Measure cylinder bores

AR01.40-W-9202G

Measure cylinder bores

8.3.06



Removing

1

Remove cylinder head for cylinder in question

AR01.30-W-5800G

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

Clean oil scraper ring (5) in cylinder liner (4)

 Only for code (MS4) BlueTec 4 or for code (MS5) BlueTec 5.

6

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

7

Adjust dial indicator (1) and quick calipers for inside measurements (2) with an outside micrometer (3) to smallest inside diameter of the read off tolerance group of 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

8.1

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

 Without code (MS4) BlueTec 4 or without code (MS5) BlueTec 5.

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.

AR01.40-W-9324G

8.2

Measure inside diameter and difference in diameter of cylinder liner (4) under shoulder (arrow) of the oil scraper ring (5)

 With code (MS4) BlueTec 4 or without code (MS5) BlueTec 5.

Conduct measurement in both measuring directions (A and B). Quick calipers for inside measurements (2) must not touch oil scraper ring (5).

*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.

AR01.40-W-9324G



Install

9

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

 The cranking device must be removed before starting engine.



*BA01.60-N-1001-01B



*407589006300

10

Install cylinder head

AR01.30-W-5800G

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

Wear 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