NUMBER: 13413

2013

S.M. REF.: Listed in Table

ENGINE: EPA04/07 Series 60

DATE: January

SUBJECT: CHECKING CYLINDER LINER PROTRUSION

ADDITIONS, REVISIONS, OR UPDATES
Publication Number

DDC-SVC-MAN-0004

DDC-SVC-MAN-0005

Platform

Section Title

Change
Added Link

EPA04 Series 60

Checking Cylinder Liner

Protrusion
Additional Information

Altered steps, Added link

Installation of Cylinder Liner

Added Link

Additional Information

Altered steps, Added link

EPA07 Series 60

NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.

THE FOLLOWING APPLIES TO DDC-SVC-MAN-0004

CHECKING CYLINDER LINER PROTRUSION

Check as follows:
1. Wipe the inside and outside of the liner clean. Be sure the block bore and counter bore are
clean, so the liner ange will seat properly. The block counter bore depth must be 8.9255
to 8.9662 mm (0.3514 to 0.3530 in) and must not vary more than 0.04 mm (0.0016 in) in
depth around the circumference. Variation between two adjacent block counter bores may not
range in depth more than 0.0508 mm (0.002 in) when measured in the center line of block.
Specications are listed in Table .

1. Cylinder Block

Figure 1

A. Counterbore Depth Measurement

Measuring Counterbore Depth

NOTE:
Thoroughly clean the cylinder block liner counter bores to remove any foreign material. Foreign
material in the cylinder liner counter bores can cause the liner to seat improperly.

2. Install the cylinder liner into the engine block without any seals.
NOTE:
It is necessary to leave the cylinder liner installation tool in place until after the liner protrusion is
measured.

3. Install J35597A , over the liner. See Figure 2.

Figure 2

Cylinder Liner Installation Tools

4. Thread three cylinder head bolts through the tool and into a head bolt hole so that the round
shoe of the tool is centered over the liner.
NOTE:
It is not necessary to torque the bolts.

5. Tighten the bolts.

6. Turn the threaded center bolt in a clockwise direction. As the round shoe of the tool reaches the
liner, ensure that the shoe is properly positioned into the cylinder liner.
7. Continue turning the bolt until the liner bottoms in the cylinder counterbore. Apply a tightening
torque of 60 Nm (44 lbft) to the installation tool center bolt.
8. Install a dial indicator sled gage. See Figure 2.

9. Measure the distance from the top of the liner ange to the top of the block. See Figure 3.

Figure 3

Cylinder Liner Protrusion

[a]

Allowable liner protrusion is -0.0127 to 0.0762 mm (-0.0005 to 0.003 in) with no more
than 0.0508 mm (0.002 in) variation between any two adjacent cylinders. Specications
are listed in Table .

[b]

If the liner protrusion exceeds the maximum allowable, remove the liner and check for
debris under the liner ange. If there is no debris, machine the liner counterbore. Refer to
section Additional Information.

ADDITIONAL INFORMATION
SHOP NOTES

Shop notes contains information on checking bearing clearances, the crankshaft remanufacturing
procedures and a glossary.
CYLINDER BLOCK LINER BORING

Further information will be printed as it is developed.

MACHINING CYLINDER BLOCK COUNTERBORES

Cutter plate assembly (J41063) is used with Porta-Matic boring tool (PT2050D) to machine cylinder
block counterbores for the installation of repair bushings. J41063 features a special diameter and
taper design which will permit the machining of the counterbore area in accordance with Detroit
specications.
NOTE:
Use the appropriate Detroit part when installing the counterbore insert (repair bushing).

Counterbore insert part number can be located in AP2005-048Rev.

Machine the cylinder block counterbores as follows:
1. Ensure block deck surface and boring tool base plate are clean and burr free.
2. Plug push tube opening, oil galleys and lower liner packing areas to seal out any contaminating
particles.
NOTE:
Ensure cutter is marked Series 60.
NOTE:
Maintain a sharp cutter bit to ensure the cylinder block counterbore is accurately machined.

