Usage:
Start By:
a. remove spacer plate
b. remove oil pump
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life. |
1. Turn the crankshaft until two of the pistons are at bottom center. Remove two rod cap bolts (1) from each rod. Remove rod caps (2).
2. Using a soft hammer, tape rod (3) away from crankshaft and remove bearing half (4).
3. Use Tool (A) to remove cylinder liners (6).
4. Remove piston and connecting rods from the cylinder liners.
Install Cylinder Liners
Cylinder Liner Projection
NOTE: This procedure alleviates the need for the "H" bar to hold liners during projection measurements.
1. Install clean liners or cylinder packs (without the filler band or the rubber seals), spacer plate gasket and clean spacer plate.
2. Install bolts and washers, as indicated above, in the holes indicated with an X. Install all bolts or the six bolts around the liner. Tighten the bolts to a torque of 95 N·m (70 lb ft).
3. Use Tool (B) to measure the liner projection at four positions. Place tool next to each hold down bolt and record the measurement. Record measurements for each of the four cylinders and divide by four to find the average.
4. If the liner projections are out of specification, try rotating the liner or install the liner in another bore to see if the measurements improve.
5. Do not exceed the maximum liner projection of 0.175 mm (.0069 in). Excessive liner projection will contribute to liner flange cracking.
6. With the proper liner projection, mark the liners in the proper position and set them aside.
7. When the engine is ready for final assembly, the O-ring seals, cylinder liner block and upper filler band must be lubricated before installation.
8. If the lower O-rings are black in color, apply liquid soap on the lower O-ring seals and the cylinder block. Use clean engine oil on the upper filler band.
9. If the lower O-rings are brown in color, apply clean engine oil on the lower O-ring seals, the cylinder block and the upper filler band.
NOTE: Apply liquid soap and/or clean engine oil immediately before assembly. If applied too early, the filler bands may swell and be pinched under the liners during installation.
10. Put liquid soap on bottom liner bore in block, on grooves in lower liner and on O-ring seals on the liner.
11. Put filler band (5) in clean SAE 30 oil for a moment and install on liner. Install cylinder pack immediately in the cylinder block (before expansion of filler band).
Typical Example
12. Make sure the mark on liner is in alignment with the mark on the block. Use Tooling (A) to push the liner into position.
13. Repeat Steps 1 through 3 for the remainder of the cylinder liners.
14. Install the pistons and connecting rods. Refer to the topic "Pistons & Connecting Rods" in this manual.
End By:
a. install oil pump
b. install spacer plate