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MBE 4000 CYLINDER BLOCK

The cylinder block has integrated oil and water channels. The upper section of the cylinder bore is induction-hardened. ‪

Cylinder Liner Removal

Remove the cylinder liner as follows: ‪

  1. Remove the piston. Refer to section .
  2. Using a paint pen, mark the position of the liner in the cylinder block. Mark both the liner and the block. Then make another set of marks 90 degrees from the first set, in a clockwise direction. See Figure 41890 .

    Note: If the same liner is used again, it must be installed at an offset of 90 degrees from its last position.

    1. Cylinder Block ‪

    2. Cylinder Liner ‪

    Mark the Cylinder Liner

    NOTICE:

    To prevent damage, never use a hammer or other unsuitable device to remove the cylinder liner.

  3. Remove the cylinder liner, using the cylinder liner removal tool, (J 41543). See Figure 41891 .

    1. Removal Plate ‪

    5. Threaded end of Spindle ‪

    2. Hold-down bolt ‪

    6. Hold-down bolt ‪

    3. Washer ‪

    7. Cylinder Liner ‪

    4. Spindle Nut ‪

    Cylinder Liner Removal

    NOTICE:

    If the removal plate is not correctly seated, the liner will be damaged.

  4. Remove the metal insert from the collar seat (the counterbore in the block). See Figure 41892 .

    1. Block ‪

    3. Cylinder Liner Collar ‪

    2. Cylinder Liner ‪

    4. Collar Seat Insert ‪

    Cylinder Liner Collar Seat

  5. Remove and discard the two O-rings from the block. See Figure 41893 .

    1. Block ‪

    4. Upper O-ring ‪

    2. Cylinder Liner ‪

    5. Lower O-ring ‪

    3. Collar Seat Insert ‪

    Cylinder Liner O-rings

  6. Thoroughly clean the cylinder liner and the collar seat.

    Note: Take special care to clean the liner collar and the seating surfaces for the collar seat insert and the two O-rings.

  7. Check the condition of the cylinder liner collar. Make sure that the height of the collar is within the specifications given. Discard the liner if the collar is not within specifications listed in Table .
  8. Check the condition of the liner collar seat. Make sure that the depth of the collar seat is within the specifications given, listed in Table .

    Description

    Value: mm (in.)

    Cylinder Liner Protrusion, From Block, , Ref. A. ‪

    0.2300.330 (0.00900.0130) ‪

    Height of the Cylinder Liner Collar, , Ref. B. ‪

    10.1010.12 (0.39760.3984) ‪

    Depth of the Collar Seat, , Ref. C. ‪

    9.95010.010 (0.3920.3941) ‪

    Thickness of the Seat Insert ‪

    0.140.16 (0.00550.0063) ‪

    Cylinder Liner Installation Tolerances
  9. Check the deformation of the cylinder liner collar at the contact surface with the seat insert. Make sure that the deformation of the collar does not exceed the admissible maximum given, listed in Table . Discard the liner if the collar is not within tolerance.

    Note: Do not attempt to machine the liner collar in order to correct inadmissible deformation. Instead, replace the cylinder liner.

  10. Check the deformation of the liner collar seat at the contact surface with the seat insert. Make sure that the deformation of the collar seat does not exceed the admissible maximum given, listed in Table .

    Description

    Value: mm (in.)

    Admissible Out-of-Round of the Cylinder Liner, where it contacts the O-rings ‪

    Max.: 0.02 (0.0007) ‪

    Admissible Deformation of the Cylinder Liner Collar, at the Contact Surface with the Seat Insert ‪

    Max.: 0.02 (0.0007) ‪

    Admissible Deformation of the Liner Collar Seat, at the Contact Surface with the Seat Insert ‪

    Max.: 0.03 (0.0011) ‪

    Cylinder Liner Inspection Tolerances

Cylinder Liner Installation

Install the cylinder liner as follows: ‪

  1. Install new O-rings, clean and dry, in the cylinder block.
  2. Install a new seat insert, clean and dry, into the liner collar seat. See Figure 41892 . Check the thickness of the seat insert according to the specifications, listed in Table .