3. Using cutter (PT2000109) set to the dimensions listed in Table 2 and see Figure 13.

Table 1

Area to be Machined

Cutter Setting Dimensions

Depth of Cut

Upper counterbore

161.798 0.0127 mm (6.370

.0005 in. Diameter)

15.29 mm (.602 in.)

PT2000109 Cutter Dimensions

Figure 4

Bushing Repair Area

4. Assemble Cutter Plate (PT2090) to the Porta-Matic mainshaft. See Figure 14.

Figure 5

Cutter Plate(PT2090) Location

5. Mount Porta-Matic over cylinder to be bored. Open feed valve to lower cutter plate into cylinder
bore. Push down rmly while rotating the mainshaft to insure proper alignment of Porta-Matic.
6. With cutter plate centered in the cylinder bore, align base plate with the four cylinder head bolt
holes in block deck while maintaining as much base plate to block deck contact as possible.
7. Cross-torque all four cylinder head bolts slowly to 67 Nm (50 lbft). Rotate mainshaft to insure
that the cutter plate is centered and moves freely.
NOTE:
If binding occurs loosen the four cylinder head bolts and repeat steps 8 and 9.

8. Pull up on the mainshaft to retract the cutter plate to the highest position and close the feed
valve to lock in position.

NOTICE:
Ensure cutter bit is completely inserted into cutter slot.

9. Insert cutter into slot of cutter plate. Hold cutter bit against the main shaft of the boring tool and
tighten the cutter plate set screw to secure the cutter.
10. Slowly lower the cutter and allow to rest onto engine block deck surface. Insert a 0.1016
mm (0.004 in.) shim between cutter and engine block. Set the depth of cut using bushing
(PT8065). Tighten socket set screw to hold depth collar in place. See Figure 15.

Figure 6

Upper Counterbore Cutting Area.

11. Retract cutter plate to the up position and lock machine.

12. Attach a right angle drill (PT7145A) and proceed to bore hole until PortaMatic freewheels.
13. Open feed valve and retract cutter plate upward. Remove cutter bit.
14. Repeat steps 5 to 13 for each of the next ve bores.
15. Cut the counterbore ledge depth to 8.966 0.0254 mm (0.353 0.001 in.) using counterbore
tool (PT2250B) and the appropriate cutter plates. Follow normal ledge cutting procedures
to achieve the nished counterbore depth.
MACHINING CYLINDER BLOCK COUNTERBORES USING SHIMS

Cutter plate assembly (J41065) is used with Counterbore tool (PT2250B) to machine cylinder block
counterbores for the installation of repair shims. See Figure 7.
NOTE:
Use the appropriate Detroit part when installing the counterbore shims.

Counterbore shim part numbers can be located in 11TS-8Rev.

1. Cylinder Block

Figure 7

2. Cylinder Liner Protrusion

3. Cylinder Liner

Cylinder Liner Protrusion

1. Remove cylinder head. Refer to section .

2. Remove oil pan. Refer to section .
3. Remove cylinder liner. Refer to section .
4. Ensure block deck surface and boring tool base plate are clean and free of burrs.
5. Plug all open areas of the engine compartment to seal out any contaminating particles.
NOTE:
Ensure cutter is marked Series 60.
NOTE:
Maintain a sharp cutter bit to ensure the cylinder block counterbore is accurately machined.

6. Retract the cutting bit into the cutting plate.

7. Mount the counterbore cutting tool over the cylinder to be machined. Install mounting bolts
into the appropriate cylinder head bolt holes, leaving the bolts loose.

8. Lower the cutting plate (2) to rest in the cylinder bore (1) and rotate the T-handle to center the
tool. See Figure 8.

Figure 8

Cutter Plate (PT2090) Location

9. Torque the two opposing mounting bolts to 68 Nm (50 lbft). Verify that the tool is still
centered in the bore. If not, then loosen bolts and re-center the tool. If centered, torque the two
remaining mounting bolts to 68 Nm (50 lbft).
10. Raise the tapered cutting head from the block and insert the spacer block. While there is no load
on the tool, extend the cutter bit outward (using a clockwise rotation of the cutting bit screw)
until it just touches a 0.15 mm (0.005 in.) feeler gauge or shim placed next to the vertical wall
of the counterbore. Tighten the Allen head hold-down screws.

