Remove/install/seal cylinder liner · ar0140w9324a · Mercedes-Benz WIS

AR01.40-W-9324A

Remove/install/seal cylinder liner

10.10.07

ENGINES 541.92# ## up to 091057 in MODEL 950, 952, 953, 954

ENGINES 542.92# ## up to 094639 in MODEL 950, 952, 954

W01.40-1090-06

1 Crankcase

2 Cylinder liner

3 Sealing ring

4 O-ring

5 O-ring

6.1  Extraction device

6.2  Insertion device

Arrows Marking

Modification notes

1.10.07	Use a commercially available open end wrench, size 24 mm, without an extension - added.	Step 11
	Special tool torque wrench handle altered.		*001589352100

	Removing
1	Remove piston for cylinder concerned	 When repairing and cleaning, no contamination may enter the crankcase (1), otherwise engine damage could occur.	AR03.10-W-7021B
2	Make an identification mark (arrows) for the cylinder liner (2) relative to the crankcase (1)	 Only if the cylinder liner (2) is used again.
3	Fit on extraction device (6.1) and pull out cylinder liner (2)		AR01.40-W-9324-01A
			*541589013300
4	Take off seal (3)
5	Take O-rings (4, 5) out of crankcase (1)
6	Clean cylinder liner (2) and cylinder liner support in crankcase (1)
7	Clean grooves for the O-rings (4, 5) in crankcase (1)
	Install
8	Insert new O-rings (4, 5) for bottom cylinder liner seal into crankcase (1)	 Insert O-rings (4, 5) dry and not twisted.
9	Insert new seal ring (3) into crankcase (1)
10	Insert cylinder liner (2) into crankcase (1)	 Grease cylinder liner (2) slightly on the outside. Install re-used cylinder liner (2) offset by 90° relative to old installation position. Observe identification (arrows).	*BR00.45-Z-1014-06A
		When installing a new cylinder liner (2) observe the piston and liner marking (code letter A, B or C).	AR03.10-W-7021-02A
		Cylinder liner inside Ø	*BE01.40-N-1001-03C
		The altered cylinder liner (2) can also be installed
	Cylinder liner modified in area of top land zone		BT01.40-W-0002-01A
11	Fit on insertion device (6.2) and press in cylinder liner (2)	 Use a commercially available open end wrench, size 24 mm, without an extension.	AR01.40-W-9324-02A
			*BA01.40-N-1020-01D
			*001589352100
			*541589013300
12	Measure projection of cylinder liner (2)		AR01.40-W-9314A
13	Install pistons		AR03.10-W-7021B

Check values for cylinder liner

Number	Designation			Engine 541.9, 542.9


BE01.40-N-1001-03C	Cylinder liner inside Ø	Code letter A	mm	129.990 to 129.995
		Code letter B	mm	129.995 to 130.005
		Code letter C	mm	130.005 to 130.010

 Crankcase, timing case cover, end cover

Number	Designation		Engine 541.9, 542.9


BA01.40-N-1020-01D	Nut for pressing the cylinder liner into the crankcase	Nm	50

541 589 01 33 00

Removal and insertion device

Torque wrench handle

001 589 35 21 00

Repair materials

Number	Designation	Order number
BR00.45-Z-1014-06A	ATE grease	-

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