a Notes for evaluation of cylinder contact surface
fm 1
AH01.40-B-0001-03A.fm Notes for evaluation of cylinder contact
surface
The following information should be helpful in assessing the cylinder
barrel and in making a correct decision concerning the condition and
further use of a crankcase or cylinder liner.
In case of a new engine, the cylinder barrel is cylindrical; it gets worn out
over time with increased operation.
The cylinder barrel is not used evenly; it becomes beveled in shape with
normal wear.
A wear or a damage can also be recognized at the honing pattern of the
cylinder contact surface.
The following illustrated damage profiles are only an excerpt of possible
forms of damage to the cylinder barrel. When evaluating the types of
damage, the surface quality of the piston and of the piston rings must be
always be considered in determining the type of damage.
AH01.40-B-0001-03A.
Engine 457.9, 904.9, 906.9, 924.9, 926.9 i
Wear or damage to the cylinder barrel is often caused by:
• leaky air intake ducts downstream of the air filter,
• fault in the fuel injection system,
• too little or too much clearance between piston skirt and cylinder
barrel,
• poor engine oil quality (viscosity) or thinning of the engine oil by fuel,
• dirty or damaged engine oil filter,
• fault in engine oil circuit e.g. engine oil pressure too low,
• twisted or damaged oil spray nozzles for the piston cooling.
i Before starting engine after repairs, fill engine oil circuit externally with
an approved engine oil. Afterwards crank engine several times by
simultaneously pressing the engine start button and engine stop button
with the starter until the engine oil pressure is present.
a Notes for evaluation of cylinder contact surface AH01.40-B-0001-03A.fm 2

Normal condition

Matt gray surface, honing pattern visible, dry cylinder barrel, without oil
residues, without polished places or reflective smooth areas There
should not be any burn marks or streaks on the cylinder barrels or liners.
Individual slight scores are not critical.
The honing pattern is more or less clearly recognizable over the cylinder
barrel. The honing pattern may be partially worn away at the reversal
point of the first piston ring.

i The cylinder liner or the crankcase can be used again.

W01.40-1044-81
a Notes for evaluation of cylinder contact surface AH01.40-B-0001-03A.fm 3

Only for engine 904.9, 906.9, 924.9, 926.9.

i The streaky pattern (arrows) in the high

range of the cylinder contact surface results
from the induction hardening when
manufacturing the crankcase and is to be
regarded as a normal condition.
The longer the runtime of the engine, the less
visible is the streaky pattern (arrows).

W01.40-1042-74
a Notes for evaluation of cylinder contact surface AH01.40-B-0001-03A.fm 4

Carbon deposits at cylinder contact surface

Check top land area of cylinder liner or of crankcase for carbon (arrow).

i If there is carbon (arrow) on the top land area:

- clean top land area and reuse cylinder liner or crankcase.
- also remove piston and assess piston rings.

W01.40-1051-81
a Notes for evaluation of cylinder contact surface AH01.40-B-0001-03A.fm 5

Individual continuous traces of scratches or score marks

Check contact surface area of cylinder liner or of crankcase for traces of

scratches (arrows).

i The cylinder liner or crankcase can be reused if there are slight traces
of scratches (arrows) or score marks.

W01.40-1052-81
a Notes for evaluation of cylinder contact surface AH01.40-B-0001-03A.fm 6

Ring shaped imprints

Color shadow markings (arrow) are visible in the upper and lower piston
ring reversal point, the honing pattern is still recognizable.

i The cylinder liner or crankcase can be used again.

W01.40-1053-81
a Notes for evaluation of cylinder contact surface AH01.40-B-0001-03A.fm 7

Pressure gloss marks, smoothings

Individual plain spots, for example, in the center (arrow) of the cylinder
barrel, or marking all around the piston ring reversal point at the top and
at the bottom
Cause can be a poor engine oil quality (oil viscosity).

i
Engine 457.9:
The cylinder liner is unusable and must be replaced.

Engine 904.9, 906.9, 924.9, 926.9:

If the engine has no in-engine complaints as e.g. noises or increased
engine oil consumption, the crankcase can be reused

W01.40-1055-81
a Notes for evaluation of cylinder contact surface AH01.40-B-0001-03A.fm 8

Optical stripes, friction marks

Not perceptible dried traces of friction or deposits (arrow) at cylinder

contact surface feathers out as of the second or third piston ring to the
bottom.
Caused by soot particles and fuel ablutions of engine oil film.
Even damaged piston rings could be the cause.

i
Engine 457.9:
The cylinder liner is unusable and must be replaced.
Additionally the piston has to be replaced.

Engine 904.9, 906.9, 924.9, 926.9:

If the engine has no in-engine complaints as e.g. noises or increased
engine oil consumption, the crankcase can be reused.

W01.40-1035-81
a Notes for evaluation of cylinder contact surface AH01.40-B-0001-03A.fm 9

Dust damage

Traces of processing by honing are only just visible or are no longer

visible. If the wear is substantial, then a stage of wear is perceptible at
the reversal point of the first piston ring (arrow).

i
Engine 457.9:
The cylinder liner is unusable and must be replaced.
Additionally check the piston and piston rings, replace if necessary.

Engine 904.9, 906.9, 924.9, 926.9:

If the engine has no in-engine complaints as e.g. noises or increased
engine oil consumption, the crankcase can be reused.

W01.40-1041-81
a Notes for evaluation of cylinder contact surface AH01.40-B-0001-03A.fm 10

Piston seizure or roughened streaks, signs of seizure

The cylinder barrel is usually roughened over the whole length. Material
deposits and perceptible seizure marks on cylinder barrel and also on
piston skirt.

i The cylinder liner or crankcase is unusable and must be replaced or

machined.
Additionally check the piston and piston rings, replace if necessary.

W01.40-1036-81