Figure 9

Spacer Block PT 220083

11. Remove the spacer block and slowly lower the cutting head into the counterbore. (Be careful
not to damage the cutting bit).

12. Adjust the lower locking collar downward until it comes in contact with bronze bushing, and
the cutter bit is not resting on lower surface of counterbore. Rotate the T-handle to ensure there
is no binding or scraping of the counterbore walls. If so, adjust cutting bit.
13. Slowly back off the lower locking collar until the cutting bit is just touching the lower surface
of the counterbore.
14. Set the depth of the cut by using the repair shim. Insert the shim between the locking collars,
lower the upper lock collar down until it comes in contact with the shim. Tighten the thumb
screw on the top collar.
NOTE:
If cutting more than one counterbore, the shim used to set the depth of the cut in each cylinder must
be used in that cylinder. Failing to do so may increase/decrease the liner protrusion.

15. Lubricate the tool bushings. Back-off the lower collar by two graduations, 0.0254 mm (0.0001
in.). Rotate the T-handle clockwise with moderate, constant pressure, stopping at random
positions to prevent creating a ridge in the counterbore. Continue backing-off the lower collar,
two graduations at a time, until the collars come together.
16. Raise the cutting tool from the counterbore and insert depth spacer.
17. Retract the cutting bit into the cutting plate to protect the bit.
18. Remove the cutting tool from engine.
19. Remove all protective material used to seal out any contaminating particles and clean any/all
areas that were not protected.
20. Place the shim on the lower ledge of the counterbore.
21. Insert the cylinder liner and measure liner protrusion. Refer to section .
22. Install the cylinder liner. Refer to section .
23. Install the cylinder head. Refer to section .
24. Install the oil pan. Refer to section .

THE FOLLOWING APPLIES TO DDC-SVC-MAN-0005

INSTALLATION OF CYLINDER LINER

Install as follows:
NOTE:
Refer to section for 14L liner, piston and connecting rod procedure.

1. Wipe the inside and outside of the liner clean. Be sure the block bore and counter bore are
clean, so the liner ange will seat properly. The block counter bore depth must be 8.9255
to 8.9662 mm (0.3514 to 0.3530 in.) and must not vary more than 0.04 mm (0.0016 in.) in
depth around the circumference. No two adjacent block counter bores may range in depth
more than 0.025 mm (0.001 in.) when gaged along the longitudinal cylinder block centerline.
Specications are listed in Table , and listed in Table .
NOTE:
Thoroughly clean the cylinder block liner counter bores to remove any foreign material. Foreign
material in the cylinder liner counter bores can cause the liner to seat improperly.

2. Lubricate the seal rings and crevice seal with clean petroleum jelly.
3. Install two new seal rings and a new crevice seal into their respective grooves in the liner.
4. Install the cylinder liner, piston and rod assembly into the cylinder bore. Refer to section
5. Install J35597A, over the liner. See Figure 10.
NOTE:
It is necessary to leave the cylinder liner installation tool in place until after the liner protrusion is
measured.

Figure 10

Cylinder Liner Installation Tools

6. Thread three cylinder head bolts through the tool and into a head bolt hole, so that the round
shoe of the tool is centered over the liner.
7. Tighten the bolts.

NOTE:
It is not necessary to torque the bolts.

8. Turn the threaded center bolt in a clockwise direction. As the round shoe of the tool reaches the
liner, ensure that the shoe is properly positioned into the cylinder liner.
9. Continue turning the bolt until the liner bottoms in the cylinder counterbore. Apply a tightening
torque of 60 Nm (44 lbft) to the installation tool center bolt.
10. Install a dial indicator sled gage. See Figure .

11. Measure the distance from the top of the liner ange to the top of the block. See Figure 11
[a]

Allowable liner protrusion is -0.0127 to 0.0762 mm (-0.0005 to 0.003 in.) with no more
than 0.0508 mm (0.002 in.) variation between any two adjacent cylinders. Specications
are listed in Table .

[b]

If the liner protrusion exceeds the maximum allowable, remove the liner and check for
debris under the liner ange.

