Install cylinder liner

AR01.40-I-9273B

Install cylinder liner

17.7.09

19.5.09

Value altered: peak-to-valley height (Rz) cylinder barrel

*BE01.40-N-1004-02B

Value altered: peak-to-valley height (Rz) cylinder crankcase-contact surface

*BE01.40-N-1011-02B

1.1

Remove cylinder liner (2)

Engine with cylinder liner (2)

AR01.40-I-9272B

1.2

Widen cylinder bore in crankcase (1)

Engine without cylinder liner (2)

AR01.40-W-9271A

Checking

2

Check crankcase (1)

 Measure bore diameter for cylinder liner (B) and for cylinder liner collar (C) in cylinder crankcase (1).

*BE01.40-N-1007-02B

*BE01.40-N-1008-02B

3

Check new cylinder liner (2)

 Measure outside diameter of new cylinder liner (2) for cylinder liner collar of new cylinder liner (2)

*BE01.40-N-1001-03B

*BE01.40-N-1002-03B

4

Calculate overlap between new cylinder liner (2) and the associated bore in the cylinder crankcase (1)

 The overlap arises from the difference between the measured outside diameter of the new cylinder liner and the bore diameter for the cylinder liner in the cylinder crankcase. The overlap must occur within the permissible tolerance range.

*BE01.40-N-1017-02B



Install

5

Coat bore in crankcase (1) with acid-free grease

*BR00.45-Z-1014-06A

6

Press in cylinder liner (2) until it projects about 20 mm

 Place crankcase (1) on the workshop press and align

Place cylinder liner (2) at right angles to the bore in the cylinder crankcase (1).

Use a suitable plate for pressing in.

7

Check cylinder liner collar for abrasion (arrow); clean with compressed air if necessary

8

Press in cylinder liner (2) fully

 All the way with a force of about 30.000 N, then relieve shortly and then press again with a force of about 70.000 N for about 5 seconds.

9

Machine contact face of crankcase
(1)

 Observe deviation stages of crankcase height (A).

*BE01.40-N-1021-02B



Information on working sealing surfaces when carrying out engine repairs

AH01.10-N-0002-01A



Markings on cylinder crankcase

AH01.40-N-0001-02A

10

Check contact surface on cylinder crankcase (1)

Peak-to-valley height of cylinder crankcase contact surface

*BE01.40-N-1011-02B

Flatness of cylinder crankcase contact surface over the overall length

*BE01.40-N-1013-02B

Parallelism of the cylinder crankcase contact surface

*BE01.40-N-1016-02B

11

Clamp crankcase (1) onto drilling tool

12

Align cylinder wall to drilling tool

 With centering device above reversal point of first piston ring.

13

Clamp in boring tool

14

Drill cylinder liner (2) in a number of operational steps

 When installing a number of cylinder liners no two neighboring cylinder liner should be installed one after the other otherwise the thermal load will be too high.

*BE01.40-N-1001-02B

 Drill out up to an inside diameter which is about 0.05 mm smaller than the specified inside diameter.

Machine settings for fine boring machine
Speed: 250 to 280 rpm

Operating speed: 0.04 to 0.06 mm/ revolution

15

Hone cylinder liner (2) to the specified inside diameter

 Adjustment values on the honing machine:
Working pressure: 2.5 to 3.0 bar

Rpm: 60 to 100 rpm

Honing angle: 40 to 60°

Number of strokes: 30 to 40

*BE01.40-N-1001-02B

16

Check bore of cylinder liner (2)

Inside diameter of cylinder liner

*BE01.40-N-1001-02B

Deviation of cylinder wall

*BE01.40-N-1002-02B

Peak-to-valley height of cylinder liner

*BE01.40-N-1004-02B

Variation of cylinder barrel, measured perpendicular to crankshaft axis and to main bearing shell seat

*BE01.40-N-1005-02B

17

Check cylinder barrel of all further cylinders

 When pressing in this can result in changes in the microstructure in the cylinder crankcase (1) which results in the cylinder barrel of the neighboring cylinder changing.

Inside diameter of cylinder liner

*BE01.40-N-1001-02B

Deviation of cylinder wall

*BE01.40-N-1002-02B

If the measurement values are not

OK : 

Hone cylinder barrel on cylinder in question until the measurements match.

18

Clean crankcase (1)

19

Correct markings on marking areas (3) on crankcase after machining



Markings on cylinder crankcase

AH01.40-N-0001-02A

Number

Designation

Engine
904.9,
engine
906.9
without code MS8

BE01.40-N-1001-02B

Cylinder internal bore dia.

Code letter A

mm

101.985 to 101.991

Code letter B

mm

101.992 to 102.008

Code letter C

mm

102.009 to 102.015

BE01.40-N-1002-02B

Deviation of cylinder bore from the cylindrical form

mm

0.012

BE01.40-N-1004-02B

Peak-to-valley height (R3z) cylinder barrel

μm

2.0 to 4.5

BE01.40-N-1005-02B

Variation of cylinder barrel, measured perpendicular to crankshaft axis and to main bearing shell seat

mm

0.050

BE01.40-N-1007-02B

Bore dia. for cylinder liner in crankcase (B)

mm

106.000 to 106.035

BE01.40-N-1008-02B

Bore dia. for cylinder liner collar in crankcase (C)

mm

109.572 to 109.626

BE01.40-N-1011-02B

Peak-to-valley height (Rz) of crankcase contact surface

μm

4 to 16

BE01.40-N-1013-02B

Crankcase flatness of separating surface

over the entire length

mm

0.030

over a length of 150 mm in longitudinal and transverse direction

mm

0.015

BE01.40-N-1016-02B

Crankcase - parallelism of contact surface, measured to main bearing shell seat

mm

0.05

BE01.40-N-1017-02B

Overlap of cylinder liner to machined crankcase

mm

0.040

BE01.40-N-1021-02B

Cylinder crankcase height (A), measured from the main bearing shell seat to the cylinder head contact surface and cylinder bore internal dia.

Height standard 0

mm

298.33 to 298.40

Cylinder internal bore dia., code letter A

mm

101.985 to 101.991

Code letter B

mm

101.992 to 102.008

Code letter C

mm

102.009 to 102.015

Height deviation -0.3

mm

298.03 to 298.10

Cylinder bore internal dia.,
code letter A

mm

102.285 to 102.291

Code letter B

mm

102.292 to 102.308

Code letter C

mm

102.309 to 102.315

Height deviation -0.6

mm

297.73 to 297.80

Cylinder bore internal dia.,
code letter A

mm

102.585 to 102.591

Code letter B

mm

102.592 to 102.608

Code letter C

mm

102.609 to 102.615

Height deviation -0.9

mm

297.43 to 297.50

Cylinder internal bore dia., code letter A

mm

102.885 to 102.891

Code letter B

mm

102.892 to 102.908

Code letter C

mm

102.909 to 102.915

Number

Designation

Engine
904.9,

Engine
906.9
without code MS8

BE01.40-N-1001-03B

Cylinder liner outer dia.

mm

106.075 to 106.095

BE01.40-N-1002-03B

Cylinder liner collar outer dia.

mm

109.374 to 109.428

Number

Designation

Order number

BR00.45-Z-1014-06A

ATE grease

-