Install cylinder liner

AR01.40-W-9273A

Install cylinder liner

17.7.09

19.5.09

Value altered: Peak-to-valley height (Rz) cylinder barrel

*BE01.40-N-1004-02B

Value altered: Peak-to-valley height (Rz) cylinder crankcase-contact surface

*BE01.40-N-1011-02B



Install

1.1

Drill out crankcase (1) for cylinder liner (2)

Engine without cylinder liner (2)

AR01.40-W-9271A

1.2

Remove cylinder liner (2)

Engine with cylinder liner (2)

AR01.40-W-9272A

2

Measure bore and collar seat in crankcase (1)

Bore dia. for cylinder liner in crankcase (B)

*BE01.40-N-1007-02B

Bore dia. for cylinder liner collar in crankcase (C)

*BE01.40-N-1008-02B

3

Coat bore in crankcase (1) with acid-free grease.

*BR00.45-Z-1014-06A

4

Measure cylinder liner (2)

Overlap of cylinder liner to machined crankcase

*BE01.40-N-1017-02B

Cylinder liner outer dia.

*BE01.40-N-1001-03B

Cylinder liner collar outer dia.

*BE01.40-N-1002-03B

5

Place crankcase (1) on workshop press and align

6

Position cylinder liner (2) at bore at right angles

7

Press in cylinder liner (2) until it projects about 20 mm

 Use a suitable plate for pressing in. Inspect collar seat for abrasion (arrow), clean with compressed air if necessary.

8

Press in cylinder liner (2) into final position

 Press in with about 3 tons up to stop, release shortly and then press again with about 7 tons for about 5 seconds.

9

Machine contact face of crankcase (1)

 Pay attention to deviation stages of crankcase height, height (A) measured from main bearing shell seat to contact surface of cylinder head.

*BE01.40-N-1021-02B

Peak-to-valley height (Rz) of crankcase contact surface

*BE01.40-N-1011-02B

Crankcase flatness of separating surface

*BE01.40-N-1013-02B

Crankcase - parallelism of contact surface, measured to main bearing shell seat

*BE01.40-N-1016-02B

10

Clamp crankcase (1) onto drilling tool

11

Align crankcase (1) to boring machine

 With centering device above reversal point of first piston ring.

12

Clamp boring tool in place and widen cylinder liner (2) in several operations

 If several cylinder liners (2) are installed, pay attention to the order of operations in order to avoid excessive thermal stresses.

Engine 904 cylinder bore 2-4-1-3

Engine 906 cylinder bore 1-3-5-2-4-6

 Machine settings for fine boring machine:

Rotational speed (n): 250 to 280 rpm

Operating speed (f): 0.04 to 0.06 mm/revolution

Drill out to within about 0.05 mm of the desired final dimension, the inner dia. of the cylinder liner.

*BE01.40-N-1001-02B

13

Hone cylinder liner (2) to the finished dimension

Cylinder liner inside dia.

*BE01.40-N-1001-02B

Variation of cylinder wall of cylinder shape

*BE01.40-N-1002-02B

Peak-to-valley height (Rz) of cylinder liner

*BE01.40-N-1004-02B

Variation of cylinder liner, measured perpendicular to crankshaft axis and to main bearing shell seat

*BE01.40-N-1005-02B

 Machine settings of honing machine:

Working pressure (p): 2.5 to 3.0 bar

Speed (n): 60...100 rpm

Honing angle (α): 40 to 60°

Number of strokes: 30 to 40

14

Measure cylinder liner (2) and rehone if necessary

 When pressing in, this can result in changes in the microstructure which lead to a slight alteration of the inner dia. of the cylinder barrel (shape of cylinder) of the adjacent cylinder liner (2).

*BE01.40-N-1001-02B

Variation of cylinder wall of cylinder shape

*BE01.40-N-1002-02B

15

Clean crankcase (1)

 Remove all chips from and in crankcase (1) to avoid engine damage.

16

Clean main oil duct

AR01.40-W-8501A

17

Newly mark marking areas (3) on crankcase (1) after machining

AR01.40-W-9273-01A

Cylinder liner inside dia.

