Remove/install/seal cylinder liner · ar0140a9324a · Mercedes-Benz WIS

AR01.40-A-9324A

Remove/install/seal cylinder liner

7.2.08

ENGINE 457.939 /945 /946 /949 in MODEL NAB372.124

ENGINE 457.939 /945 in MODEL NAB372.317

A01.40-0005-06

1 Cylinder crankcase

2 Cylinder liner

3 Sealing ring

4 O-ring

5 O-ring

6  Quick calipers for inside measurements

7  Dial indicator

a Collar height of cylinder liner

b Groove depth of cylinder bore

c Protrusion of cylinder liner

	Removing
1	Remove cylinder head		AR01.30-A-5800A
2	Remove pistons		AR03.10-A-7021A
3	Mark installation position of cylinder liner (2) relative to crankcase (1) (arrow)	 If cylinder liner is reinstalled, it must be installed turned through 90°.
4	Remove cylinder liner (2)	 The cylinder liner collar seat on the cylinder liner (2) and the crankcase (1) must not be reworked.	AR01.40-W-9324-01C
			*457589003300
			*541589013300
5	Take off seal (3)
6	Take O-rings (4, 5) out of crankcase (1)
	Clean
7	Clean cylinder liner (2) and its seat in the crankcase (1)	 In particular, clean the collar of the cylinder liner (2) and the seat of the O-rings (4, 5) and seal ring (3).
	Checking
8	Inspect outside of cylinder liner (2) for cavitation erosion and corrosion
9	Inspect collar of cylinder liner (2)	Collar height of cylinder liner (a)	*BE01.40-N-1004-03G
		Maximum variation of collar height	*BE01.40-N-1005-03G
		If permissible values are not maintained: 
		replace cylinder liner (2) if necessary.
		 The collar of cylinder liner (2) must not be reworked!
10	Inspect step of cylinder bore in crankcase (1)	Depth of groove of cylinder bore (b)	*BE01.40-N-1002-02I
		Maximum variation of depth of shoulder	*BE01.40-N-1003-02I
	Install
11	Insert new O-rings (4, 5) into crankcase (1)	 Grease O-rings (4, 5) before installation.	*BR00.45-Z-1014-06A
12	Insert new sealing ring (3)	 The sealing ring (3) and step in the crankcase (1) must be clean and dry.	*BE01.40-N-1006-03G
13	Insert cylinder liner (2) into crankcase (1)	 Grease cylinder liner (2) slightly on the outside. If a cylinder liner (2) is reused, turn its installation position through 90° (arrows)!	*BR00.45-Z-1014-06A
14	Press in cylinder liner (2)		AR01.40-W-9324-02C
			*BA01.40-N-1009-01L
			*000589260100
			*001589442100
			*457589003300
			*541589013300
15	Measure projection of cylinder liner (c)		AR01.40-A-9314A
16	Measure inner diameter of cylinder liner at the O-rings (4, 5)	Perform three measurements, each offset 60°.	*BE01.40-N-1007-03G
			*001589532100
		Quick calipers for internal measurements
		If permissible values are not maintained: 
		Remove cylinder liner (2). Inspect O-rings (4, 5) and grooves for O-rings in crankcase (1) for soiling. If O-rings (4, 5) are damaged, install new ones.
17	Install pistons		AR03.10-A-7021A
18	Install cylinder head		AR01.30-A-5800A

Inspection data of crankcase

Number	Designation		Engine 457.9


BE01.40-N-1002-02I	Groove depth of cylinder bore	mm	9.955 to 10.005
BE01.40-N-1003-02I	Variation of groove depth	mm	0.03

Check values for cylinder liner

Number	Designation		Engine 457.939/949	Engine 457.945/946


BE01.40-N-1004-03G	Collar height of cylinder liner	mm	10.10 to 10.12	10.10 to 10.12
BE01.40-N-1005-03G	Variation of collar height	mm	0.02	0.02
BE01.40-N-1006-03G	Thickness of sealing ring (metal)	mm	0.14 to 0.16	0.14 to 0.16
BE01.40-N-1007-03G	Out-of-roundness of cylinder liner in area of O-rings	mm	0.02	0.02