Measure cylinder bores

AR01.40-W-9202B

Measure cylinder bores

8.3.06

26.1.06

Measuring procedure altered.

Step 7



Removing

1

Remove cylinder head for cylinder in question

AR01.30-W-5800B

2

Remove cap at timing case TDC inspection hole and attach turning device



*BA01.60-N-1009-01B



*407589006300

3

Position piston of cylinder liner to be inspected (4) at bottom dead center.

 Rotate crankshaft with cranking device



*407589006300

4

Thoroughly clean cylinder liner (4)

 Cover piston crown.

5

Assess honing pattern in the cylinder liner (4)

 If the honing pattern cannot be assessed very clearly, establish degree of wear where necessary and measure cylinder bores.



Notes for evaluation of cylinder contact surface

AH01.40-N-0001-03A



Measure

6

Adjust the dial indicator (1) and the quick calipers for inside measurements (2) with the outside micrometer (3) to the smallest inside diameter of the read off tolerance group of the cylinder liner (4) and set dial indicator (1) to "0"

 Read off code letter A, B or C at liner edge of the cylinder liner (4).

Adjust quick calipers for inside measurements (2) to have an additional 5 mm preload.

*BE01.40-N-1001-03C



*001589532100



*WH58.30-Z-1001-12A



*WH58.30-Z-1002-12A

7

Measure inside diameter and difference in diameter of cylinder liner (4) at upper reversal point (arrow) of first piston ring

 Conduct measurement in both measuring directions (A and B).

*BE01.40-N-1001-03C

*BE01.40-N-1005-03C



*001589532100



*WH58.30-Z-1001-12A

The specifications must be maintained. The cylinder liner (4) must not be reworked; replace cylinder liner (4) if necessary:



Engine 541.9 up to final no. 091057

Engine 542.9 up to final no. 094639

AR01.40-W-9324A

Engine 541.9 as of end no. 091058

Engine 542.9 as of end no. 094640

AR01.40-W-9324B



Cylinder liner modified in area of top land zone

BT01.40-W-0002-01A



Install

8

Remove turning device and attach cap to timing case TDC inspection hole

 The cranking device must be removed before starting the engine.



*BA01.60-N-1001-01B



*407589006300

9

Install cylinder head

AR01.30-W-5800B

Number

Designation

Engine
541.9, 542.9

BE01.40-N-1001-03C

Cylinder liner inside dia.

Code letter A

mm

129.990...129.995

Code letter B

mm

129.995...130.005

Code letter C

mm

130.005...130.010

BE01.40-N-1005-03C

Sear of cylinder liner at top reversal point of first piston ring

mm

0.08

Number

Designation

Engine
541.9, 542.9

BA01.60-N-1001-01B

Bolt, end cover of TDC inspection hole to timing case

Nm

25

BA01.60-N-1009-01B

Bolt, engine cranking device to timing case

Nm

25

Number

Designation

WH58.30-Z-1001-12A

Quick calipers for internal measurements

WH58.30-Z-1002-12A

Micrometer