*BE01.40-N-1001-02B

Crankcase housing (A)

*BE01.40-N-1021-02B

18

Reinstall detachable parts

19

Install oil filter housing

Model 668, 670

AR18.20-D-3471D

Model 374, 375, 673, 674, 676, 950, 952, 953, 954, 957, 958, 970, 972, 974, 975, 976

AR18.20-W-3471A

20

Install oil/water heat exchanger

Engine 904.9 in model 668, 670

AR18.30-D-6840D

Engine 904.9 in model 374, 375, 673, 674, 676, 958, 970, 972, 975, 976

AR18.30-W-6840A

Engine 906.9

AR18.30-W-6840D

21

Install camshaft

AR05.20-W-6292A

22

Install oil spray nozzles

Engine 904.9 up to engine end no. 066192

Engine 906.9 up to engine end no. 067198

AR18.00-W-4000A

engine 904.9 from engine end no. 066193

Engine 906.9 as of engine end no. 067199

AR18.00-W-4000C

23

Install crankshaft

AR03.20-W-4351A

24

Install pistons

 Install piston (piston height) according to the crankcase height (A) to avoid engine damage.

AR03.10-W-7021A

Number

Designation

Engine
904.9,
engine
906.9
without code MS8

BE01.40-N-1001-02B

Cylinder internal bore dia.

Code letter A

mm

101.985 to 101.991

Code letter B

mm

101.992 to 102.008

Code letter C

mm

102.009 to 102.015

BE01.40-N-1002-02B

Deviation of cylinder bore from the cylindrical form

mm

0.012

BE01.40-N-1004-02B

Peak-to-valley height (R3z) cylinder barrel

μm

2.0 to 4.5

BE01.40-N-1005-02B

Variation of cylinder barrel, measured perpendicular to crankshaft axis and to main bearing shell seat

mm

0.050

BE01.40-N-1007-02B

Bore dia. for cylinder liner in crankcase (B)

mm

106.000 to 106.035

BE01.40-N-1008-02B

Bore dia. for cylinder liner collar in crankcase (C)

mm

109.572 to 109.626

BE01.40-N-1011-02B

Peak-to-valley height (Rz) of crankcase contact surface

μm

4 to 16

BE01.40-N-1013-02B

Crankcase flatness of separating surface

over the entire length

mm

0.030

over a length of 150 mm in longitudinal and transverse direction

mm

0.015

BE01.40-N-1016-02B

Crankcase - parallelism of contact surface, measured to main bearing shell seat

mm

0.05

BE01.40-N-1017-02B

Overlap of cylinder liner to machined crankcase

mm

0.040

BE01.40-N-1021-02B

Cylinder crankcase height (A), measured from the main bearing shell seat to the cylinder head contact surface and cylinder bore internal dia.

Height standard 0

mm

298.33 to 298.40

Cylinder internal bore dia., code letter A

mm

101.985 to 101.991

Code letter B

mm

101.992 to 102.008

Code letter C

mm

102.009 to 102.015

Height deviation -0.3

mm

298.03 to 298.10

Cylinder bore internal dia.,
code letter A

mm

102.285 to 102.291

Code letter B

mm

102.292 to 102.308

Code letter C

mm

102.309 to 102.315

Height deviation -0.6

mm

297.73 to 297.80

Cylinder bore internal dia.,
code letter A

mm

102.585 to 102.591

Code letter B

mm

102.592 to 102.608

Code letter C

mm

102.609 to 102.615

Height deviation -0.9

mm

297.43 to 297.50

Cylinder internal bore dia., code letter A

mm

102.885 to 102.891

Code letter B

mm

102.892 to 102.908

Code letter C

mm

102.909 to 102.915

Number

Designation

Engine
904.9,

Engine
906.9
without code MS8

BE01.40-N-1001-03B

Cylinder liner outer dia.

mm

106.075 to 106.095

BE01.40-N-1002-03B

Cylinder liner collar outer dia.

mm

109.374 to 109.428

Number

Designation

Order number

BR00.45-Z-1014-06A

ATE grease

-