Install cylinder liner

AR01.40-B-9273TA

Install cylinder liner

12.02.16



Install

1.1

Reaming the engine block (1) for the cylinder wall (2)

Engine without cylinder wall (2)

AR01.40-B-9271TA

1.2

Disassemble the cylinder liner (2)

Engine with cylinder wall (2)

AR01.40-B-9272TA

2

Measuring the perforation and seating in the engine block (1)

Diameter of the basic bore for the cylinder liner in the engine block (B)

*BE01.40-B-1007-02C

Diameter of the perforation for the cylinder liner edge in the engine block (C)

*BE01.40-B-1008-02C

3

Grease the engine block (1) boring with acid free grease.

*BR00.45-B-1008-06A

4

Measure the cylinder liner (2)

Cylinder liner coverage for the machined engine block

*BE01.40-B-1017-02C

Cylinder wall outside diameter

*BE01.40-B-1001-03C

Cylinder wall edge outside diameter

*BE01.40-B-1002-03C

5

Put the engine block (1) in the workshop press and align

6

Position the cylinder liner (2) in the bore in right angle

7

Press the cylinder liner (2) with approximately 20 mm oversize

 Use an adequate plate for pressing. Check the seat slippage (arrow) if necessary clean with compressed air.

8

Finish pressing the cylinder liner (2)

 Press against stop with approximately 3 t, then give briefly and press again during 5 s with approximately 7 t.

9

Machine the engine block (1) deck so it remains flat

 Observe the stages of the engine block height (A) measurement which is measured from the main bearing seat to the engine block deck.

*BE01.40-B-1006-02C

Roughness (Rz) of engine block deck

*BE01.40-B-1011-02C

Flatness of the detachable part of the engine block

*BE01.40-B-1013-02C

Parallelism of the engine block deck, measured in relation to the main support bearing

*BE01.40-B-1016-02C

10

Prepare and secure the engine block (1) in the boring machine

11

Align the engine block (1) in relation to the boring machine

 With centering device above the top dead center of the 1st piston ring.

12

Position the boring tool and proceed with the boring of the cylinder liner (2) in several stages

 If several cylinder liners (2) are installed, observe the working sequence to avoid a high thermal load.

Engine 904 cylinder bore 2-4-1-3

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

 Setting values of the precision boring machine:

Speed (n): 250...280 rpm

Feed (f): 0.04...0.06 mm/revolution

Ream to approximately 0.05 mm of the final aimed measurement of the cylinder liner inside diameter.

*BE01.40-B-1001-02C

13

Hone the cylinder wall (2) to the final measurement

Cylinder liner inside diameter

*BE01.40-B-1001-02C

Deviation of the cylinder route (cylinder shape)

*BE01.40-B-1002-02C

Cylinder wall roughness (R3z)

*BE01.40-B-1004-02C

Cylinder wall deviation measured vertically in relation to the crankshaft and to the main support bearing

*BE01.40-B-1003-02C

 Settings of the honing machine:

Effective pressure (p): 2,5...3,0

Speed (n): 60...100 rpm

Honing angle (α): 40...60°

Quantity of feeds: 30...40

14

Measure the cylinder liner (2) and if necessary hone again

 Due to the pressing, structure alterations may occur, which can cause the inner Ø of the cylinder wall (cylinder's shape) of the next cylinder liner (2) to alter slightly.

*BE01.40-B-1001-02C

Deviation of the cylinder route (cylinder shape)

*BE01.40-B-1002-02C

15

Clean the engine block (1)

 To avoid engine damage remove all filings from the engine block (1).

16

Clean the main oil gallery

AR01.40-B-8501TA

17

Remark the marking faces (3) on the engine block (1) after the machining

AR01.40-B-9273-01TA

Cylinder liner inside diameter

*BE01.40-B-1001-02C

Engine block height (A)

*BE01.40-B-1006-02C

18

Install again the aggregate parts

19

Install the oil filter housing

AR18.20-B-3471TA

20

Install the oil-coolant heat exchanger

Engine 904.9

AR18.30-B-6840TA

Engine 906.9

AR18.30-B-6840TD

21

Install the camshaft

AR05.20-B-6292TA

22

Install the oil spray nozzles

AR18.00-B-4000TC

23

Install the crankshaft

AR03.20-B-4351TA

24

Installing the piston

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

AR03.10-B-7021TA

Número

Denominação

Engine 904.9 and 906.9

Engine 924.9 and 926.9

BE01.40-B-1001-02C

Cylinder's internal diameter, finishing

Normal

Tolerance A

mm

101,985...101,991

105,985...105,991

Tolerance B

mm

101,992...102,008

105,992...106,008

Tolerance C

mm

102,009...102,015

106,009...106,015

Repair I

Tolerance A

mm

102,285...102,291

106,285...106,291

Tolerance B

mm

102,292...102,308

106,292...106,308

Tolerance C

mm

102,309...102,315

106,309...106,315

Repair II

Tolerance A

mm

102,585...102,591

106,585...106,591

Tolerance B

mm

102,592...102,608

106,592...106,608

Tolerance C

mm

102,609...102,615

106,609...106,615

Repair III

Tolerance A

mm

102,885...102,891

106,885...106,891

Tolerance B

mm

102,892...102,908

106,892...106,908

Tolerance C

mm

102,909...102,915

106,909...106,915

BE01.40-B-1002-02C

Out of round and taper in the cylinder/deviation from the cylinder's travel (with liner and without liner)

