Overhaul

11. Repeat above procedures for other pistons in turn ensuring that pistons and connecting rods are fitted in cylinder bores from which they were removed.
12. Fit connecting rod bearings. ENGINE - Td5, OVERHAUL, Bearings - connecting rods.

CAUTION: If new pistons, connecting rods or crankshaft have been fitted, it will be necessary to select correct thickness of cylinder head gasket using the following procedures:

13. There are three thicknesses of cylinder head gasket available and in order that the correct gasket is fitted, it is necessary to determine the stand proud (protrusion) of each piston above the top face of the cylinder block. Gaskets have either 1, 2 or 3 identification holes and the following procedures must be followed in order that the correct gasket is selected.
14. Temporarily fit and lightly tighten new crankshaft pulley bolt.

15. Assemble a magnetic base DTI to cylinder block top face adjacent to No.1 cylinder bore.
16. Position stylus to cylinder block top face and zero gauge.
17. Using crankshaft pulley bolt, rotate crankshaft in a clockwise direction until No. 1 piston is at TDC - Woodruff key slot in crankshaft is at 12 o'clock.
18. Position stylus of DTI at rear edge of piston and directly over gudgeon pin axis.
19. Measure and record No.1 piston protrusion.
20. Repeat measurement at front edge of piston.
21. Establish average of 2 readings taken.
22. Repeat above procedures for remaining pistons.
23. From readings obtained, determine HIGHEST piston protrusion figure and select the appropriate cylinder head gasket: l Piston protrusion = 0.351 to 0.50 mm (0.014 to 0.02 in) select the 2 hole gasket l Piston protrusion = 0.501 to 0.57 mm (0.021 to 0.022 in) select the 1 hole gasket l Piston protrusion = 0.571 to 0.65 mm (0.022 to 0.025 in) select the 3 hole gasket
24. Remove the DTI.
25. Remove and retain crankshaft pulley bolt.
26. Fit cylinder head gasket. ENGINE - Td5, OVERHAUL, Gasket - cylinder head.