[c]

c. If the liner protrusion does the meet the minimum allowable, remove the liner and
machine the counterbore. Refer to Additional Information.

Figure 11

Cylinder Liner Protrusion

ADDITIONAL INFORMATION
SHOP NOTES

Shop notes contains information on checking bearing clearances, the crankshaft remanufacturing
procedures and a glossary.
CYLINDER BLOCK LINER BORING

Further information will be printed as it is developed.

MACHINING CYLINDER BLOCK COUNTERBORES

Cutter plate assembly (J41063) is used with Porta-Matic boring tool (PT2050D) to machine cylinder
block counterbores for the installation of repair bushings. J-41063 features a special diameter and
taper design which will permit the machining of the counterbore area in accordance with Detroit
specications.
NOTE:
Use the appropriate Detroit part when installing the counterbore insert (repair bushing).

Counterbore insert part number can be located in AP2005-048Rev.

Machine the cylinder block counterbores as follows:
1. Ensure block deck surface and boring tool base plate are clean and burr-free.
2. Plug all open areas of the engine compartment to seal out any contaminating particles.
NOTE:
Ensure cutter is marked Series 60.
NOTE:
Maintain a sharp cutter bit to ensure the cylinder block counterbore is accurately machined.

3. Verify that the Micrometer block is within specications. Insert the setting standard with the
side stamped UP between the cutter stop and the spindle. Hold the setting standard rmly;
turn the micrometer thimble until the micrometer spindle is in contact with the setting standard.
Does the micrometer read 5.000 inches?
[a]

Yes, go to step 5.

[b]

No, the micrometer will need to be calibrated. Go to step 4.

4. To calibrate the Micrometer, loosen the set screw and move the micrometer to read 5.000
inches. Slide the spindle to t snug against the setting standard; tighten the set screw. Back
off the micrometer and recheck the reading. If it does not read 5.000 inches, readjust again
and recheck. See Figure 12.

1. Cutter Stop

4. Thimble

2. Spindle

5. Setting Standard

3. Set Screw

6. Micrometer

Figure 12

Micrometer

5. Using cutter (PT2000109) set to the dimensions listed in Table 2 and see Figure 13.

Table 2

Area to be Machined

Cutter Setting Dimensions

Depth of Cut

Upper counterbore

161.798 0.0127 mm (6.370

.0005 in. Diameter)

15.29 mm (.602 in.)

PT2000109 Cutter Dimensions

Figure 13

Bushing Repair Area

6. Assemble Cutter Plate (PT2090) to the Porta-Matic mainshaft. See Figure 14.

Figure 14

Cutter Plate (PT2090) Location

7. Mount Porta-Matic over cylinder to be bored. Open feed valve to lower cutter plate into cylinder
bore. Push down rmly while rotating the mainshaft to insure proper alignment of Porta-Matic.
8. With cutter plate centered in the cylinder bore, align base plate with the four cylinder head bolt
holes in block deck while maintaining as much base plate to block deck contact as possible.
9. Cross-torque all four cylinder head bolts slowly to 67 Nm (50 lbft). Rotate mainshaft to insure
that the cutter plate is centered and moves freely.
NOTE:
If binding occurs, loosen the four cylinder head bolts and repeat steps 7 through 9.

10. Pull up on the mainshaft to retract the cutter plate to the highest position and close the feed
valve to lock in position.
NOTICE:
Ensure cutter bit is completely inserted into cutter slot.

11. Insert cutter into slot of cutter plate. Hold cutter bit against the main shaft of the boring tool and
tighten the cutter plate set screw to secure the cutter.

12. Slowly lower the cutter and allow to rest onto engine block deck surface. Insert a 0.1016
mm (0.004 in.) shim between cutter and engine block. Set the depth of cut using bushing
(PT8065). Tighten socket set screw to hold depth collar in place. See Figure 15.

Figure 15

Upper Counterbore Cutting Area.