    Note: The cylinder liner collar and collar seat must remain completely free of oil.

  3. Apply a light coating of engine oil to the lower part of the liner, from where it contacts the O-rings up to the bevelled area.
  4. When installing a new liner, make sure that the diameter tolerance code corresponds to the one marked on the piston. See Figure 41894 for the location of tolerance codes.

    1. Piston ‪

    2. Cylinder Liner ‪

    Tolerance Codes

    1. Cylinder liners with tolerance code A require a piston of code BA.
    2. Cylinder liners with tolerance code B require a piston of either code BA or BC.
    3. Cylinder liners with tolerance code C require a piston of code BC.
  5. Install the cylinder liner, using the cylinder liner installation tool (J 46168 or 449 589 01 33 00) . See Figure 41895 .

    1. Installation Nut ‪

    3. Cylinder Block ‪

    2. Cylinder Liner ‪

    Cylinder Liner Installation

    1. If installing a new liner, be sure to make a reference mark on the liner to match up with the one made on the cylinder block upon removal.
    2. NOTICE:

      Do not overtighten the installation tool. This may deform the liner and make the installation tool more difficult to remove.

    3. Tighten the installation tool just enough to hold the installation tool inside the liner without turning.
    4. NOTICE:

      To prevent damage to the O-rings, the liner must be rotated during installation.

      Note: If installing a new liner, use the first reference mark. If installing the old liner, use the second reference mark, offset 90 degrees from the first one.

    5. Insert the cylinder liner into the cylinder block until it contacts the O-rings. Continue to insert the liner past the O-rings, being careful to keep turning the installation tool until the liner is properly seated.
    6. Remove the installation tool from the cylinder liner.
  6. Measure the cylinder liner protrusion from the block. See Figure 41892 . The specifications are listed in Table . Refer to section .
  7. Measure the inside diameter of the cylinder liner and check for out-of-round. See Figure 41896 .

    1. Cylinder Liner ‪

    3. Dial Gauge ‪

    2. Quick Calipers ‪

    4. Cylinder Block ‪

    Measuring the Cylinder Liner Inside Diameter

    1. Measure at three different locations 60 degrees apart in the area of the two O-rings.
    2. Compare the three measurements. If they differ by more than the maximum admissible out-of-round listed in Table , remove the liner and inspect the two O-rings and their seating area in the cylinder block.
    3. If the O-rings are damaged, replace them.
    4. Check the out-of-round again until it meets specifications.
  8. Install the piston. Refer to section .
Cylinder Liner Bore Inspection and Measurement

Inspection

Inspect the cylinder liner bore as follows: ‪

  1. Check the wall of the cylinder liner for signs of excessive wear or deformation.
  2. Check the honing pattern on the cylinder liner for damage caused by penetration of dirt into the cylinder. If the honing pattern is faded or no longer visible, discard the cylinder liner. See Figure 41897 for an intact honing pattern and see Figure 41898 for a faded honing pattern.

    Note: Minor fading of the honing pattern at the top ring inversion area is not sufficient cause to reject the liner.

    Intact Honing Pattern

    Faded Honing Pattern

  3. Do an external visual check of the cylinder liner for signs of cavitation and corrosion. Discard the liner if any damage is noted.

Measurement

  1. Set the dial gauge and quick calipers with a dial caliper to the inside diameter of the cylinder liner. Preload the dial gauge to 5 mm (0.20 inch). See Figure 41899 for set-up and listed in Table are specifications.

    1. Dial Gauge ‪

    3. Dial Caliper ‪

    2. Quick Calipers (for internal measurements) ‪

    Setting the Dial Gauge

    Where To Measure

    What To Measure

    Value: mm (in.)

