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Measuring, boring and honing cylinder bores - AR01.40-P-9201AA: Notes

ENGINES 112.910/911 /912 /920 /921 /922 /923 /940 /941 /942 /943 /944 /945 /946 /947 /960 /961 /970 

ENGINES 113.940 /941 /942 /943 /960 /961 /962 /963 /965 /968 /981 /982 /990 /991 /992 /993 /995 

Fig 1: Identifying Measuring Points Of Cylinder Bore
G04605628
1 Clean cylinder bores    
2 Measure cylinder bore IMPORTANT Measure cylinder bores with an internal measuring instrument at 3 measuring points (1, 2, 3) in a longitudinal direction (A) and transverse direction (B).  
Cylinder diameter *BE01.40-P-1001-01F 
Cylinder bore *BE01.40-P-1001-02E 
Cylinder length *BE01.40-P-1004-01F 
Undercut *BE01.40-P-1005-01F 
COMMERCIALLY AVAILABLE TOOLS Internal measuring instrument ø 50 to 150 mm,
with 0.01 mm indication and measuring point pressure relief		 *WE58.40-Z-1003-21A 
COMMERCIALLY AVAILABLE TOOLS Setting micrometer for internal measuring instrument GRM 2125 with setting range 50 to 200 mm *WE58.40-Z-1004-21A 
3 Set honing machine for pre-honing Cylinder diameter setting for repair size (+0.25) *BE01.40-P-1002-01F 
Stroke setting with 70 mm stone length on 70th stroke scale of machine *BE01.40-P-1006-01F 
Stone overrun at top and bottom *BE01.40-P-1007-01F 
Engine speed *BE01.40-P-1008-01F 
Feed *BE01.40-P-1009-01F 
Stroke *BE01.40-P-1010-01F 
Display *BE01.40-P-1011-01F 
COMMERCIALLY AVAILABLE TOOLS Automatic cylinder repair machine *WE58.40-Z-1002-21A 
COMMERCIALLY AVAILABLE TOOLS Set of stones for rough honing C 30-A 53, or C30 J64, 70 mm long *WH58.30-Z-1031-04A 
4 Cylinder bore pre-honing IMPORTANT With full honing oil feed.  
5 Measure cylinder bore IMPORTANT Immediately after pre-honing, the measurement deviates by approx.
+0.02 mm due to heat expansion.		 *BE01.40-P-1003-01F 
COMMERCIALLY AVAILABLE TOOLS Internal measuring instrument ø 50 to 150 mm, with 0.01 mm indication and measuring point pressure relief *WE58.40-Z-1003-21A 
6 Set honing machine for precision honing Cylinder diameter setting for repair size (+0.25) *BE01.40-P-1002-01F 
Stroke setting with 70 mm stone length on 70th stroke scale of machine *BE01.40-P-1006-01F 
Stone overrun at top and bottom *BE01.40-P-1007-01F 
Engine speed *BE01.40-P-1008-01F 
Feed *BE01.40-P-1009-01F 
Stroke *BE01.40-P-1010-01F 
Display *BE01.40-P-1011-01F 
COMMERCIALLY AVAILABLE TOOLS Finish-honing, stone set C 30-J 84, 70 mm long *WH58.30-Z-1032-04A 
7 Cylinder bore precision honing IMPORTANT With full honing oil feed.  
8 Measure cylinder bore IMPORTANT Immediately after precision honing, an oversize of approx. +0.01 mm is obtained because of heating. *BE01.40-P-1003-01F 
COMMERCIALLY AVAILABLE TOOLS Internal measuring instrument ø 50 to 150 mm, with 0.01 mm indication and measuring point pressure relief *WE58.40-Z-1003-21A 
