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MS Motor Service International GmbH74196 Neuenstadt, Germanywww.ms-motor-service.com
KOLBEN
PISTON
40 013 600
2 x Z17
128,000 mm
verwendbar für / suitable for
MERCEDES BENZ
6 5 4 1 4
( 0 1 ) 0 4 0 5 2 9 3 8 0 0 0 0 1 6
( 2 1 ) J 2 V P F 2 P 4 0 0 4 4 0 D
E N G L I S H
Basic information
3
Installationofpistonsandcylinderliners
3.1Installationanddirectionofinstallation
Youwillndinformationaboutthenominal
pistondiameterandpistonclearanceon
thepistoncrown.Thecombinationofthis
givesthenominaldiameterofthecylinder
bore.Beforeinstallation,thepistonand
cylinderdiametersneedtobemeasured
andcomparedwiththenominaldiameters.
Example
Pistondiameter 79.98mm
Spclearance 0.02mm
Cylinderdiameter 80.00mm
Example Symbol Direction of installation in engine
BMW,MercedesBenz,VW Controlside(oppositeforcetransfer/clutch)
MercedesBenz,Scania SpecialcaseforsomeVengines:Enginecentredirection
Citroën,RenaultAV
Controlside(oppositeforcetransfer/clutch)
“AV”standsfor“avant”=front
Citroën,RenaultAR
Flywheel(forcetransfer/clutch)
“AR”standsfor“arrière”=rear
Peugeot,RenaultV
Flywheel(forcetransfer/clutch)
“V”standsfor“volant”=Flywheel
Peugeot,Vauxhall Flywheel(forcetransfer/clutch)
Citroën,Peugeot,Renault Flywheel(forcetransfer/clutch)
Fiat,Iveco > Flywheel(forcetransfer/clutch)
Vauxhall,Perkins Groove Controlside(oppositeforcetransfer/clutch)
GM,Perkins FRONT Controlside(oppositeforcetransfer/clutch)
Hatz,Liebherr front Controlside(oppositeforcetransfer/clutch)
Deutz,MWM Exhaustair Forair-cooledenginesthedirectionofcoolingair
Nominal piston diameter Trade mark
Installation marking
Art. no.
Measuring window
Batch number
Clearance
Theoverviewbelowliststhesymbolsandtheirmeaningforthedirectionofinstalla-
tionintheengine.
Dependingontheenginemanufacturers,
thesamesymbolscanhavedierent
meanings.
Forpistonswithskirtcoatingwithoutmeasuringwindow,0.01-0.03mmof
layerthicknessstillneedtobededucted
fromthemeasurementtogetthestamped
pistondiameter.
Forpistonswithmeasuringwindow,the
pistondiametercanbedeterminedhere
withoutdeductingthethicknessofthe
skirtcoating.
Flywheel (force transfer/clutch)
Control side
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B C+ C- C
B C C
Basic information
3.2
Gapdimensionandpistonpositionintopdeadcentre
Piston protrusion or piston recess dimen-
sion in top dead centre for different engine
versions*
BelowthedimensionC,theprotrusion
(markedby+)ortherecess(markedby-)
ofthepistoninthetopdeadcentreisto
beunderstoodinrelationtothecylinderblocksealingface.Thesealthicknessor
geometricalshapesofthecylinderhead
arenottakenintoaccount.
Forengineswithwetcylinderliner,the
protrusionorrecessofthepistonisalso
measuredinrelationtothecylinderblock
face.
Aprotrusionofthecylinderlineroran
existinglandedgeisnottakeninto
account.
Forair-cooledcylinders,dimensionCrefers
tothedistancebetweenpistoncrownand
theseatofthecylinderheadontheair
cooledcylinder.
Anodised piston crowns
Forpistonswithanodisedpistoncrown,
thecrownforsettingthepistonprotrusion
mustnotbescrewedo.
Thepistonscanberecognisedbythegrey
colourofthecrownsurface.
Note
Forsettingthepistonprotrusion,pistons
withreducedcompressionheightare
alsoavailableinadditiontothestandard
pistons.
