7/30/2017 G3306 Gas Engine G6X00001-UP(SEBP3728 - 26) - Documentation

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Product: GAS ENGINE
Model: G3306 GAS ENGINE G6X03678
Configuration: G3306 Gas Engine G6X00001-UP

Testing and Adjusting

G3304 and G3306 Engines
Media Number -SENR7939-08 Publication Date -01.09.2011 Date Updated -01.02.2017

i01547856

Cylinder Liner Projection

SMCS - 1216-082

Before you perform this procedure, make sure that the engine block, the spacer plate, and the cylinder liners
meet the requirements that are published in the Specifications manual.

Table 1
Tools Needed Quantity

1U-9895 Crossblock (1) 1

3H-0465 Push-Puller Plate (1) 3

8F-6123 Bolt (2) 2

1P-2396 Adapter Plate 1

8T-4193 Bolt 28
2S-5658 Hard Washer 28

8F-1484 Washer 28

7K-1977 Washer 28

8T-0455 Liner Projection Tool Group 1

(1) This item is part of the 8B-7548 Push-Puller Tool Gp.
(2) Bolt size is 3/4 16 NF and 140 mm (5.5 inch).

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Illustration 1 g00769678
(1) 8T-4193 Bolt
(2) 2S-5658 Hard Washer
(3) 8F-1484 Washer
(4) 7K-1977 Washer
(5) Spacer plate
(6) 1P-2396 Adapter Plate
(7) 3H-0465 Push-Puller Plate

1. Make sure that the top surface of the cylinder block is clean. Install a new plate gasket onto the cylinder
block. Place spacer plate (5) onto the plate gasket.

Illustration 2 g00770644
(1) 8T-4193 Bolt
(2) 2S-5658 Hard Washer
(3) 8F-1484 Washer
(4) 7K-1977 Washer

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Note: The 7K-1977 Washer (4) is made of a cotton fabric that is impregnated with resin. The washer will
not damage the sealing surface of the cylinder block.

2. Secure the spacer plate to the cylinder block with bolts (1) and gaskets (2), (3) and (4). Use two bolts on
each side of each cylinder. Use three gaskets for each bolt. Tighten the bolts evenly in four steps:

a. Tighten the bolts to a torque of 14 N·m (10 lb ft).

b. Tighten the bolts to a torque of 35 N·m (25 lb ft).

c. Tighten the bolts to a torque of 70 N·m (50 lb ft).

d. Tighten the bolts to a torque of 95 N·m (70 lb ft).

Note: Use the bare cylinder liners. Do not install the filler bands or the O-ring seals onto the cylinder
liners yet.

3. Make sure that the surfaces of the engine block, the cylinder liner, and the spacer plate are clean. Remove
any nicks from the surface of the spacer plate.

4. Place a cylinder liner into a bore. Fit adapter (6) onto the cylinder liner. Place plate (7) onto the adapter.

Illustration 3 g00740417
(7) 3H-0465 Push-Puller Plate
(8) 1U-9895 Crossblock
(9) 8F-6123 Bolt
(10) 8T-0455 Liner Projection Tool Group

5. Use crossblock (8), two plates (7), and two bolts (9) to seat the cylinder liner in the bore. Tighten the bolts
evenly in four steps:

a. Tighten the bolts to a torque of 7 N·m (5 lb ft).

b. Tighten the bolts to a torque of 20 N·m (15 lb ft).

c. Tighten the bolts to a torque of 35 N·m (25 lb ft).

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d. Tighten the bolts to a torque of 70 N·m (50 lb ft).

After the bolts are tightened, Measure the distance from the bottom edge of the crossbar to the
surface of the spacer plate. The distance must be equal on both sides of the cylinder liner. If the
distance is not equal, repeat the bolt tightening.

6. Use the 8T-0455 Liner Projection Tool Group (10) to measure the cylinder liner projection.

Note: The Special Instruction, SMHS7727 is provided with the tool group.

Illustration 4 g00770022
8T-0455 Liner Projection Tool Group
(11) Bolt
(12) Dial indicator
(13) Gauge body
(14) Gauge block

a. Loosen bolt (11) until dial indicator (12) can be moved. Place gauge body (13) and dial indicator
(12) on the long side of gauge block (14).

b. Slide dial indicator (12) downward until the point contacts gauge block (14) and the needle of the
dial indicator moves to the vertical position. Tighten bolt (11). Zero the dial indicator.

c. Place gauge block (14) on the spacer plate with the point of the dial indicator on the cylinder liner
flange. Read the dial indicator in order to find the amount of cylinder liner projection.

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Illustration 5 g00769831
Points to measure around each cylinder liner

d. Measure the projection of four points that are equally distant around each cylinder liner.

