Crankshafts with Pluigs (page 4 of 4)

seal/shim fitted. This requires that the liners are pushed into the cylinder block under pressure. The workshop uses a special appliance as shown in Fig. 1.34. The same operation: can, however, be carried out under a large drilling machine. Important is that the liners are pushed fully down. The maximum protrusion to April 1989 must not exceed 0.14 mm, after this date it must not exceed 0.10 mm. Also measure the difference between two adjacent liners. Proceed in a similar manner as described earlier on, but place the dial gauge stylus onto the shoulders of two adjacent liners. If the difference is more than 0.04 mm, replace the seal/shim of the liner with the higher protrusion.

• After all liners have been measured in the manner described, secure them in position with the clamps.
• Assemble the pistons and connecting rods and fit the pistons into the cylinder liners as described later on.
• Insert the big end bearing shells in accordance with the markings into the con rods (if the original shells are used). The tabs on the shells must enter the locating recesses in the connecting rods. Fit the bearing caps to the connecting rods and tighten the bolts to 4.0 kgm (30 ft.lb.). Refer to “Pistons and Connecting Rods” for details of fitting direction, piston rings, etc.
• Lubricate the camshaft journals with engine oil and insert the shaft into the cylinder block. Insert the keeper plate into the groove of the camshaft, align the plate with the threaded bores of the cylinder block and insert and tighten the two bolts to 1.7 kgm (12.5 ft.lb.).
• Place a new paper gasket over the cylinder block and attach the intermediate plate to the block (1.0 kgm/7.5 ft.lb.).
• Slide the double timing sprocket over the end of the crankshaft with the Woodruff key entering the groove. The timing mark must be positioned on the outside.
• Rotate the crankshaft and the camshaft until the timing marks in the two