9.1 Chamfer cylinder bore IMPORTANT Except engines 112.945, 113.962 /982 in model 463. AR01.40-P-9201-01A 
10 Set honing machine for polishing Cylinder diameter setting for repair size (+0.25) *BE01.40-P-1002-01F 
Stroke setting with 70 mm stone length on 70th stroke scale of machine *BE01.40-P-1006-01F 
Stone overrun at top and bottom *BE01.40-P-1007-01F 
Engine speed *BE01.40-P-1008-01F 
Feed *BE01.40-P-1009-01F 
Stroke *BE01.40-P-1010-01F 
Display *BE01.40-P-1011-01F 
COMMERCIALLY AVAILABLE TOOLS Set of stones for polishing C 30-C 03-81, 70 mm long *WH58.30-Z-1033-04A 
11 Polish cylinder bore IMPORTANT Polish with full honing oil feed up to final repair size. *BE01.40-P-1003-01F 
12 Measure cylinder bore IMPORTANT Allow crankcase to cool down to approx. 20°C before measuring  
Cylinder diameter *BE01.40-P-1001-01F 
COMMERCIALLY AVAILABLE TOOLS Internal measuring instrument ø 50 to 150 mm, with 0.01 mm indication and measuring point pressure relief *WE58.40-Z-1003-21A 
13 Clean cylinder bore and dry    
14 Set honing machine for lapping IMPORTANT Set to same diameter as after polishing (final diameter).  
Cylinder diameter according to machining stage. *BE01.40-P-1003-01F 
Stroke setting with 70 mm felt length on 70th stroke scale of machine *BE01.40-P-1012-01F 
Felt insert overrun at top and bottom *BE01.40-P-1013-01F 
Engine speed *BE01.40-P-1008-01F 
Feed *BE01.40-P-1009-01F 
Stroke *BE01.40-P-1010-01F 
Display *BE01.40-P-1011-01F 
COMMERCIALLY AVAILABLE TOOLS Felt insert C 30-F 85 *WH58.30-Z-1036-04A 
COMMERCIALLY AVAILABLE TOOLS Set of felt insert holders CK3130 *WH58.30-Z-1035-04A 
COMMERCIALLY AVAILABLE TOOLS Stone holder for felt insert CK-30 35 *WH58.30-Z-1034-04A 
15 Rub-in cylinder bore and filter insert using honing paste IMPORTANT Without honing oil feed, the cylinder wall must be dry. Only the specified honing paste may be used. Only this one guarantees the specified final result.
Polmot honing paste order no. 600.11		 *BR00.45-Z-1050-06A 
16 Lap cylinder bore and expose silicone crystals. IMPORTANT Without honing oil feed.
Operating time of honing machine		 *BE01.40-P-1014-01F 
17 Coat filter insert again with honing paste IMPORTANT Do not coat cylinder bore with honing paste.
Polmot honing paste order no. 600.11		 *BR00.45-Z-1050-06A 
18 Lap cylinder bore and expose silicone crystals. IMPORTANT Without honing oil feed, removed material cannot be measured.
Operating time of honing machine		 *BE01.40-P-1014-01F 
19 Clean cylinder bore and dry NOTES Clean crankcase very carefully with honing paste. If possible, clean crankcase in a major assembly washing machine, so that no cylinder wall damage will be caused by residues when running the engine later.  
20 Inspect cylinder bore IMPORTANT Allow crankcase to cool down to approx. 20°C before inspecting.
Cylinder diameter of repair size		 *BE01.40-P-1001-01F 
CHECK VALUES FOR CRANKCASE