Gap dimension*Thegapdimension(B)istheprotrusionor
recessofthepistoninthetopdeadcentre
inrelationtothesealingfaceofthecyl-
inderblock.Thethicknessofthecylinder
headgasketandapossiblerecessinthe
cylinderheadaretakenintoaccountfor
measuring.Thisdimensionisalsoknown
as“leaddimension”.
* see pictogram line un-
der item 1 “Instructions
for using the catalogue”
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B A B
E N G L I S H
Basic information
3.3
Installationofcylinderliners
Whenreplacingcylinderliners,someprep-
arationworkneedstobeperformedandcriticalissuesmustbechecked.Oncethe
oldcylinderlinersareremovedandbefore
thenewcylinderlinersareinserted,the
engineblockmustbethoroughlycleaned.
Particularlyforengineblockswithwet
cylinderliners,allcoolantresiduesand
fragmentsofgasketsaretoberemoved
fromtheareaofthecylinderlinerxture.
Installation of wet cylinder liners
1.Firstofallthecylinderlinersare
insertedwithoutsealingrings.Thisway
itischeckedwhetherthecylinderliners
canbeinsertedeasilyandwithoutjam-
ming.Ajammingofthecylinderlinerin
theborealwaysresultsindeformationof
thecylinderbore.Furthermoreitneedsto
becheckedwhetherthelinerangerests
completelyushandplane-parallelinthe
engineblock.Forthispurposethecontact
Particularcareneedstobetakenforall
contactsurfaces.Theymustbepreparedso
thattheyaremetallicallyclean,completely
levelandnon-corroded.
Hardtoolslikescrapers,cuttersetc.must
notbeusedduetotheriskofdamaging
thesesurfaces.Worncylinderblockfacesandlinerange
counterboresmustbereworked.Ifthe
diametersofthecylinderlinerboreexceed
themaximumpermissibledimension,
thesurfacesareseverelycorrodedorare
distorted,theengineblockmustbedrilled
openaccordingly.
Thecylinderlinersmustthenbeinserted
withoutsideoversizeand/orlinerswith
oversizedange.Cylinderlinerswith
dierentoversizesareavailableintheKS
deliveryprogramformanyenginetypes.
Correct fange seat Liner protrusion B
surfacescanbecoatedwithsurfacepaste
tocheckthewearpatternthisway.Ifthe
wearpatternisnotimmaculate,theange
counterboreintheengineblockneedsto
bereworked.
2.Thentheamountofprotrusionofthe
cylinderlinersmustbechecked.Ifcylinder
linersareconcernedwhereametalseal
(Tombak,stainlesssteel)isusedforseal-
ingothelinerange,itmustbeinserted
formeasuringtheangeprotrusion.Ifthe
amountofprotrusionistoolittle,thismust
becorrectedbyusingcylinderlinerswith
oversizedangeheightorsteelshims.If
theamountofangeprotrusioniswrongor
iftheangeseatisuneven,thesealofthe
combustionchamberisnotguaranteed.
Thiscanresultincylinderdistortionsand
linerangefractures.
3.Fornalinstallationofthecylinder
linersincludingElastomerseals,lubricant
mustbeusedforeasierandsaferinstalla-
tionofthecylinderliners.Thelubricantor
assemblypasteisappliedtothesurfaces
ofthecylinderlinerandengineblock,
acrosswhichthesealingsringsmustslide
duringassembly.TheElastomerseals
themselvesdonotneedanylubricant.The
cylinderlinersmustbeinsertedslowlyby
handandsecuredinthesystem.Theymust
notbeinsertedwithforceorhardblowsof
thehammer.
4.Oncethecylinderlinersareinstalled,
thecylinderboresmustbecheckedfor
roundnessandconstrictionsinthearea
ofthesealingringswithaboremeasuring
devicewithdialgauge.
Attention:
Liquidsealantsandsealingpastemustnot
beusedwheninstallingwetcylinderliners.
Areliabletofthecylinderlinerscannot
beguaranteedinthiscase.Furthermore,
theElastomersealscannotmeettheirseal-
ingfunctionifthesealingringgroovesare
lledadditionallywithsealant.Themetal
discsthatmightbesuppliedwiththecylin-
derlinersandthataremadeofTombakor
stainlesssteelareseals.Themetalseals
mustbeinsertedbetweenengineblock
andcylinderlinerinanycase.Themetal
sealsarenotsuitedtoconguringtheliner
protrusion.Multiplesealsmustnotbe
placedandinstalledontopofeachother.
