Replacing Cylinder Liner

NOTE: Numbers in parentheses ( ) indicate a component or tool in the associated illustration.

REMOVAL
1 Press out cylinder liners
2 Thoroughly clean basic bore
3 Measure basic bore in crankcase
If bore diameter is exceeded, replace crankcase
Specifications of crankcase bore for liners D2 90.000-90.035 mm





INSTALLATION
1. Prepare Cylinder Block (Crankcase):
- On engines without cylinder liners, bore out cylinder bore in crankcase (1), refer to Boring Cylinder Block (Crankcase) For Liner Installation
OR:
- On engines with cylinder liners, remove cylinder liner as outlined above.
2. Place crankcase (1) onto the press and align
3. Place new cylinder liner (2) onto the bore and align at right angles
4. Press in cylinder liner (2)
- Use a suitable plate for pressing in.
- Inspect cylinder liner seat for abrasion and clean with compressed air if necessary.
- After pressing in, maintain the pressure on the cylinder liner for about 7 seconds (settling pressure).
5. Machine contact surface of crankcase (1) together with timing case cover, refer to Reface Contact Surface of Cylinder Block (Crankcase).
- Stock removal at contact surface should be as minimal as possible
6. Clean crankcase (1)
7. Bore and hone cylinder bores.

Commercially available tools (see Workshop Equipment Manual)
Designation
Make (e.g.)
Internal measuring instrument for 80-100 diameter
Hahn und Kolb Borsigstr.50 70469 Stuttgart
Setting gage for micrometer
Hahn und Kolb Borsigstr.50 70469 Stuttgart
Micrometer 75-100 mm
Hahn und Kolb Borsigstr.50 70469 Stuttgart
P9
Installing cylinder liner
ENGINE 604, 605, 606/