Crankcase - Service instruction

Measuring the wear the cylinder liners

Use a micrometer screw a new cylinder liner , (starting measurement ) set dial gauge

Clean the inner surface the cylinder liner oughly before the

T ake measurements the upper end, the lower end and the centre the cylinder liner

Check the display value for wear and runout (compare with nominal

Removing the cylinder liner the cylinder liners are used they must marked that they can reused the same

Remove the cylinder liners using the puller 38000001 1 and 1TSW

Checking the cylinder block

Clean the cylinder block and all oil

Check cooling ducts and ensure correct engine remove scale and dirt deposits from the

Check that cup plugs and threaded plugs cylinder block are secure and examine cylinder block and sealing surfaces ensure their condition

Measure wear camshaft bearings (compare with nominal

NOTE: the upper surface the cylinder block must the pistons must shortened the same Check the valve plate release the upper surface the piston.

Changing the camshaft bearing bush

1 Pull out the bearing bush with inner removal

When the rear end connecting piece the camshaft has been drive out the bearing bush using a long

Clean the bush

Press a new bearing Note the position the oil The bearing bush does not need reamed, a correctly installed bearing bush has a correct inner diameter

NOTE: All camshaft bearing points have a separate bearing bush. Observe the different outer diameters when moving and pressing the bearing

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The numbering starts the front end the engine.

Oversize bearing bushes for the camshaft the seat the camshaft bearing bush (front bearing) a bearing bush with oversize outer diameter 0,4 can The machining dimensions for the seats the bearing bushes are shown the

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Note the position the oil holes the bearing bushes. (see sectional drawing AThe bearing bushes must not reamed after being inserted

Camshaft oversize bearing bushes

Inserting the plug the rear end the camshaft

Clean the seat for the

Apply sealing material Loctite 572) the contact

Press the plug with the press - tool 380000004

NOTE: not drive plug too far because may otherwise affect the axial

Pressing oversize plug the rear end the camshaft after inserting oversize bearing bush

The standard plug replaced with oversize plug with O - ring seal after working the

Inserting the cylinder liner

Clean the cylinder liner and the liner recess the cylinder The liner must turn freely without O - ring its installed

Apply a thin layer marking colour the bottom the cylinder liner Insert the cylinder liner without O - rings and turn both Pry out the cylinder liner and check whether the coating has deposited over the entire contact

Clean the contact a cylinder liner too low , a liner with a higher flange must inserted. oversize the cylinder liner (higher flange) labelled follows the exterior with one more marking grooves: 0,05 = 1

20. Insert the cylinder liners and fix each liner with two Measure the cylinder liner height with a dial gauge and the holder 380000364 Set the dial gauge a flat surface the cylinder block Measure each cylinder liner four The cylinder liner should protrude from the cylinder block face betweenThe dif ference height between the cylinder liners under one cylinder head must not exceed addition central cylinder liner must lie lower than one the outer ones.

0,10 = 2

22. the liner height a cylinder liner not the same over the entire cylinder liner flange and recess depth the cylinder block must Cylinder liners with deformed flanges must necessary , work the bush seat the cylinder block with a seat cutter . SS99N050

23. Insert O - rings grooves bottom cylinder section and lubricate with liquid soap (not engine

NOTE: When pulling the cylinder stretch the O - rings little The permitted sion 6 % SS05N291

Press the cylinder liners into the cylinder should possible press them easily until they are the initial position. Make sure that the der liners can longer move upwards after being pressed