    Measuring Point 1: At the area of the O-rings ‪

    Inside Diameter of the Cylinder Liner, A Class ‪

    127.990127.995 (5.03905.0392) ‪

    Measuring Point 1: At the area of the O-rings ‪

    Inside Diameter of the Cylinder Liner, B Class ‪

    127.995128.005 (5.03925.0396) ‪

    Measuring Point 1: At the area of the O-rings ‪

    Inside Diameter of the Cylinder Liner, C Class ‪

    128.005128.010 (5.03965.0398) ‪

    Measuring Point 2: Upper Reversal Point of the First Piston Ring ‪

    Max. Wear to Cylinder Liner, Measured Along Axis A and Axis B ‪

    0.08 (0.003) ‪

    At Measuring Point 2, Compare Axis A to Axis B ‪

    Admissible Wear Out ‪

    Max.: 0.08 (0.003) ‪

    Cylinder Liner Measurements

    Note: This measurement serves as a baseline against which to measure the actual wear.

  2. Measure the inside diameter of the cylinder liner at measuring point 1: near the O-ring area. See Figure 41900 .

    Measuring the Inside Diameter

    1. Make the first measurement along the fore-to-aft axis.
    2. Make the second measurement 90 degrees away, along the side-to-side axis.
    3. When finished, set the dial gauge to zero.
  3. Measure the wear on the inside diameter of the liner at measuring point 2: the upper reversal point of the first piston ring. Measure the cylinder liner in both directions: fore-to-aft and side-to-side. See Figure 41901 . The specifications are listed in Table .

    1. Cylinder Liner ‪

    2. Measuring Point 2 (upper reversal point of the first piston ring) ‪

    Measuring Points

    1. Make the first measurement along the fore-to-aft axis (axis A).
    2. Make the second measurement 90 degrees away, along the side-to-side axis (axis B).
    3. If there is more than 0.08 mm (0.003 inch) of wear, replace the cylinder liner.
  4. Check the cylinder liner for out-of-round. If the two measurements vary by more than 0.010 mm (0.0004 in.), replace the cylinder liner.
  5. Replace the cylinder liner, if required. Refer to section .
Cylinder Liner Protrusion Measurement

Measure the cylinder liner protrusion as follows: ‪

  1. Remove the cylinder head. Refer to section .

    Note: Correct liner protrusion is necessary to obtain a perfect seal when the head gasket is compressed by the cylinder head.

  2. Clean the contact surfaces of the cylinder block, the cylinder liner, and the measuring plate.
  3. Install the measuring plate (J 46071 or 402 589 00 21 00) on the cylinder block and cylinder liner. Fasten the measuring plate to the block by inserting the cylinder head bolts into the spacers and then threading them into the holes in the cylinder block. See Figure 41905 .

    1. Cylinder Head Bolts ‪

    Measuring Plate Installation

  4. Tighten the cylinder head bolts 50 Nm (37 lbft).
  5. Install the dial gauge so that the feeler on the dial gauge extends into the slot in the measuring plate. The feeler must touch the contact surface of the cylinder block with some preload. Support the dial gauge. See Figure 41906 .

    1. Dial Gauge ‪

    3. Feeler ‪

    2. Slot (4 qty.) ‪

    Dial Gauge Installation

  6. Measure the cylinder liner protrusion from the block in four places, once at each slot in the measuring plate. See Figure 41907 . The acceptance/rejection criteria is listed in Table .

    1. Cylinder Block ‪

    2. Cylinder Liner ‪

    Measuring Protrusion

    Description

    Value: mm (in.)

    Cylinder Liner Protrusion From Block ‪

    0.2300.330 (0.00900.0130) ‪

    Difference Between the Four Measuring Points ‪

    Max.: 0.02 (0.0007) ‪

    Specifications for Measuring Cylinder Liner Protrusion
    1. Set the scale on the dial gauge to zero.
    2. Move the dial gauge until the feeler touches the cylinder liner collar. Record the reading on the dial gauge.
    3. Move the dial gauge and support to the next slot, and repeat the measurement process, until four measurements have been made, one at each slot. Record each measurement.
    4. Check each measurement. If any one measurement records protrusion of less than 0.230 mm (0.0090 inch), or more than 0.330 mm (0.0130 inch), remove the cylinder liner and check it according to the procedures that refer to section .
    5. Compare the four measurements. If any measurement differs from any one of the others by more than 0.02 mm (0.0007 inch), replace the cylinder liner.
  7. Remove the bolts, spacers and measuring plate (J 46071) , as installed.
  8. Install the cylinder head. Refer to section .
Fuel System Leak Test

Perform the following procedure to ensure that the fuel gallery is properly sealed and does not leak. ‪

Note: This procedure can be performed with the engine installed or removed from the vehicle.

