Cylinder Liner: Service and Repair

Renewal







A 4.3 - 4.6 mm
B 96.02 - 96.08 mm
C 0.25 - 0.35 mm
D 94.000 - 94.035 mm

1 Press out cylinder liners with mandrel, part number 603 589 00 15 00 and a press.
2 Thoroughly clean basic bore.
3 Measure basic bore (D) in cylinder crankcase.

If the out-of-true condition exceeds 0.1 mm, do not use cylinder crankcase any longer.

4 Press out new cylinder liners with mandrel 603 589 00 15 00 on a press.

After pressing-in cylinder liner, leave for another approx. 7 seconds under pressure of press (setting pressure).

Chamfer:

5 Mill or grind off projecting liner flange. Remove as little as possible from cylinder crankcase parting surface. Guide milling cutter or grinding wheel centrally over cylinder bores.
6 Enlarge cylinder liner bores in two steps. For honing, leave an allowance of 0.03 mm in bores.
7 Chamfer cylinder liners.
8 Hone cylinder bores.
9 Measure cylinder bores and select pertinent pistons.