Remove/install/seal cylinder liner

AR01.40-T-9324A

Remove/install/seal cylinder liner

27.1.09



Removing

1

Remove cylinder head

 Clean surface of crankcase and of cylinder liner.

Engine 447, 489 in model 671.

AR01.30-T-5800A

Engine 441.980 in model 613.355/ 364/ 365,
engine 402.970, 446.938 in model 613.455/ 485.

AR01.30-T-5800B

2

Remove pistons

Engine 447, 489.

AR03.10-T-7021A

Engine 441.980 in model 613.355/ 364/ 365,
engine 402.970, 446.938 in model 613.455/ 485.

AR03.10-T-7021B

3

Pull out cylinder liner

AR01.40-T-9324-01A



*403589003300



Checking

 First of all clean all parts to be inspected.

4

Inspect cylinder liner for wear

Install new cylinder liner if damaged.



Notes for assessing wear to cylinder wall in the case of dust damage

AH03.10-N-0001-01A

5.1

Assigning a standard dimension piston to a cylinder bore

 Only when replacing the cylinder liner: this can only be only be obtained with the associated piston as a replacement part repair kit.

Engine 447, 489.

AR03.10-T-7021-02A

*BE01.40-N-1001-03D

*BE03.10-N-1001-02F

Engine 441.980 in model 613.355/ 364/ 365,
engine 402.970, 446.938 in model 613.455/ 485.

AR03.10-T-7021-02B

*BE01.40-N-1003-03F

*BE03.10-N-1001-02I



Install

6

Seal cylinder liner

Engine 447, 489,
engine 402.970 in model 613.455/ 485.

AR01.40-T-9324-04A



*000589012500

*BR00.45-Z-1014-06A

Engine 441.980 in model 613.355/ 364/ 365,
engine 446.938 in model 613.455/ 485.

AR01.40-T-9324-04B

7

Press in cylinder liner

AR01.40-T-9324-02A



*403589003300

*BR00.45-Z-1014-06A

8

Measure projection of cylinder liner

AR01.40-T-9314A

9

Inspect seat of lower sealing rings of cylinder liner

 Inspect by measuring out-of-roundness of cylinder wall at lower contact point.

AR01.40-T-9324-05A

Engine 447, 489.

*BE01.40-N-1001-03D

Engine 447, 489.

*BE01.40-N-1006-03D

Engine 402.970, 441.980, 446.938.

*BE01.40-N-1003-03F

Engine 402.970, 441.980, 446.938.

*BE01.40-N-1004-03F



*001589532100

Quick calipers for internal measurements

Micrometer

If the out-of-roundness measured is greater than the tolerance: 

Remove cylinder liner and inspect whether the lower sealing rings are correctly seated, install new rings if necessary.

10

Install pistons

 In order to avoid loosening of the cylinder liner during installation of pistons the respective cylinder liner should be fixed in place using two suitable sleeves and two cylinder head bolts.

Engine 447, 489.

AR03.10-T-7021A

Engine 441.980 in model 613.355/ 364/ 365,
engine 402.970, 446.938 in model 613.455/ 485.

AR03.10-T-7021B

11

Install cylinder head

Engine 447, 489 in model 671.

AR01.30-T-5800A

Engine 441.980 in model 613.355/ 364/ 365,
engine 402.970, 446.938 in model 613.455/ 485.

AR01.30-T-5800B

Number

Designation

Engine 447

Engine 489

BE01.40-N-1001-03D

Cylinder liner inner 

Code letter B

mm

127.990-127.995

127.990-127.995

Code letter C

mm

127.995-128.000

127.995-128.000

Code letter D

mm

128.000-128.005

128.000-128.005

Code letter E

mm

128.005-128.010

128.005-128.010

BE01.40-N-1006-03D

Out-of-roundness of cylinder wall at lower contact surface

mm

0.04

0.04

Number

Designation

Engine 402.970

Engine 441.980

BE01.40-N-1003-03F

Cylinder liner inner dia.

Code letter B

mm

124.990 to 124.995

127.990 to 127.995

Code letter C

mm

124.995 to 125.000

127.995 to 128.000

Code letter D

mm

125.000 to 125.005

128.000 to 128.005

Code letter E

mm

125.005 to 125.010

128.005 to 128.010

BE01.40-N-1004-03F

Out-of-roundness of cylinder barrel at bottom entrance

mm

0.04

0.04

Number

Designation

Engine 446.938

BE01.40-N-1003-03F

Cylinder liner inner dia.

Code letter B

mm

127.990 to 127.995

Code letter C

mm

127.995 to 128.000

Code letter D

mm

128.000 to 128.005

Code letter E

mm

128.005 to 128.010

BE01.40-N-1004-03F

Out-of-roundness of cylinder barrel at bottom entrance

mm

0.04

Number

Designation

Engine 447

Engine 489

BE03.10-N-1001-02F

Piston 

Group marking

BC

mm

127.780 to 127.785

127.780 to 127.785

BCD

mm

127.785 to 127.790

127.785 to 127.790

CDE

mm

127.790 to 127.795

127.790 to 127.795

DE

mm

127.795 to 127.800

127.795 to 127.800

Number

Designation

Engine 402.970

Engine 441.980, 446.938

BE03.10-N-1001-02I

Piston dia.

Group marking

BC

mm

124.790 to 124.795

127.780 to 127.785

BCD

mm

124.795 to 124.800

127.785 to 127.790

CDE

mm

124.800 to 124.805

127.790 to 127.795

DE

mm

124.805 to 124.810

127.795 to 127.800

Number

Designation

Order number

BR00.45-Z-1014-06A

ATE grease

-