B01.40-0030-09
1 Cylinder liner
2 Top sealing ring
3 Metal ring
4 Engine block
5 Bottom sealing ring
6 Cylinder liner removal device
7 Cylinder liner insertion device
8 Dial gage
9 Device for measuring inside diameters
b Diameter of top collar
C Cylinder liner protrusion on engine block
f Diameter of bottom adjustment
h Collar recess
k Cylinder liner diameter
m Maximum permissible deformation on bottom face
n Maximum permissible eccentricity between top and bottom adjustments
p Cylinder liner outside diameter
r Top adjustment diameter
z Cam diameter
x Overall length
y Collar recess
z Cam diameter
| Remove | ||
1 | Removing pistons | ||
2 | Mark the cylinder liner (1) to be removed in relation to the engine block. | ||
3 | Install the cylinder liner removal device (6) and remove the cylinder liner (1). | ||
| |||
4 | Remove the metal ring (3). | In the case of removing several cylinder liners and there are shims under the metal sealing rings, it is convenient to pay attention on the shim thickness of each cylinder. At assembly, install shims with respective corresponding measurement in each cylinder. | |
5 | Remove the top sealing ring (2) and the sealing rings (5). | ||
6 | Clean the cylinder liner (1), specially the cylinder liner collar and the housing of the rings (2, 3 and 5). | ||
| Check | ||
7 | Check the cylinder liner (1) for cavitation and corrosion. | Cavitation: Is a form of erosion that may eventually arise in the cooling pressure line affecting the cylinder liner forming cavities. Cavitation is produced by the coolant in motion that forms steam bubbles. The oxygen contained inside these bubbles added to the continuous shock, corrodes the cylinder liner metal. The electrolytic process also contributes to aggravate the problem. | |
The following preventive measures inhibit cavitation: a - The use of coolant composed and prepared with specific products and in the correct mix proportion recommended by the manufacturer. b - The periodic control of the coolant's density to evaluate its concentration. c - The constant replenishment of consumed coolant utilizing the appropriate coolant and prepared in advance. d - Changing the coolant in the recommended periods. e - To maintain the engine temperature within the recommended operating range. f - To maintain the cooling system in perfect conditions and utilizing caps, hoses and other components in perfect conditions. | |||
Corrosion is the oxidization formed around the cylinder liner in all its cooling area reached by the circulating coolant. Oxidization is caused by the prolonged contact with the coolant (not within specification) and may occur in the following circumstances: a - Lack of recommended additives in the preparation of the coolant. b - Incorrect proportion of the mix utilized in the constant replenishing. | |||
8 | Total length (x) of the cylinder liner. | ||
9 | Height (y) of the cylinder liner collar. | ||
10 | Recess (h) of the cylinder liner collar. | ||
11 | Diameter (b) of the top collar | ||
12 | Diameter (r) of the top adjustment. | ||
13 | Diameter (z) of the cam. | ||
14 | Maximum permissible deformation (m) on the bottom face | ||
15 | Maximum permissible eccentricity (n). | ||
16 | Outside diameter (p) of the cylinder liner. | ||
17 | Diameter (k) of the cylinder liner. | ||
18 | Diameter (f) of the bottom adjustment | ||
19 | Maximum permissible wear on the running surface at the top reversing point of the first piston ring | ||
| Installing | ||
20 | Install in the housings of the engine block (4) the two bottom rings (5) dry and clean. | ||
21 | Install the metal ring (3) in the block (4). | ||
In the case there is a shim under the metal ring (3), install it in the housing of the cylinder liner collar in the block and next install the metal ring (3) (utilized in exceptional cases, in the case of having machined the housing of the cylinder liner collar). | |||
22 | Install the dry and clean top ring (2) in the cylinder liner. | ||
23 | Install the cylinder liner (1) in the engine block (4). | Apply a film of engine oil around the cylinder liner (1). | |
If the cylinder liner is a new one, preferably install it in the block with the letter B-C-D or E (corresponding to the size) positioned to the engine front. This will be a reference to turn the cylinder liner 90 degrees in a future removal. | |||
If the cylinder liner is used one, install it in the block offset 90 degrees from the original position. | |||
24 | Install the assembly device in the cylinder liner (7) and insert it in the cylinder. | ||
Apply a film of engine oil around the cylinder liner | |||
| |||
25 | Measure the cylinder liner (1) protrusion in the block (4). | ||
26 | Measure the cylinder liner (1) inside diameter (in the area of the sealing rings) in three points separated 60 degrees from each other. | In the case of an out-of-round above the specified values, remove the cylinder liners and check the rings. | |
| |||
If there is not a perfect seating of the cylinder liner in the block, caused by a burnt metal ring, machine the cylinder liner collar housing. | |||
27 | Installing pistons |
Inspection data of cylinder liner
Número | Denominação | Engine 475.9, 476.9 | |||
BE01.40-B-1001-03B | Liner internal diameter (k) | Letter B | mm | 127.990...127.995 | |
Letter C | mm | 127.995...128.000 | |||
Letter D | mm | 128.000...128.005 | |||
Letter E | mm | 128.005...128.010 | |||
BE01.40-B-1002-03B | Liner collar diameter (b) | mm | 153.657...153.757 | ||
BE01.40-B-1003-03B | Upper adjustment diameter (r) | mm | 145.778...145.800 | ||
BE01.40-B-1004-03B | Tappet diameter (z) | mm | 141.8...142.0 | ||
BE01.40-B-1005-03B | Liner external diameter (p) | mm | 144.7...145.0 | ||
BE01.40-B-1006-03B | Lower adjustment diameter (f) | mm | 144.451...144.475 | ||
BE01.40-B-1007-03B | Collar height (y) | mm | 9.90...9.92 | ||
BE01.40-B-1008-03B | Collar recess (h) | mm | 1.1...1.15 | ||
BE01.40-B-1009-03B | Total length (x) | mm | 269.5...270.5 | ||
BE01.40-B-1010-03B | Maximum difference between the four measurement points | mm | 0.02 | ||
BE01.40-B-1011-03B | Maximum allowed eccentricity between the upper and lower adjustment (n) | mm | 0.025 | ||
BE01.40-B-1012-03B | Maximum allowed wearing in the sliding surface, in the upper point of inversion of the 1st piston ring | mm | 0.08 | ||
BE01.40-B-1013-03B | Maximum allowed roundness in the lower adjustment | Externally | mm | 0.06 | |
Internally (liner assembled) | mm | 0.04 | |||
BE01.40-B-1015-03B | Diameter | external of the upper metallic ring (d) | mm | 153.4...153.6 | |
internal of the upper metallic ring (d) | mm | 147.3...147.5 | |||
Normal Thickness | mm | 0.14...0.16 | |||
Normal Thickness I | mm | 0.48...0.52 | |||
BE01.40-B-1016-03B | Thickness of the shim rings in the cases of the block machining | mm | 0.80; 1.00; 1.50 | ||
541 589 01 33 00
Cylinder liner removal device
001 589 53 21 00
Dial gage
055 589 00 61 00
Cylinder liner installation device
Produtos para reparos
Número | Denominação | Número de pedido |
BR00.45-B-1022-06A | Engine oil | SAE 30 |
Referenced documents
- ar0140b9304a Re-machine collar seat in crankcase
- ar0140b9314a Measure projection of cylinder liner
- ar0140b932401a Pull out cylinder liner
- ar0140b932402a Press in cylinder liner
- ar0310b702102a Assigning a standard dimension piston to a cylinder bore
- ar0310b7021d Remove/install piston