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The fange seat A must be plane-parallel.
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B
D
C
Basic information
B
D
C
Installation of dry cylinder liners in
“Slipfit” version ( “Finished”)
1.Theselinersarenishedontheinternaldiameterandcanberemovedandre-
installedmanuallyorwithsuitabletools.
Theengineblockdoesnotneedtobe
removedfromthevehicleforthispurpose.
Installation of dry cylinder liners in
“Pressfit” version (“Semi-finished” )1.Thesecylinderlinersareonlynished
ontheexternaldiameter.
Theinsidediameterisonlycoarselypre-
nished.Toreplacethesecylinderliners,
theengineblockmustberemovedfromthe
vehicleandcompletelydisassembled.
2.Toremovethecylinderlinerstheseare
eitherdestroyedwithachiselorsimilar
toolordrilledoutoftheengineblock.
Furtherpreparation/checkingoftheengine
blockisthesameasforthe“Slip-t”version.
3.Asthesecylinderlinershaveapress
ttingintheengineblock,theymustbe
pressedintotheengineblockbyusinga
press.
Thepressttingisseveralhundredth
millimetresandisdeterminedbythe
specicationsoftheenginemanufacturer.
Beforepressingin,thecylinderlinersmust
becoatedwithasuitable,thinlubricanton
theexternaldiameter.Thecylinderliners
shouldbepressedintotheengineblockin
onestepwithoutinterruptionifpossible.
Aninterruptionofthepress-inproce-
dureresultsinlargebreakawaytorques
whenpressingcontinuesandfrequently
B = Liner protrusionC = Chamfer D = Radius
For“Slipt“cylinderlinerstheclearanceis
0.00-0.015mm.If0.015mmisexceeded,
anoversizelinermustbeused.
inbreakingofthecylinderliners.Ifthe
press-inprocedurecannotbeperformedinonestepduetoamissingpressstroke,the
shortpartthatismissingmustbecovered
atthestartofthepressstrokeandthelast
parttakingfulladvantageoftheavailable
pressstroke.
Thepressureplatewhichisinserted
betweenpressstampandcylinderliner
mustbethickenoughsothatitdoesnot
breakduringpressing.
Animpressionofthelinerangecanbe
preventedthisway.
Installation dimensions for “Pressfit”
cylinder liners
Cylinder diameter 50 - 80 mm 80 - 120 mm 120 - 180 mm
Presst 0.045mm-·0.070mm 0.055 - 0.080 mm 0.065 - 0.090 mm
2.Beforeinsertingthecylinderliner,the
cylinderlinercounterboremustbechecked
forroundnessanddistortion.Thebevelled
edge(C)inthehousingmustcorrespondto
therounding(D)onthecylinderliner.
3.Beforeinsertingthecylinderliners,thecylinderboresmustbecheckedforround-
nessordeformations.Forthesecylinder
liners,thelinerprotrusiondimension(B)
speciedbythemanufacturermustbe
adheredto.Thisisimportanttoensure
thatthelinersarepressedrmlydown
ontotheirseatduringoperationandare
anchoredcorrectlyintheengineblock.
Insufficientprotrusionresultsinsealing
problemsandformationofcracksonthe
liners.
4.Asthecylinderlinersdeformslightly
duringpressingin,theymuststillbenishedtottherequiredcylinderend
dimensionthroughdrillingandhoning.
Duetothepresstting,thesecylinder
linersdonotcompulsorilyrequirealiner
angeanddogenerallynothavealiner
protrusion(B).Oncethecylinderlinersare
pressedin,thecylinderblockfacemustbe
fullyreworkedonce,sothatthecylinder
linersdonotprotrudeovertheengine
blockface.
Thespecicationsarereferencevalues.Thespeciedscalesoftheenginemanufacturerare
decisiveinthiscase.
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E N G L I S H
Basic information
3.4
Fittingthepistons
Assembly of pistons and connecting rods
Beforeinstallingtheconnectingrodsthey
needtobecheckedfordistortionand
twistingwithasuitabletestinginstrument.