If the projection is not within the “Cylinder liner projection” that is listed in Table 6, remove the
cylinder liner. Turn the cylinder liner to a different position and seat the cylinder liner into the
cylinder bore. Measure the projection again. If the projection will not meet the specifications, install
the cylinder liner into a different bore.

e. After the projection of the cylinder liner is within specifications, mark the radial position of the
cylinder liner for the cylinder. Be sure to identify the particular cylinder liner with the
corresponding cylinder.

f. Record the measurements in Table 2. Add the four measurements for each cylinder. Divide the sum
by four in order to calculate the average projection for each cylinder liner. Record the averages in
Table 2.

Table 2
Cylinder Liner Projection

Points Measurement
1A

1B
1C

1D
Sum

Average
2A

2B
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2C

2D
Sum

Average
3A
3B

3C
3D

Sum
Average

4A
4B

4C
4D

Sum
Average

5A

5B
5C
5D
Sum

Average
6A
6B
6C

6D
Sum
Average

g. Record the maximum measurement and the minimum measurement for each cylinder in Table 3.
Subtract the minimum measurement from the maximum measurement in order to determine the
maximum variation for each cylinder liner projection.
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Table 3
Maximum Variation for Each Cylinder
Cylinder 1 (maximum)

Cylinder 1 (minimum)
Variation
Cylinder 2 (maximum)
Cylinder 2 (minimum)
Variation

Cylinder 3 (maximum)
Cylinder 3 (minimum)
Variation
Cylinder 4 (maximum)

Cylinder 4 (minimum)
Variation
Cylinder 5 (maximum)
Cylinder 5 (minimum)

Variation
Cylinder 6 (maximum)
Cylinder 6 (minimum)
Variation

h. Record the average measurement for the adjacent cylinder liners in Table 4. Determine the variation
between the adjacent cylinder liners. Record the variations in Table 4.

Table 4
Variation of the Average Measurements for Adjacent Cylinder Liners
Cylinder 1 (average)
Cylinder 2 (average)

Variation
Cylinder 2 (average)
Cylinder 3 (average)
Variation
Cylinder 3 (average)
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Cylinder 4 (average)
Variation
Cylinder 4 (average)
Cylinder 5 (average)

Variation
Cylinder 5 (average)
Cylinder 6 (average)
Variation

i. Determine the cylinder with the greatest average measurement and the cylinder with the least
average measurement. Record the measurements in Table 5. Subtract the minimum average
measurement from the maximum average measurement in order to determine the maximum
variation of all the cylinder liner projections.

Table 5
Maximum Variation of All of the Cylinder Liner Projections
Greatest average measurement
Least average measurement
Variation

7. Compare the results to the specifications that are listed in Table 6.

Table 6
Specifications for Cylinder Liner Projection

0.033 to 0.175 mm
Cylinder liner projection
(0.0013 to 0.0069 inch)
Maximum variation for each cylinder liner 0.05 mm (0.002 inch)

Maximum average variation between adjacent cylinder

0.05 mm (0.002 inch)
liners
Maximum variation for all of the cylinder liners (G3304
0.08 mm (0.003 inch)
Engine)
Maximum variation for all of the cylinder liners (G3306
0.10 mm (0.004 inch)
Engine)

Result 1

The cylinder liner projection is correct. - The results meet the specifications that are listed in Table 6.
Remove the cylinder liners and remove the tooling from the spacer plate. Install the filler bands and the O-ring
seals onto the cylinder liners. Refer to Disassembly and Assembly, "Cylinder Liners - Install".

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Result 2

One or more cylinder liner projections exceeds the maximum specifications. - At least one of the results
exceed the specifications that are listed in Table 6. Use any of the following methods in order to correct the
condition:

Machine the engine block. The 8S-3140 Counterboring Tool Group can be used. Refer to Instruction,
FM055228. After the cylinder block is reworked, use any of the following shims in order to obtain the
correct cylinder liner projection: 8S-6045 Shim ( 0.18 mm (0.007 inch)), 8S-6046 Shim ( 0.20 mm
(0.008 inch)), 8S-6047 Shim ( 0.23 mm (0.009 inch)), 8S-6048 Shim ( 0.38 mm (0.015 inch)) and 8S-
6049 Shim ( 0.76 mm (0.030 inch)).

Obtain new cylinder liners.

Obtain a new engine block.

Result 3

One or more cylinder liner projections is less than the minimum specifications. - At least one of the results
is less than the maximum specifications that are listed in Table 6. Use any of the following methods in order to
correct the condition:

Shim the cylinder liner. Use the shims that are listed in “Result 2” in order to obtain the correct cylinder
liner projection.

Obtain new cylinder liners.

Obtain a new engine block.

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