Replacement of Cylinder Liner

08028-0D/H5250/94.08.12

Description:

Replacement of cylinder liner.

Hand tools:

Adjustable spanner.

Starting position:

Cylinder head and piston/connecting rod dismantled,working card 505-01.00 and 506-01.00.

L23/30H

Dismounting of Cylinder Liner

1) Prior to mounting of the lifting tool and dismounting from the frame, it must be ensured that the liner and frame have been marked to match, for the sake of a possible remounting of the liner, see fig 1.

Hole for charging air

Hole for roller guide house

Marking scratch frame

Marking scratch liner

Fig 1.

2)Mount the lifting tool as shown, see fig 2.

3)Turn the lifting eye nut to pull out the liner until the upper edge of the liner lie aligned against the copper protecting pieces of the cross bar.

4)Attach a tackle hook to the eye nut or the wire and the cross bar, and lift the liner out from the engine frame and put it down onto wooden supports.

5)Clean all parts and inspect for damage and wear according to the description. For measurement of cylinder liner, see working card 506-01.35.

Fig 2.

Mounting of Cylinder Liner

6)Check that the sealing surfaces on engine frame, cylinder liner, and sealing rings are perfectly clean.

7)Mount the lifting tool, attach a tackle hook to the eye nut or to the wire in the cross bar and lift the liner.

8)Check that the O-ring grooves are clean. Mount the O-rings and lubricate with a little oil.

9)Lower the cylinder liner carefully into the engine frame.

When the first O-ring touches the sealing face, align the liner so that the scratch mark on the liner flange points to the scratch mark on the frame as illustrated.

10) Mount the piston/connecting rod and cylinder head according to working card 506-01.20 and 50501.40.

08028-0D/H5250/94.08.12

Fig 1.

Grinding

1)Loosen the sealing ring in liner flange and take

it out.

2)Face-grind the sealing grooves in the cylinder liner flange, see Fig 2, and the sealing surface on the cylinder head, see Fig 3, with the use of grinding pasta and the grinding tool.

Fig 3.

3)After grinding, remove all traces of abrasives and grinding compound.

4)When having ground the contact faces, it must be observed that the gap between cylinder head and liner is no less than 0.5 mm, i.e. the difference between measurements y and z must not be less than

0.5mm, see Fig 4.

08028-0D/H5250/94.08.12

L23/30H

Dismantling of Piston at Low Overhaul Heights

1)Lift up the piston and the connecting rod through the cylinder liner until the piston is clear of the liner.

2)Mount the collar on the connecting rod, see plate 52050, item no 045.

3)Place the piston with the collar on the cylinder

liner.

4)Mount pull-lifts on the collar.

Dismantling of Cylinder Liner at Low Overhaul

Heights

1)Mount the normal lifting tool for cylinder liners.

2)Carefully pull the cylinder liner half-way out of the frame.

3)Mount a special lifting tool for cylinder liners at low overhaul heights, see plate 52050, item no 033.

4)Attach pull-lifts on the lifting tool for the cylinder liner, see plate 52050, item no 033.

5)Take out the liner over the camshaft side.