W01.40-0004-06
1 Engine block
2 Cylinder liner
3 Drilling bench
| Remove | ||
1 | Remove the drive shaft | ||
2 | Remove the camshaft | ||
3 | Remove the oil nozzles | ||
4 | Remove the oil/water heat exchanger | If there chips are found in the oil circuit, the oil-water exchanger should be replaced. | |
Engine 904.9 | |||
Engine 906.9 | |||
5 | Remove and clean the oil filter housing | If dirt is found, replace the oil filter. | |
6 | Remove the remaining aggregate parts | ||
Machining | |||
7 | Fasten the engine block (1) on the drilling bench (3) | ||
8 | Align the engine block (1) on the drilling bench (3) | Using the centering device above the top dead center of the 1st piston ring. | |
9 | Position the cutting steel and open the cylinder liner (2) in several steps until half of the wall thickness | If several cylinder liners (2) are removed, pay attention to the work sequence to prevent high thermal load. Engine 904, cylinder bore 2-4-1-3 Engine 906, cylinder bore 1-3-5-2-4-6 | |
Bore of the cylinder liner | |||
Outside diameter of the cylinder liner | |||
10 | Open the cylinder liner (2) to approximately 0.2 mm below the outside diameter | With this setting of the cutting steel, the edge of the cylinder liner becomes loose. | |
Outside diameter of the cylinder liner | |||
11 | Using a three-side file, mark/rip the total length of the cylinder liner (2) | Thus the cylinder liner (2) breaks. Avoid damaging the engine block (1). | |
12 | Remove the cylinder liner (2) remains from the engine block (1) | ||
13 | Clean the engine block (1) | ||
| Install | ||
14 | Mount a new cylinder liner (2) |
Inspection data of crankcase
Número | Denominação | Engine 904.9 and 906.9 | |||
BE01.40-B-1001-02C | Cylinder's internal diameter, finishing | Normal | Tolerance A | mm | 101,985...101,991 |
Tolerance B | mm | 101,992...102,008 | |||
Tolerance C | mm | 102,009...102,015 | |||
Repair I | Tolerance A | mm | 102,285...102,291 | ||
Tolerance B | mm | 102,292...102,308 | |||
Tolerance C | mm | 102,309...102,315 | |||
Repair II | Tolerance A | mm | 102,585...102,591 | ||
Tolerance B | mm | 102,592...102,608 | |||
Tolerance C | mm | 102,609...102,615 | |||
Repair III | Tolerance A | mm | 102,885...102,891 | ||
Tolerance B | mm | 102,892...102,908 | |||
Tolerance C | mm | 102,909...102,915 | |||
Inspection data of cylinder liner