311-14.pdf - cylinder liner and piston - freightliner … · 2 inspection of the cylinder liner...

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SUBJECT DATE

Cylinder Liner and Piston March 2014

Additions, Revisions, or Updates

Publication Number / Title Platform Section Title Change

DDC-SVC-MAN-0081 DD Platform

Inspection of theCylinder Liner

Added analysis of the cylinder liner

Further analysis of theCylinder Liner New Sections

Inspection of the Piston

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All information subject to change without notice. 33 11-14Copyright 2014 DETROIT DIESEL CORPORATION

2 Inspection of the Cylinder Liner

Inspect as follows:

NOTICE: Cavitation is due to poor cooling system maintenance. If uncorrected, it will eventually make holesthrough the liner. This can result in combustion gases blowing water out of the radiator, oil in the coolant, or whenthe engine is stopped will allow water to flow into the cylinder and result in major engine damage due to water inthe oil or hydraulic lockup.

1. Inspect the cylinder liner.a. Check the cylinder liner for cracks or scoring. If cracks or scoring are present, replace the liner.b. Check the cylinder liner for cavitation. If cavitation is present, replace the liner.c. Check for bore polishing; if detected, replace the cylinder liner.d. On GHG14 engines, check the recessed area at the top of the liner where the Carbon Scraper ring mounts. If

damaged, replace the liner.2. Inspect the outside diameter of the liner.

a. Check the liner for fretting.b. If any fretting is found, remove it from the surface of the liner with a course, flat stone.

3. Inspect the liner flange in two steps:a. Inspect the top surface of compression seal for cracks, smoothness and flatness.b. Inspect the balcony (bottom stop).

4. Inspect the block bore and cylinder liner.a. Measure the block bore (B) and the outside diameter of the liner (A).b. If the liner does not meet specification, replace with a new part.

Table 1.Location DD13 DD15 DD16

A 158.98 to 159 mm (6.2590 to6.2598 in.)166.98 to 167 mm (6.5740 to

6.5748 in.)166.98 to 167 mm (6.5740 to

6.5748 in.)

B 141.97 to 141.95 mm (5.589 to5.588 in.)148.95 to 148.97 mm (5.864 to

5.865 in.)148.95 to 148.97 mm (5.864 to

5.865 in.)

5. Inspect the cylinder liner.

2 Inspection of the Cylinder Liner

4 All information subject to change without notice.Copyright 2014 DETROIT DIESEL CORPORATION3 11-14

a. Check the two seal ring grooves for burrs or sharp edges.b. If any are detected, smooth with a Scotch-Brite pad.

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3 Further analysis of the Cylinder Liner

With a new engine, the cylinder liner is cylindrical. With increasing operating time, cylinder bore is not worn evenly; itnormally wears conical. The honing or cross pattern on the cylinder wall can also wear or damage.

The damage patterns shown below are just a few possible forms of damage to the cylinder bore. When assessing the types ofdamage, surface characteristics of the piston and piston rings in the diagnosis must be involved.

Cylinder liner damage is caused by the following:

Leaking air intake ducts from the air filter. Fault in fuel injection system. Incorrect piston clearance between the piston skirt and the cylinder liner wall. Poor quality engine oil (oil viscosity) or engine oil dilution by fuel. Dirty or damaged engine oil filter. Engine oil pressure is too low. Damaged or clogged piston cooling nozzles.

Table 2.Normal condition of the cylinder liner

Grey matte finish, honing pattern visible, dry cylinder liner, no oilresidues, no shiny spots or reflective finish.

Slight brush marks are not critical. The honing or cross pattern is clearly visible on the entire cylinder

liner. At the top dead center of the first piston ring, the honing pattern

can be partially removed. The cylinder liner can be used.

Table 3.Normal condition of the cylinder liner that requires cleaning

Carbon deposits on the cylinder liner above the top piston ring landarea.- Clean the top land area and the cylinder liner for further use.

