Remove/install/seal cylinder liner

AR01.40-W-9324C

Remove/install/seal cylinder liner

31.8.10

5.8.10

"Check sealing ring (3) for wear by visual inspection" added.

Step 5

"Clean cylinder liner support and housing bores and at separating point" added

Step 8

AR01.40-W-9303-01C



Removing

1

Remove piston for cylinder concerned

 Ensure that the crankcase (1) is not contaminated during repair and cleaning work, otherwise the engine can be damaged.

AR03.10-W-7021C

2

Mark cylinder liner (2) (arrows A) in relation to 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-9324-01C

 Supplementary set

*457589003300

 Removal and insertion device

*541589013300

4

Take off seal (3)

 Measure thickness of the sealing ring (3) using an outside micrometer and note the value.

5

Visually check sealing ring (3) for wear.

 If the sealing ring (3) is not discolored, the collar seat in the crankcase (1) is okay.

If the sealing ring (3) is discolored:



Check cylinder liner collar seat in crankcase.

AR01.40-W-9303C



Notes for evaluating sealing ring wear on cylinder liner

AH01.40-N-1000-07A

6

Remove sealing ring (8) on the cylinder liner (2)

 Only if a sealing ring (8) is installed.



Cylinder liner altered

BT01.40-W-0002-02A

7

Remove O-rings (4, 5) from crankcase (1)

8

Clean cylinder liner support and holes (1.1) in crankcase (1) and at separating point

AR01.40-W-9303-01C



Stop plugs for closing off bores

WF58.50-W-0100-04A



Cap for hole of cylinder liner

WF58.50-W-0100-05A

9

Clean grooves for O-rings (4, 5) in crankcase (1)

10

Clean cylinder liner (2)

 Only if the cylinder liner (2) is used again.



Checking

11

Check whether there is a rounded off chamfer on the inner diameter of the collar seat in the cylinder crankcase (1)

 A chamfer can be added to the collar seat if there is no chamfer present:



Chamfer cylinder bore retrospectively

AR01.40-W-9201-01E

 Magnetic pin

*210589004000



Stop plugs for closing off bores

WF58.50-W-0100-04A



Cap for hole of cylinder liner

WF58.50-W-0100-05A



Cylinder liner altered

BT01.40-W-0002-02A



Install

12

Insert new O-rings (4, 5) for bottom cylinder liner seal into crankcase (1)

 Insert O-rings (4, 5) dry and not twisted.

13

Lay new seal ring (3) into crankcase (1)

 Install sealing ring (3) with the same thickness as the removed sealing ring (3).

*BE01.40-N-1006-03J

14

Insert new sealing ring (8) on the cylinder liner (2)

 Only if a sealing ring (8) or a new cylinder liner (2) is installed.

Observe installation position of sealing ring (8) in groove of cylinder liner (2). Both chamfers (arrow B) must point outwards. Do not insert the sealing ring (8) turned around the wrong way.



Cylinder liner altered

BT01.40-W-0002-02A

15

Insert cylinder liner (2) into crankcase (1)

 Grease cylinder liner (2) slightly on the outside.

*BR00.45-Z-1014-06A

Install re-used cylinder liner (2) offset by 90° relative to old installation position. Observe identification (arrows A).

Only for vehicles without code (MS4) BlueTec 4 or without code (MS5) BlueTec 5.



When installing a new cylinder liner (2) observe the piston and liner marking (code letter A, B or C).

AR03.10-W-7021-02C

*BE01.40-N-1001-03J

16

Fit on insertion device (6.2) and press into cylinder liner (2)

Use a commercially available open end wrench, size 24 mm, without an extension.

AR01.40-W-9324-02C



*BA01.40-N-1009-01U

 Torque wrench handle

*001589352100

 Supplementary set

*457589003300

 Removal and insertion device

*541589013300

17

Measure projection of cylinder liner (2)

AR01.40-W-9314C

18

Install pistons

 Additionally on vehicles with code (MS4) BlueTec 4 or with code (MS5)
BlueTec 5:



AR03.10-W-7021C

When installing new cylinder liner (2) always replace scraper ring (7).

Number

Designation

Engine
457.9

BE01.40-N-1001-03J

Cylinder liner inner diameter

Code letter A

mm

127.990 to 127.995

Code letter B

mm

127.995 to 128.005

Code letter C

mm

128.005 to 128.010

BE01.40-N-1006-03J

Thickness of sealing ring (metal)

mm

0.14 to 0.16

Number

Designation

Engine
457.9

BA01.40-N-1009-01U

Nut for pressing the cylinder liner into the crankcase

Nm

50

Number

Designation

Order number

BR00.45-Z-1014-06A

ATE grease

-