correctly.

The first step of the process includes the installation of a cylinder head stress plate in order to stress the engine block as though the cylinder head is installed. The cylinder bore is then methodically measured and honed in order to dimension the cylinder bore to specifications. Stress honing will be used to correct the following deficiencies in the cylinder sleeve bore size that are created during the installation of the cylinder sleeve: bore diameter, out of roundness and taper. The final step of the process will be the inspection of the crosshatch scratch pattern. The crosshatch scratch pattern that remains on the cylinder walls after honing must conform to the guidelines that are stated in this procedure.

Correcting the deficiencies in the cylinder bore after installation of the cylinder sleeve will ensure proper engine operation and an extended service life.

Installation of the Cylinder Head Stress Plate

A Cylinder Head Stress Plate must be installed in order to reproduce the distortion that occurs to the cylinder bore after the cylinder head has been torqued to the block. Install the Cylinder Head Stress Plate prior to taking measurements or honing the newly installed cylinder sleeve .

There are two different Cylinder Head Stress Plates that are available for use. Follow the correct installation procedure for the Cylinder Head Stress Plate that is being used:

126-8132 Cylinder Head Stress Plate

Illustration 7	g00495523
(1) 126-8132 Cylinder Head Stress Plate

The following items will be necessary in order to correctly install the 126-8132 Cylinder Head Stress Plate :

• 14 of the 8T-0362 Bolts

• 14 of the 8T-3282 Hard Washers

• Cylinder Head Gasket of standard thickness

Illustration 8	g00495524
(1) 126-8132 Cylinder Head Stress Plate (2) 8T-0362 Bolts (3) 8T-3282 Hard Washers (4) Cylinder Head Gasket (5) Engine Block

1. Install a cylinder head gasket of standard thickness on the deck of the cylinder block.

2. Position the cylinder head stress plate (1) on top of the cylinder head gasket (4) .

3. Install the 8T-0362 Bolts (2) and the 8T-3282 Hard Washers (3) .

Show/hide table



Illustration 9	g00904636

4. Torque the cylinder head bolts (2). Use the torque sequence that is shown in Illustration 9. Torque the bolts to 150 ± 15 N·m (111 ± 11 lb ft).

5. Torque the cylinder head bolts (2) again. Use the torque sequence that is shown in Illustration 9. Torque the bolts to 435 ± 20 N·m (320 ± 14 lb ft).

Note: The cylinder head gasket may be reused several times with the cylinder head stress plate. When you are performing the final cylinder head installation, a new gasket must be used.

4C-4377 Cylinder Head Stress Plate

Illustration 10	g00506770
(1) 4C-4377 Cylinder Head Stress Plate

The following items will be necessary in order to correctly install the 4C-4377 Cylinder Head Stress Plate :

• 4 of the 8T-0657 Bolts

• 4 of the 8T-3282 Hard Washers

• Cylinder Head Gasket of standard thickness

Illustration 11	g00907233
(1) 4C-4377 Cylinder Head Stress Plate (2) 8T-0657 Bolts (3) 8T-3282 Hard Washers (4) Cylinder Head Gasket (5) Engine Block

1. Install the cylinder head gasket (4) on the cylinder block (5) .

2. Position the cylinder head stress plate (1) on top of the cylinder head gasket (4) .

3. Install the 8T-0657 Bolts (2) and the 8T-3282 Hard Washers (3) .

4. Use a crisscross pattern to tighten the cylinder head bolts (2). Torque the bolts to 150 ± 15 N·m (111 ± 11 lb ft).

5. Use a crisscross pattern to tighten the cylinder head bolts (2) again. Torque the bolts to 435 ± 20 N·m (320 ± 14 lb ft).

Note: The cylinder head gasket may be reused several times with the cylinder head stress plate. When you are performing the final cylinder head installation, a new gasket must be used.

Measuring the Cylinder Bore Diameter

Note: In order to accurately measure the cylinder bore diameter, a cylinder head stress plate must be installed on the engine block. Refer to ""Installation of the Cylinder Head Stress Plate" " for more information.

Prior to honing the cylinder sleeve bore, measurements of the cylinder bore diameter must be taken in order to determine the extent of honing that is necessary.

Note: Machining the newly installed cylinder sleeve bore may be necessary if there is an excessive amount of base material that needs to be removed.

Illustration 12	g00495528
The dial bore gauge is used to measure bore diameter.

The use of a dial bore gauge is necessary in order to accurately measure the cylinder bore diameter.