Refer to section "Cleaning of the Cylinder Liner"- Remove the piston to evaluate the piston and rings.

Light scratches



NOTE: The scratches in the graphic below have been highlighted.

Table 4.Normal condition of the cylinder liner that requires cleaning

Single continuous scratches (arrows) in the cylinder liner should beverified that they are not cracks.

A cylinder liner that has light scratches (arrows) or scores cancontinue to be used.

Single continuous scratches

Table 5.Annular Marks

The honing pattern (arrow) is only visible at the upper and lowerpiston ring reversal points. The cylinder liner can be used.

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Table 6.Pressure shiners and smoothing

Individual bright spots (arrow) of the cylinder liner. Imprints where the piston rings contact the cylinder liner. The cause maybe bad quality engine oil. The cylinder liner is unusable and must be replaced.

Table 7.Optical stripe and traces of piston seizure

Abrasion formation (arrow) on the cylinder liner from the second orthird piston ring.

Can be caused by soot particles or fuel diluted engine oil. Can be caused by damaged piston rings. The cylinder liner is unusable and must be replaced.

Table 8.Dust damage

The machining marks by honing are barely or no longer visible. Advanced wear on top dead center of the first piston ring (arrow). The cylinder liner is unusable and must be replaced.



Table 9.Piston seizure

The cylinder liner is usually roughened along the entire length ofthe bore.

Material deposits from the piston skirt are often embedded into thebore of the cylinder liner.

The cylinder liner is unusable and must be replaced.

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4 Inspection of the Piston

Inspect as follows:

The following information is intended for the assessment of the piston to help make a professional decision of further use ofthe piston.

The subsequent damage patterns are just a few possible forms of damage to the piston and the piston rings. When inspectingdamage forms, the surface finish of the cylinder liner must be included in the inspection.

Piston damage is caused by the following:

Leaking air intake ducts for the air filter. Fault in fuel injection system. Incorrect piston clearance between the piston skirt and the cylinder wall. Poor quality engine oil (oil viscosity) or engine oil dilution by fuel. Dirty or damaged engine oil filter. Engine oil pressure is too low. Damaged or clogged piston cooling nozzles.



Table 10.Pistons without damage

Carbon on the piston crown and in the combustion chamberrecess is normal, as the sign of the spray pattern of the fuelinjectors on the piston crown and in the combustion chamberrecess.

The spray pattern on the piston dome from the fuel injectors iscorrect.

Continue to use the piston after it has been cleaned.

Carbon build-up on the piston crown, the top land (arrows) and inthe combustion chamber cavity is normal.

Continue to use the piston after it has been cleaned.

Table 11.Pistons with dust damage

The wear pattern on the shaft has a matte appearance and themachining grooves on the piston skirt are completely eroded.

In advanced stages, there are slight seizure marks on the shaftand the piston rings are sharp-edged.

Replace piston and inspect the cylinder liner.

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Table 12.Seizure marks on the piston shaft

The surfaces of the seizure marks appear glossy and dark-colored. Can be caused by improper running clearance between the piston

and the cylinder liner. Can be caused by poor cooling around the cylinder liner. Replace piston and inspect the cylinder liner.

Table 13.Scuffing places in the tread area of the piston skirt

The surface of the seizure marks is pure metallic, textured andhigh-gloss without transitions.

There was an oil shortage between the piston and the cylinderliner running surface.

Can be caused by engine oil dilution by fuel.

Replace piston and perform additional work:

Check cylinder bore and cylinder bore measurements, if necessary replace. Inspect engine oil for cross contamination. Inspect the engine oil filter. Inspect the engine oil system in the engine. Inspect the oil spray nozzles for damage or clogging.



1 3 11-142 Inspection of the Cylinder Liner3 Further analysis of the Cylinder Liner4 Inspection of the Piston

311-14.pdf - cylinder liner and piston - freightliner … · 2 inspection of the cylinder liner...

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