Number Designation Engine 112 except 112.951, 113.940/941/ 942/943/944/ 945/946/948/ 960/961/963/ 965/966/967/ 968/980/981/ 984/986/992/ 995 Engine 113.962/982/ 987/988/989/ 990/991/993
BE01.40-P-1001-02E Cylinder bore Peak-to-valley height (RZ ) of top separating surface mm 0.001 to 0.0045 0.001 to 0.0045
Wear limit at BDC and TDC of 1st piston ring mm ≤ 30.03 ≤ 0.03
Permissible deviation of cylinder shape mm 0.014 0.007
contact surface peak-to-valley height μm - -
CHECK VALUES FOR CYLINDER BORE

Number Designation Engine 112.910/ 911 Engine 112.913/920/921/922/ 923/940/941/942/943/ 944/945/949 113.940/941/942/943/945
BE01.40-P-1001-01F Cylinder dia. Standard marking X mm 83.200...83.215 89.900...89.915
Auxiliary stage Marking ⓧ mm 83.250...83.265 83.250 ... 83.265
Repair size mm 90.150 ... 90.165 90.150...90.165
BE01.40-P-1002-01F Cylinder dia., setting for repair size (+0.25) Pre-honing mm 83.200 89.900
Precision honing mm 83.380 90.080
Polishing mm 83.430 90.130
BE01.40-P-1003-01F Cylinder dia. according to machining phase Pre-honing mm 83.380 90.080
Precision honing mm 83.430 90.130
Polishing mm 90.150 ... 90.165 90.150...90.165
BE01.40-P-1004-01F Cylinder length mm 129.5 129.5
BE01.40-P-1005-01F Undercut mm 12 12
BE01.40-P-1006-01F Stroke setting with 70 mm stone length on 70th stroke scale of machine mm 130 130
BE01.40-P-1007-01F Stone overrun at top and bottom mm 9.5 9.5
BE01.40-P-1008-01F Engine speed Pre-honing rpm 125 125
Precision honing rpm 125 125
Polishing rpm 125 125
Lapping rpm 230 230
BE01.40-P-1009-01F Feed Pre-honing 4 4
Precision honing 3 3
Polishing 2 2
Lapping 1 1
BE01.40-P-1010-01F Stroke Pre-honing rpm 57 57
Precision honing rpm 57 57
Polishing rpm 57 57
Lapping rpm 80 80
BE01.40-P-1011-01F Display Pre-honing % 20 to 30 20 to 30
Precision honing % 20 to 30 20 to 30
Polishing % 20 to 30 20 to 30
Lapping % 20 to 30 20 to 30
BE01.40-P-1012-01F Stroke setting with 70 mm felt length on 70th stroke scale of machine mm 115 115
BE01.40-P-1013-01F Felt insert overrun at top and bottom mm 2 to 4 2 to 4
BE01.40-P-1014-01F Operating time of honing machine S 40 40
CHECK VALUES FOR CYLINDER BORE

Number Designation Engine 112.951/961 Engine 112.970
BE01.40-P-1001-01F Cylinder dia. Standard marking X mm 89.900...89.915 97.000 to 97.015
Auxiliary stage Marking ⓧ mm 89.950 to 89.965 97.050 to 97.065
Repair size mm 90.150...90.165 97.250 to 90.165
BE01.40-P-1002-01F Cylinder dia., setting for repair size (+0.25) Pre-honing mm - 97.000
Precision honing mm - 97.180
Polishing mm - 97.230
BE01.40-P-1003-01F Cylinder dia. according to machining phase Pre-honing mm - 97.180
Precision honing mm - 97.230
Polishing mm - 97.250 ... 97.265
BE01.40-P-1004-01F Cylinder length mm - 130.90 to 131.00
BE01.40-P-1005-01F Undercut mm - 0.6...1.0
BE01.40-P-1006-01F Stroke setting with 70 mm stone length on 70th stroke scale of machine mm - 132
BE01.40-P-1007-01F Stone overrun at top and bottom mm - 9.5
BE01.40-P-1008-01F Engine speed Pre-honing rpm - 125
Precision honing rpm - 125
Polishing rpm - 125
Lapping rpm - 230
BE01.40-P-1009-01F Feed Pre-honing - 4
Precision honing - 3
Polishing - 2
Lapping - 1
BE01.40-P-1010-01F Stroke Pre-honing rpm - 57
Precision honing rpm - 57
Polishing rpm - 57
Lapping rpm - 80
BE01.40-P-1011-01F Display Pre-honing % - 20 to 30
Precision honing % - 20 to 30
Polishing % - 20 to 30
Lapping % - 20 to 30
BE01.40-P-1012-01F Stroke setting with 70 mm felt length on 70th stroke scale of machine mm - 115
BE01.40-P-1013-01F Felt insert overrun at top and bottom mm - 2 to 4
BE01.40-P-1014-01F Operating time of honing machine S - 70
CHECK VALUES FOR CYLINDER BORE

