Boring and honing cylinder bores - AR01.40-P-9291A

ENGINES 604, 605, 606 /

Fig 1: Identifying Cylinder Bores Diameter

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Picture	Work instructions
D	Cylinder bore Ø	Measure	Figure
			*WH58.30-Z-1012-12A
			*WH58.30-Z-1011-12A
			*WH58.30-Z-1002-12A
D1	Bore diameter	Ascertain, and adjust machine tool accordingly The bore Ø (D1) equals the cylinder bore Ø (D) minus the material feed for the honing process. The material feed for honing should be no greater than max. 0.05 mm. The repair size Ø (D) is to be selected according to the existing pistons (A, X, B).	*BE01.40-P-1001-01E
	Cylinder bore	Chamfer	AR01.40-P-9201-01B
	Honing	Perform according to specified data	BE01.40-P-1007-01E BE01.40-P-1006-01E

Test values for cylinder bore

Number	Designation			Engine 604.910/912	Engine 604.915/917, 605.91/96, 606.91/96
BE01.40-P-1001-01E	Cylinder liner Ø	Normal dimension, standard	mm	89,0	87,0
		Group code letter A	mm	89,000...89,006	87,000...87,006
		Group code letter X	mm	89,006...89,012	87,006...87,012
		Group code letter B	mm	89,012...89,018	87,012...87,018
BE01.40-P-1006-01E	Cylinder liner	Peak-to-valley height (R3_Z )	mm	0,002...0,005	0,002...0,005
BE01.40-P-1007-01E	Honing angle		∠°	40...60	40...60

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Commercially available tools

Number	Designation
WH58.30-Z-1002-12A	Micrometer
WH58.30-Z-1011-12A	Internal measuring instrument
WH58.30-Z-1012-12A	Setting gage for micrometer