Maximum admissible

mm

0,012

0,012

BE01.40-B-1003-02C

Maximum admissible wear at the sliding surface of the cylinders (with and without liners)

At the reversino point of the first piston ring

mm

0,1

0,1

At the center of the cylinder

mm

0,05

0,05

BE01.40-B-1004-02C

Cylinder wall roughness (R3Z)

micron

2,5...4,0

2,5...4,0

BE01.40-B-1006-02C

Height (A) of the block, measured between the main bearings (upper shell seat) and the block's top face

Normal

mm

298,35...298,50

298,33...298,40

Repair I (- 0,3)

mm

298,05...298,20

298,03...298,10

Repair II (- 0,6)

mm

297,75...297,90

297,73...297,80

Repair III (- 0,9)

mm

297,45...297,60

297,43...297,50

BE01.40-B-1007-02C

Diameter (B) of the seat-hole to the cylinder liner, at the block

mm

106,000...106,035

-

BE01.40-B-1008-02C

Diameter (C) of the seat - hole to the liner collar, in the block

mm

109,572...109,626

-

BE01.40-B-1011-02C

Roughness of the block's upper surface

Rz

mm

0,008...0,016

0,008...0,016

BE01.40-B-1013-02C

Maximum admissible deviation of the flatness at the ngine block surface

On the total length

mm

0,030

0,030

on a 150 mm length

mm

0,015

0,015

BE01.40-B-1016-02C

Parallelism deviation between the block upper face with regard to the upper shells seats in the main bearings

maximum

mm

0,05

0,05

BE01.40-B-1017-02C

Cylinder liner overlaying on the block

mm

0,040

-

Número

Denominação

Engine 924.9, 926.9 with code MS5

BE01.40-B-1001-02C

Cylinder's internal diameter, finishing

Normal

Tolerance A

mm

105,985...105,991

Tolerance B

mm

105,992...106,008

Tolerance C

mm

106,009...106,015

Repair I

Tolerance A

mm

106,285...106,291

Tolerance B

mm

106,292...106,308

Tolerance C

mm

106,309...106,315

Repair II

Tolerance A

mm

106,585...106,591

Tolerance B

mm

106,592...106,608

Tolerance C

mm

106,609...106,615

Repair III

Tolerance A

mm

106,885...106,891

Tolerance B

mm

106,892...106,908

Tolerance C

mm

106,909...106,915

BE01.40-B-1002-02C

Out of round and taper in the cylinder/deviation from the cylinder's travel (with liner and without liner)

Maximum admissible

mm

0,012

BE01.40-B-1003-02C

Maximum admissible wear at the sliding surface of the cylinders (with and without liners)

At the reversino point of the first piston ring

mm

0,1

At the center of the cylinder

mm

0,05

BE01.40-B-1004-02C

Cylinder wall roughness (R3Z)

micron

2,5...4,0

BE01.40-B-1006-02C

Height (A) of the block, measured between the main bearings (upper shell seat) and the block's top face

Normal

mm

298,33...298,40

Repair I (- 0,3)

mm

298,03...298,10

Repair II (- 0,6)

mm

297,73...297,80

Repair III (- 0,9)

mm

297,43...297,50

BE01.40-B-1007-02C

Diameter (B) of the seat-hole to the cylinder liner, at the block

mm

-

BE01.40-B-1008-02C

Diameter (C) of the seat - hole to the liner collar, in the block

mm

-

BE01.40-B-1011-02C

Roughness of the block's upper surface

Rz

mm

-

BE01.40-B-1013-02C

Maximum admissible deviation of the flatness at the ngine block surface

On the total length

mm

0,030

on a 150 mm length

mm

0,015

BE01.40-B-1016-02C

Parallelism deviation between the block upper face with regard to the upper shells seats in the main bearings

maximum

mm

0,05

BE01.40-B-1017-02C

Cylinder liner overlaying on the block

mm

-

Número

Denominação

Engine 902.9; 904.9, 906.9

BE01.40-B-1001-03C

Liner outer diameter

mm

106,075...106,095

BE01.40-B-1002-03C

Liner collar outer diameter

mm

109,374...109,428

Número

Denominação

Número de pedido

BR00.45-B-1008-06A

Grease

DBL 6898.0 (Molykote HTP)