Number Designation Engine 112.946/947/ 948/960 Engine 112.912
BE01.40-P-1001-01F Cylinder dia. Standard marking X mm 89.900...89.915 83.200...83.215
Auxiliary stage marking ⓧ mm 89.950 to 83.265 83.250...83.265
Repair size mm 90.150...90.165 83.450 to 83.465
BE01.40-P-1002-01F Cylinder dia., setting for repair size (+0.25) Pre-honing mm 89.900 83.200
Precision honing mm 90.080 83.380
Polishing mm 90.130 83.430
BE01.40-P-1003-01F Cylinder dia. according to machining phase Pre-honing mm 90.080 83.380
Precision honing mm 90.130 83.430
Polishing mm 90.150...90.165 83.450 to 83.465
BE01.40-P-1004-01F Cylinder length mm 129.5 129.5
BE01.40-P-1005-01F Undercut mm 12 12
BE01.40-P-1006-01F Stroke setting with 70 mm stone length on 70th stroke scale of machine mm 130 130
BE01.40-P-1007-01F Stone overrun at top and bottom mm 9.5 9.5
BE01.40-P-1008-01F Engine speed Pre-honing rpm 125 125
Precision honing rpm 125 125
Polishing rpm 125 125
Lapping rpm 230 230
BE01.40-P-1009-01F Feed Pre-honing 4 4
Precision honing 3 3
Polishing 2 2
Lapping 1 1.
BE01.40-P-1010-01F Stroke Pre-honing rpm 57 57
Precision honing rpm 57 57
Polishing rpm 57 57
Lapping rpm 80 80
BE01.40-P-1011-01F Display Pre-honing % 20 to 30 20 to 30
Precision honing % 20 to 30 20 to 30
Polishing % 20 to 30 20 to 30
Lapping % 20 to 30 20 to 30
BE01.40-P-1012-01F Stroke setting with 70 mm felt length on 70th stroke scale of machine mm 115 115
BE01.40-P-1013-01F Felt insert overrun at top and bottom mm 2 to 4 2 to 4
BE01.40-P-1014-01F Operating time of honing machine S 40 40
CHECK VALUES FOR CYLINDER BORE

Number Designation Engine 113.960/961/ 962/963/964/ 965/967/968/ 971/980/981/ 982/984/987/ 988/989/990/ 991/992/993/ 995
BE01.40-P-1001-01F Cylinder dia. Standard marking X mm 97.000 to 97.015
Auxiliary stage Marking ⓧ mm 97.050 to 97.065
Repair size mm 97.250 to 97.265
BE01.40-P-1002-01F Cylinder dia., setting for repair size (+0.25) Pre-honing mm 97.000
Precision honing mm 97.180
Polishing mm 97.230
BE01.40-P-1003-01F Cylinder dia. according to machining phase Pre-honing mm 97.180
Precision honing mm 97.230
Polishing mm 97.250 to 97.265
BE01.40-P-1004-01F Cylinder length mm 129.5
BE01.40-P-1005-01F Undercut mm 12
BE01.40-P-1006-01F Stroke setting with 70 mm stone length on 70th stroke scale of machine mm 130
BE01.40-P-1007-01F Stone overrun at top and bottom mm 9.5
BE01.40-P-1008-01F Engine speed Pre-honing rpm 125
Precision honing rpm 125
Polishing rpm 125
Lapping rpm 230
BE01.40-P-1009-01F Feed Pre-honing 4
Precision honing 3
Polishing 2
Lapping 1
BE01.40-P-1010-01F Stroke Pre-honing rpm 57
Precision honing rpm 57
Polishing rpm 57
Lapping rpm 80
BE01.40-P-1011-01F Display Pre-honing % 20 to 30
Precision honing % 20 to 30
Polishing % 20 to 30
Lapping % 20 to 30
BE01.40-P-1012-01F Stroke setting with 70 mm felt length on 70th stroke scale of machine mm 115
BE01.40-P-1013-01F Felt insert overrun at top and bottom mm 2 to 4
BE01.40-P-1014-01F Operating time of honing machine S 70
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1030-04A Honing head CK-3000 for 76-127 mm dia. CK-2600,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1031-04A Pre-honing, stone set C 30-A 53, or C30 J64, 70 mm long,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1032-04A Precision honing, stone set C 30-J 84, 70 mm long,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1033-04A Polishing, stone set C 30-C 03-81, 70 mm long,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1034-04A Stone holder for felt insert CK-30 35,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1035-04A Felt insert holder set CK3130,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1036-04A Felt insert C 30-F 85,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WORKSHOP EQUIPMENT

WE58.40-Z-1002-21A Automatic cylinder repair machine
WE58.40-Z-1003-21A Internal measuring device (50... 150 mm dia., with 0.01 mm display and measuring point for pressure relief)
WE58.40-Z-1004-21A Adjusting micrometer for internal measuring device (with adjustment range 50-200 mm)
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1050-06A Polmot honing paste Order no. 600.11 Polmat - Poliertechnik GmbH Troggberg 11
38302 Wolfenbuttel
Germany
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