ar0140b9271b

Widen cylinder bore in crankcase

Type ar · topic 01.40 · version 0201 · 2020-03-07

Applies to: Engine 904 in model 368.004/006/112/115/117/185/187, 384.067/201/223, 688.276/277 Engine 906 in model 368.054/100/154, 382.123/175/184/185/186/188/189

Where it sits

Function group 1 Engine › 01 Complete engine, crankcase ventilation, cylinder head, crankcase › 01.40 Crankcase, timing case cover, end cover — Series 368 (models 004, 006, 054, 100, 112, 115, 117, 154, 185, 187) · Series 382 (models 123, 175, 184, 185, 186, 188, 189) · Series 384 (models 067, 201, 223) · Series 688 (models 276, 277) · Series 904 · Series 906

EinPAS 15 Engine › 15.15 Combustion engine, complete/engine housing/crank assembly › 15.15.31 Crankcase/oil separator/ventilation — Series 368 (models 004, 006, 054, 100, 112, 115, 117, 154, 185, 187) · Series 382 (models 123, 175, 184, 185, 186, 188, 189) · Series 384 (models 067, 201, 223) · Series 688 (models 276, 277) · Series 904 · Series 906

AR01.40-B-9271B

Widen cylinder bore in crankcase

18.02.2020

Engine

904 in model 368.004/006/112/115/117/185/187, 384.067/201/223, 688.276/277

Engine

906 in model 368.054/100/154, 382.123/175/184/185/186/188/189

Widen cylinder bore in crankcase

1

Engine block

A

Engine block height

B

Cylinder liner housing diameter, in the basic bore

C

Cylinder liner housing diameter, in the basic bore

D

Distance between the seating surface for the cylinder liner collar and the mating surface for the main bearing cap

E

Max. radius in the housing of the cylinder liner collar

F

Chamfer on the seating surface for the cylinder liner collar

W01.40-0002-06

Check

1

Check the height (A) of the engine block (1)

Replace the engine block, if the height (A) is smaller than the bottom tolerance limit specified for repair stage III (-0.9).

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

*BE01.40-B-1006-02C

Machining

2

Secure the engine block (1) in the boring machine

3

Center the cylinder to be machined, in relation to the boring machine

Have as reference for centralization, the cylinder diameter in the area above the top reversion point of the 1st piston ring.

4

Adjust the tool and carry out the machining, in several steps, until obtaining a diameter 0.05 mm smaller than the final diameter (B)

In the case of machining one or more cylinders, observe the work sequence to avoid damages due to excessive heating: 4-cylinders engines; 2-4-1-3, and 6-cylinders engines; 1-3-5-2-4-6.

Boring machine setting values:
Rotation; 250 - 280/min (rpm).
Feed rate of the tool; 0.04 - 0.06 mm/turn.

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

*BE01.40-B-1007-02C

5

Hone the cylinder liner housing until obtaining the diameter (B), final finish

Honing machine setting values:
Working pressure; 2.5 - 3.0 bar
Rotation; 60 - 100/min (rpm)
Honing angle; 40°- 60°
Double stroke; 30 - 40/min.

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

*BE01.40-B-1007-02C

Roughness on the hole seat surface (liner lodging), after polishing

*BE01.40-B-1012-02C

6

Machine the housing for the cylinder liner collar using a tool with a 90°-cutting angle

Make sure the following indicated dimensions are obtained:

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

*BE01.40-B-1008-02C

Distance (D) between the seat surface to the liner collar and the main bearing cap holder surface

*BE01.40-B-1009-02C

Surface finishing of the liner collar seat at the hole - seat

*BE01.40-B-1014-02C

Roughness of the liner collar lodging (C) and eccentricity with regard to the liner lodging (B)

*BE01.40-B-1015-02C

Radius (E) in the liner collar lodging

*BE01.40-B-1018-02C

7

Machine the chamfer (F) on the seat surface for the cylinder liner collar

Remove eventual burr on the corners of the chamfer (F).

Chamfer (F) on the seat surface for the liner collar

*BE01.40-B-1019-02C

Engine block test values

Number

Designation

Engine 904.9, 906.9

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

Repair I (- 0,3)

mm

298,05...298,20

Repair II (- 0,6)

mm

297,75...297,90

Repair III (- 0,9)

mm

297,45...297,60

Engine block test values

Number

Designation

Engine 904.9, 906.9

BE01.40-B-1007-02C

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

mm

106,000...106,035

Engine block test values

Number

Designation

Engine 904.9, 906.9

BE01.40-B-1008-02C

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

mm

109,572...109,626

Engine block test values

Number

Designation

Engine 904.9, 906.9

BE01.40-B-1009-02C

Distance (D) between the seat surface to the liner collar and the main bearing cap holder surface

mm

338,9...339,1

Engine block test values

Number

Designation

Engine 904.9, 906.9

BE01.40-B-1012-02C

Roughness on the hole seat surface (liner lodging), after polishing

mm

0,025

Engine block test values

Number

Designation

Engine 904.9, 906.9

BE01.40-B-1014-02C

Surface finishing of the liner collar seat at the hole - seat

Concentricity

mm

0,030

Flatness deviation

mm

0,010

Roughness

Rz

mm

0,016

Engine block test values

Number

Designation

Engine 904.9, 906.9

BE01.40-B-1015-02C

Roughness of the liner collar lodging (C) and eccentricity with regard to the liner lodging (B)

Maximum eccentricity (C with regard to B)

mm

0,060

Roughness

Rz

mm

0,025

Engine block test values

Number

Designation

Engine 904.9, 906.9

BE01.40-B-1018-02C

Radius (E) in the liner collar lodging

Maximum

mm

0,2

Engine block test values

Number

Designation

Engine 904.9, 906.9

BE01.40-B-1019-02C

Chamfer (F) on the seat surface for the liner collar

mm

0,3...0,4