01-110 Measuring, drilling and honing cylinder bores
Operation No. of operation texts and operation values or standard texts and flat rates |
Matching piston and cylinders
Engine 102.91/92/ 96 | Group number (1st version)1) | Piston | Cylinder | Group code letter (2nd version)2) | Piston | Cylinder |
|
Standard | 0 | 88.968 88.982 | 88.998 89.008 | A | 88.973 88.979 | 89.000 89.006 |
size | 1 | 88.978 88.992 | 89.009 89.018 | X | 88.978 88.986 | 89.007 89.012 |
2 | 88.988 89.002 | 89.019 89.028 | B | 88.985 88.991 | 89.013 89.018 | |
Repair size 1 (+0.5) | 0 | 89.468 89.482 | 89.498 89.508 | A | 89.473 89.479 | 89.500 89.506 |
1 | 89.478 89.492 | 89.509 89.518 | X | 89.478 89.486 | 89.507 89.512 | |
2 | 89.488 89.502 | 89.519 89.528 | B | 89.485 89.491 | 89.513 89.518 | |
Repair size 2 (+1.0) | 0 | 89.968 89.982 | 89.998 90.008 | A | 89.973 89.979 | 90.000 90.006 |
1 | 89.978 89.992 | 90.009 90.018 | X | 89.978 89.986 | 90.007 90.012 | |
2 | 89.988 90.002 | 90.019 90.028 | B | 89.985 89.991 | 90.013 90.018 | |
1) 1st version in group numbers (1, 2, 3).
2) 2nd version in group code letters (A, X, B).
The group numbers or group code letters are indicated on the piston crown and are stamped in the contact surface of the crankcase.
Engine 102.982/985 | Group number (1st version)1) | Piston | Cylinder | Group code letter (2nd version)2) | Piston | Cylinder |
|
Standard | 0 | 95.468 95.482 | 95.498 95.508 | A | 95.473 95.479 | 95.500 95.506 |
size | 1 | 95.478 95.492 | 95.509 95.518 | X | 95.478 95.486 | 95.507 95.512 |
2 | 95.488 95.502 | 95.519 95.528 | B | 95.485 95.491 | 95.513 95.518 | |
Repair size 1 (+0.5) | 0 | 95.968 95.982 | 95.998 96.008 | A | 95.973 95.979 | 96.000 96.006 |
1 | 95.978 95.992 | 96.009 96.018 | X | 95.978 95.986 | 96.007 96.012 | |
2 | 95.988 96.002 | 96.019 96.028 | B | 95.985 95.991 | 96.013 96.018 | |
Repair size 2 (+1.0) | 0 | 96.468 96.482 | 96.498 96.508 | A | 96.473 96.479 | 96.500 96.506 |
1 | 96.478 96.492 | 96.509 96.518 | X | 95.478 96.486 | 96.507 96.512 | |
2 | 96.488 96.502 | 96.519 96.528 | B | 96.485 96.491 | 96.513 96.518 | |
1) 1st version in group numbers (1, 2, 3).
2) 2nd version in group code letters (A, X, B).
The group numbers or group code letters are indicated on the piston crown and are stamped in the contact surface of the crankcase.
Wear limit in direction of travel or transverse direction | 0.10 |
Permissible variation of cylinder shape | when new | 0.007 |
wear limit | 0.05 | |
Permissible variation from rectangularity related to cylinder height | 0.05 |
Averaged peak-to-valley height (Rz) after ceramic finish honing | 0.002 - 0.004 |
Chamfer of cylinder bores | see instruction |
Honing angle | 50°10° |
Commercially available tool
Snap gauge for internal measurements, 80 - 100 mm | |
Note
When performing repairs, the cylinder bores should be finished to the dimensions of the existing pistons in accordance with the table for matching pistons and cylinders.
Following final honing, chamfer the cylinder bore as shown in the sketch.
The infeed of the honing tool should be not more than 0.05 mm for honing.
P03-0060-13
Measuring
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Measure the cleaned cylinder bores with an internal measuring device at measuring points 1, 2 and 3 in longitudinal direction A (piston pin axis) and in transverse direction B.
With pistons installed, measuring point 3 is just above the piston, which must be at the bottom dead centre.
Measuring points 1 - 3
A Longitudinal direction
B Transverse direction
a Top reversal point of 1st piston ring
b Bottom dead centre of piston
c Bottom reversal point of oil scraper ring
P01-0091-13