FIRE

To avoid injury from fire, keep all potential ignition sources away from diesel fuel, including open flames, sparks, and electrical resistance heating elements. Do not smoke when refueling.

  1. Drain all fuel from engine.
  2. Remove all six injector unit pumps from the engine block. Refer to section .
  3. Install all six dummy unit pumps (J 45982-6-1) , from the Head and Block Leak Tester Tool Kit (J 45982) . See Figure 44569 .

    1. Fuel Gallery Inlet ‪

    3. Fuel Gallery Outlet ‪

    2. Pressure Gauge Fitting ‪

    Installing Dummy Injector Unit Pumps

    Note: One of the dummy unit pumps has a fitting for pressure gauge installation and it must be installed at the easiest position for gauge installation.

  4. Block the fuel gallery inlet and outlet with special plugs from kit (J 45982) . See Figure 44569 .
  5. Install the pressure gauge assembly (pressure gauge, pressure regulator, and shut off valve) from kit (J 45982) . See Figure 44574 .
  6. Connect a compressed air supply to the pressure gauge assembly.

    1. Pressure Gauge on Dummy Unit Pump ‪

    Installing Pressure Gauge Assembly to Dummy Unit Pump

    EYE INJURY

    To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

  7. Pressurize the system with 2 bar (29 psi). Use the pressure regulator to set the pressure.
  8. Check for leaks around the dummy unit pumps and inlet/outlet plugs using a soap solution. Eliminate leaks.
  9. Close the shut off valve.
  10. Watch the pressure for 30 seconds. If the pressure holds at 2 bar (29 psi), the fuel gallery is properly sealing. In case of a pressure drop, the engine block should not be reused.
Cylinder Block Leak Test

Perform the following steps to conduct a cylinder block leak test to see if the engine block is leaking coolant. ‪

Note: This procedure can only be performed with the engine removed from the vehicle and using only the engine block with the liners installed.

  1. Place the engine block with installed liners on the engine stand.
  2. Install all six top block cover plates(J 45982-1) from the Head and Block Leak Test kit (J 45982) using the special bolts supplied.See Figure 44575 .

    1. Block Cover Plates (6) - part of kit J 45982 ‪

    3. Pressure Gauge Fitting ‪

    2. Water Pump Cover Plate - part of kit J 45982 ‪

    4. Oil Cooler/Filter Housing Cover Plate - part of kit J 45982 ‪

    Installing Block Cover Plates

  3. Install the oil cooler/filter housing cover plate, from the kit, on the right hand side of the engine block using supplied hardware. See Figure 44575 .
  4. Install the water pump cover plate, from the kit, on the front of the engine using supplied hardware. See Figure 44575 .

    Note: The water pump cover plate has a fitting for installing the supplied pressure gauge.

  5. Block the air compressor coolant inlet and outlet from the engine block with the special plugs and copper washers as supplied in the leak test kit (J 45982). See Figure 44534 .

    1. Coolant Line to Air Compressor ‪

    2. Air Compressor Outlet location from Engine Block ‪

    Blocking Air Compressor Inlet/Outlet from Engine Block

  6. Install the pressure gauge assembly (pressure gauge, pressure regulator, and shut off valve) from kit (J 45982). See Figure 44578 .

    1. Pressure Gauge Assembly ‪

    Installing Pressure Gauge Assembly

  7. Connect a compressed air supply to the pressure gauge assembly. See Figure 44578 .

    EYE INJURY

    To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

  8. Pressurize the system with 2 bar (29 psi). Use the pressure regulator to set the pressure.
  9. Check for leaks around the all cover plates and plugs using a soap solution. Eliminate leaks.
  10. Close the shut off valve.
  11. Watch the pressure for 30 seconds. If the pressure holds at the 2 bar (29 psi), the cylinder block coolant system is properly sealed. In case of a pressure drop, the engine block should not be reused.