Several measurements should be taken during the measurement procedure. By evaluating the bore diameter at several locations along the length of the cylinder sleeve bore, the following characteristics of the cylinder sleeve bore should be evaluated:

Bore Diameter - Bore diameter represents the size of the cylinder bore at the location that is being measured.

Taper - Taper of the cylinder bore is observed by evaluating the bore diameter along the length of the cylinder.

Out Of Roundness - The out of roundness of the cylinder bore is determined by comparing the different measurements of bore diameter that are observed around a single location. (Refer to locations (N) or location (O) in Illustration 13.)

Illustration 13	g00921963
Measurement locations for checking the cylinder bore diameter. (P) 6.4 mm (0.25 inch)

1. Ensure that the Cylinder Head Stress Plate has been correctly installed on the cylinder block.

2. Measure the cylinder bore diameter along the length of the cylinder at the primary locations that are shown in Illustration 13.

   Locate positions (N) by measuring a distance (P) from both the top and from the bottom of the cylinder sleeve. Location (O) can be found at the halfway point of the length of the cylinder sleeve.

   Measurements of the cylinder sleeve bore must include points that are perpendicular to the length of the engine block as primary measurements. Points that are parallel to the length of the engine block should also be evaluated.

3. Use the measurements that have been obtained to evaluate the characteristics of the cylinder sleeve bore. Refer to Table 3 or Table 4 for specification data.

Honing Procedure

Note: In order to accurately hone the cylinder sleeve bore, a cylinder head stress plate must be installed on the engine block. Refer to ""Installation of the Cylinder Head Stress Plate" " for more information.

Refer to Table 1 for information on the recommended tooling for honing the cylinder sleeve bore.

1. Perform a preliminary measurement of the cylinder sleeve bore size. Refer to ""Measuring the Cylinder Bore Diameter" " for instructions that are related to the measurement of the bore diameter.

2. Refer to Table 3 or Table 4 for information that is related to honing machine settings and operation. Use the information that is found in Table 3 or Table 4 to determine the correct honing operation for the cylinder bore diameter. Compare the measurement of the bore diameter to the information that is provided in order to determine the extent of the honing operation that is necessary.

3. Inspect the cylinder carefully during the honing operation. Measure the diameter of the cylinder sleeve bore often. Check the cylinder for the following deficiencies:

   Burnishing - Burnishing the cylinder wall during the honing operation can be identified by a surface finish that has become smooth or shiny. Burnishing can be caused by one or more of the following conditions:

   • uneven contact of the honing stones to the cylinder wall

   • improper alignment of the honing stones

   Check that the honing stones are correctly seated. Also check for uneven wear on the pads of the honing stones and ensure that the tooling is properly aligned.

   Glazing - Glazing produces a brown color on the surface of the cylinder wall. Glazing of the cylinder can be caused by one or more of the conditions that are listed:

   • honing stones that are not cutting correctly

   • stones that are overheating

   Inspect the tool in order to ensure that the honing stones are seated correctly. The honing stones must be used with the correct volume and the correct type of honing oil. Check that the following machine settings are correct: "Stock Removal Rate", "Amount of Honing per 0.03 mm of Stock Removal, Advanced Feed" and "Advanced Feed Setting". Refer to Table 3 or Table 4 for information that is related to the correct settings for the honing machine.

Show/hide table



Illustration 14	g00921964
(7) Crosshatch scratch pattern (J) 140 ± 10 degrees

4. After honing is complete, check the cylinder sleeve bore for the correct crosshatch scratch pattern (7). The crosshatch scratch pattern should have an angle (J) of 140 ± 10 degrees. The pattern should be consistent throughout the circumference and the length of the cylinder wall.

Cleaning Procedure

After the honing operation is complete, remove the camshaft bearings from the engine block. This will permit cleaning of the cylinder block. Cleaning should be done while the engine is disassembled.

Use a 1P-5580 Cleaning Brush Gp and a strong solution of detergent and water in order to thoroughly clean the cylinder block. Be sure to clean the following items: the cylinder block, the main oil gallery, oil supply passage, the oil passages for the front camshaft bearing and cylinder bores.

The cylinder block must be soaked in a tank of cleaning solvent that is equipped with an agitator.

Note: Use the 1U-7429 Brush to clean the honed bore of the cylinder sleeve. Saturate all machined surfaces with clean engine oil (30W) after the cleaning procedure is completed.

Keep a protective cover on the cylinder block until the final assembly.

Final Assembly

Refer to the specific engine Service Manual for special procedures and bolt torques during engine assembly.