13. Retract cutter plate to the UP position and lock machine.

14. Attach a right angle drill (PT7145A) and proceed to bore hole until PortaMatic freewheels.
15. Open feed valve and retract cutter plate upward. Remove cutter bit.
16. Repeat steps 7 to 15 for each of the next ve bores.
17. Cut the counterbore ledge depth to 8.966 0.0254 mm (0.353 0.001 in.) using counterbore
tool (PT2250B) and the appropriate cutter plates. Follow normal ledge cutting procedures
to achieve the nished counterbore depth.
MACHINING CYLINDER BLOCK COUNTERBORES USING SHIMS

Cutter plate assembly (J41065) is used with Counterbore tool (PT2250B) to machine cylinder block
counterbores for the installation of repair shims. See Figure 16.
NOTE:
Use the appropriate Detroit part when installing the counterbore shims.

Counterbore shim part numbers can be located in 11TS-8Rev.

1. Cylinder Block

Figure 16

2. Cylinder Protrusion

3. Cylinder Liner

Cylinder Liner Protrusion

1. Remove cylinder head. Refer to section .

2. Remove oil pan. Refer to section .
3. Remove cylinder liner. Refer to section .
4. Ensure block deck surface and boring tool base plate are clean and free of burrs.
5. Plug all open areas of the engine compartment to seal out any contaminating particles.
NOTE:
Ensure cutter is marked Series 60.
NOTE:
Maintain a sharp cutter bit to ensure the cylinder block counterbore is accurately machined.

6. Retract the cutting bit into the cutting plate.

7. Mount the counterbore cutting tool over the cylinder to be machined. Install mounting bolts
into the appropriate cylinder head bolt holes, leaving the bolts loose.

8. Lower the cutting plate (2) to rest in the cylinder bore (1) and rotate the T-handle to center the
tool. See Figure 17.

Figure 17

Cutter Plate (PT2090) Location

9. Torque the two opposing mounting bolts to 68 Nm (50 lbft). Verify that the tool is still
centered in the bore. If not, then loosen bolts and re-center the tool. If centered, torque the two
remaining mounting bolts to 68 Nm (50 lbft).
10. Raise the tapered cutting head from the block and insert the spacer block. While there is no load
on the tool, extend the cutter bit outward (using a clockwise rotation of the cutting bit screw)
until it just touches a 0.15 mm (0.005 in.) feeler gauge or shim placed next to the vertical wall
of the counterbore. Tighten the Allen head hold-down screws.

Figure 18

Spacer Block PT 220083

11. Remove the spacer block and slowly lower the cutting head into the counterbore. (Be careful
not to damage the cutting bit).

12. Adjust the lower locking collar downward until it comes in contact with bronze bushing, and
the cutter bit is not resting on lower surface of counterbore. Rotate the T-handle to ensure there
is no binding or scraping of the counterbore walls. If so, adjust cutting bit.
13. Slowly back off the lower locking collar until the cutting bit is just touching the lower surface
of the counterbore.
14. Set the depth of the cut by using the repair shim. Insert the shim between the locking collars,
lower the upper lock collar down until it comes in contact with the shim. Tighten the thumb
screw on the top collar.
NOTE:
If cutting more than one counterbore, the shim used to set the depth of the cut in each cylinder must
be used in that cylinder. Failing to do so may increase/decrease the liner protrusion.

15. Lubricate the tool bushings. Back-off the lower collar by two graduations, 0.0254 mm (0.0001
in.). Rotate the T-handle clockwise with moderate, constant pressure, stopping at random
positions to prevent creating a ridge in the counterbore. Continue backing-off the lower collar,
two graduations at a time, until the collars come together.
16. Raise the cutting tool from the counterbore and insert depth spacer.
17. Retract the cutting bit into the cutting plate to protect the bit.
18. Remove the cutting tool from engine.
19. Remove all protective material used to seal out any contaminating particles and clean any/all
areas that were not protected.
20. Place the shim on the lower ledge of the counterbore.
21. Insert the cylinder liner and measure liner protrusion. Refer to section .
22. Install the cylinder liner. Refer to section .
23. Install the cylinder head. Refer to section .
24. Install the oil pan. Refer to section .

ADDITIONAL SERVICE INFORMATION

Additional service information is available in Power Service Literature.

Detroit , DDC, Series 60 and the spinning arrows design are registered trademarks of Detroit Diesel Corporation.
Copyright 201 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.