Why Liner Protrusion Matters
Cylinder liner protrusion - the height of the liner above the block deck - controls how the head gasket seals combustion pressure. Too little protrusion and the gasket leaks; too much and the liner flange cracks. Measure with a depth micrometer or dial gauge at four points around the liner and compare with the engine manual tolerance (typically 0.05-0.15 mm for mid-size diesels).
Liner Cavitation
Cylinder liner cavitation is pitting on the water jacket side caused by vibration bubbles collapsing against the liner wall. It is common on wet-liner engines with neglected coolant. Use the correct coolant additive (SCA/DCA), maintain concentration and replace liners at the first signs of deep pitting.
Tools You Need
A cylinder liner puller for removal, a protrusion gauge, and a proper installation tool with even clamping force. Cheap hammers crack liners.
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