Positionthepistonandtheconnectingrod
accordingtotheinstallationdirection.The
oiledpiniscarefullyinsertedintothepin
boresofthepistonandintotheconnecting
rodeyeoftheconnectingrod.Forpistons
withtightlytolerancedpinbore,insertion
ofthepiniseasierifthepistonisheatedto
approx.40°C.
For swimming pins
Retainerringsaresuppliedforxationof
thepin.
Usedretainerringsmustnolongerbe
used.Topreventlastingdeformations,
theretainerringsmustnotbepressed
togethertoohard.
Assembly of connecting rod with fixed pin
Theboreintheconnectingrodeyemust
haveapressttothepin.Forassembly
theconnectingrodistobeheatedto280-
320°C(noopename!).Afterwardsquickly
insertthewelloiledandcoldpinintothe
connectingrodeye.Toensurecorrectposi-
tioningofthepinintheconnectingrod,a
devicewithstoppinistobeused.
Whethertheringshavesafelylockedinto
thegroovescanbecheckedbyslightly
turningthem.Thejointoftheretention
mustalwaysbeindirectionofthepiston
stroke.
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Basic information
Checking the piston rings
Checkwhethertheringscanbefreely
(turned)rotatedintheringgrooves.
Forpistonringsmarkedwith“TOP”,the
markingmustpointtothepistoncrown.
Thisensurestheintendedfunctioniswork-
ing.
Spiral expander oil control rings
Thejointendsofthespiralexpander
shouldalwaysbeexactlyoppositethering
jointforspiralexpanderrings.Forspiral
expanderswithTeonsheath,thesheath
restsagainsttheringjoint.
Inaddition,forspiralexpanderringswith
locatinghookitisimportantthatthelocat-
inghookislockedintotheoilslot.
3-part steel rail oil control rings
Duringtransportthespiralendsare
untightenedandcansliponeabove
another.Thepositionmightneedtobe
correctedbeforeinstallation.Bothcolour
markingsatthespiralendsmustbevis-
ible.Iftheyarenotvisible,thespiralhas
overlappedandtheringisnotworking.
Theringjointsofthe3-partoilcontrol
ring(thetwosteelrailsandtheexpander
spring)mustbeturnedagainsteachother
by120°eachbeforeinstallation.
Oil slot Locating hook
Spiral expander ring with locating hook
red colour mark green colour mark
Installationrecommendation
overlapped joint
wrong:
correct:
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E N G L I S H
Basic information
Inserting the piston into the cylinder liner
Cleanthecylinderblockthoroughly.Make
surethatallglidingsurfacesarefreefrom
dirtandwelloiled.Pressthepistonrings
togetherwithasqueezertoenablethe
pistonglidingintothecylinderlinerwith-
outresistance.ForDieselenginesmeasurethegapdimensionorpiston'samountof
protrusionandalwaysadheretomanufac-
turer'sspecications.
3.5
Running-innotes
Theenginemustberuninontheroadif
notestrigisavailableforimplementinga
denedrun-inroutine.
•Thevehicleshouldnotbefullyladen.
•Runtheengineatconstantlychanging
speedlevelsnotexceeding2/3ofthe
maximumenginespeed.
•Shiftupbrisklywhilstdriving
andavoidunderrevving.
•Avoidmaximumgearspeeds.
•Avoidlengthyuphilldriving
(excessiveload).
Further advice
• Keepaconstantcheckontheoillevel
duringtherun-inphase.
Theoilconsumptioncanbeincreased.
Itisadvisabletochecktheoillevel
every50to100kmandtopupwithoilif
necessary.Ifthereisanoticeabledropin
theoillevelonthedipstick,continueto
monitoratshorterintervals.
•Donotoverlltheenginewithoil.
•Oilchangeafter1000km–Anoillter
changeisimportanthere.Thedirtand
abrasionfromrun-inhastoberemoved
fromtheengine.
•Avoidlengthydownhilldriving
(insufficientloadandundesirable
overrun).
•Donotuseenginebrakingsystems.
•Donotdriveonmotorwaysorattop
speed.
• Avoiddrivingincongestedtraffic.Driving
onopenroadsandinfree-owingurban
trafficisbest.Butnourbantrafficwith
extremelyhotoutsidetemperaturesand
withfrequentstopsattrafficlightsand
waitingtimes.
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