Measuring cylinder bores - AR01.40-P-9202AW

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

ENGINES 601, 602, 603 (except, 602.982)

Fig 1: Identifying Cylinder Bores Measuring Points

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Work instructions
For repair work on engines 601.91/92, 602.91/96, 603.91/96 (naturally aspirated engines), oversize pistons or cylinder liners with standard-size pistons are to be installed. On engines 603.970/971 (turbocharged engines), cylinder liners and standard-size pistons are to be installed.
Pistons	removing	AR03.10-P-7021AW
Cylinder bores	Measure cleaned cylinder bores using an internal micrometer at the 3 measuring points (1, 2, 3) in the longitudinal and transverse directions.	Figure
		*WH58.30-Z-1011-12A
	Cylinder diameter	*BE01.40-P-1001-01E
	Permissible deviation from true cylinder (new condition).	*BE01.40-P-1004-01E
	Wear limit in longitudinal and transverse direction	*BE01.40-P-1003-01E
	Runout	*BE01.40-P-1005-01E
	If wear is excessive and/or if running surface is damaged ↓ On naturally aspirated engines Install repair-size pistons, see ↓ Boring and honing cylinder bores or as for turbocharged engines ↓	AR01.40-P-9291AW
	On turbocharged engines Install cylinder liners and standard-size pistons, see ↓ Widening cylinder bore in crankcase ↓	AR01.40-P-9271AW
	Installing cylinder liner	AR01.40-P-9273AW
	Boring and honing cylinder bores	AR01.40-P-9291AW
	On engines with installed cylinder liner ↓ (engines already repaired) Removing cylinder liner ↓	AR01.40-P-9272AW
	Installing cylinder liner ↓	AR01.40-P-9273AW
	Boring and honing cylinder bores	AR01.40-P-9291AW

TEST VALUES FOR CYLINDER BORE

Number	Designation			Engines 601.91/92, 602.91/93/96, 603 except 603.97	Engines 602.94, 603.97
BE01.40-P-1001-01E	Cylinder liner dia.	Standard dimensions	mm	87.0	89.0
		Group code letter A	mm	87.000...87.006	89.000...89.006
		Group code letter X	mm	87.007...87.012	89.007...89.012
		Group code letter B	mm	87.013...87.018	89.013...89.018
BE01.40-P-1003-01E	Cylinder liner	Wear limit in longitudinal and transverse direction	mm	0.20	0.20
BE01.40-P-1004-01E	Cylinder liner	Permissible deviation from a cylindrical shape (when new)	mm	0.007	0.007
BE01.40-P-1004-01E	Cylinder liner	Wear limit	mm	0.05	0.05
BE01.40-P-1005-01E	Cylinder liner	Runout	mm	0.07	0.07

Fig 2: Identifying Dial Indicator (001 589 53 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1011-12A	Internal measuring instrument