Remove/install/seal cylinder liner

AR01.40-B-9324B

Remove/install/seal cylinder liner

12.02.16



Remove

1

Removing pistons

AR03.10-B-7021C

2

Remove the cylinder liner (2)

Mark the position of cylinder liner (2) in relation to the engine block (arrow), this will be necessary in the case of cylinder liner re-utilization, to be installed offset in 90°.

AR01.40-B-9324-01B



*541589013300



*457589003300

3

Remove the annular metal gasket (3)

4

Remove the annular gaskets (4,5) from the block (1)



Cleaning

5

Clean the cylinder liner (2) and its housing in the engine block (1)

Clean the cylinder liner collar (2) and the seating surface of the gaskets (3, 4 and 5).



Check

6.1

Check the cylinder liner (2) externally

Externally check the cylinder liner for damage from cavitation and corrosion.

AH01.40-B-0001-03B

6.2

Check the cylinder liner collar (2) for condition

Cylinder liner collar height

*BE01.40-B-1004-03D

Maximum cylinder liner collar deformation on the contact surface with the annular metal gasket (3)

*BE01.40-B-1005-03D

 It is not permissible to machine the cylinder liner collar to correct eventual deformation.

If necessary, replace the damaged cylinder liner.

6.3

Check the cylinder liner collar housing in engine block (1) for condition

Maximum deformation in housing (A), on the contact surface with the ring (3).

*BE01.40-B-1002-02C

Depth of the housing (A).

*BE01.40-B-1001-02C



Installing

7

Install the new annular gaskets (45)

Before installing, clean and dry the housings in the engine block .

8

Install the new annular metal gasket (3)

Before installing, clean and dry the cylinder liner collar housing in the engine block .

*BE01.40-B-1006-03D

9

Prepare the cylinder liner for installation

Before installing, clean and dry the cylinder liner collar and its housing .Apply a film of engine oil, to the bottom part of the cylinder liner (2), in the contact area of the rings (4, 5) up to the chamfered area.

10

Install the cylinder liner (2)

Insert the cylinder liner in the engine block, turning it, from the beginning of contact of the annular gaskets up to its seating.

AR01.40-B-9324-02B

When installing new cylinder liners, observe if the diameter tolerance code corresponds with the piston.

If re-utilizing the cylinder liner, position it 90° offset in relation to the previous position (arrow).

AR03.10-B-7021-02B



*055589006100



Measuring

11.1

Measure the protrusion of the cylinder liner (2) in relation to the engine block deck (1)

AR01.40-B-9314B

12.2

Measure the inside diameter of the cylinder liner (2)

Measure in the area of the annular gaskets (4, 5), in three points offset in 60°, if an out-of-round condition is observed above the maximum permissible, remove the cylinder liner and examine the annular gaskets and their seats for dirt. If the gaskets are damaged, replace them.

*BE01.40-B-1009-03D



*001589532100

Gage for measuring inside diameters

13

Installing the piston

AR03.10-B-7021C

Número

Denominação

Engine 457.9; 460.984

BE01.40-B-1004-03D

Liner collar height

mm

10.10...10.12

BE01.40-B-1005-03D

Distress on the lower face of the liner collar (mating surface with wire ring)

Max. permissible

mm

0.02

BE01.40-B-1006-03D

Thickness of wire ring (steel)

mm

0.14...0.16

BE01.40-B-1009-03D

Max. permissible roundness inside the liner, at the o-rings area

Liner installed

mm

0.02

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

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