Removal

Piston Assemblies - Engine Set

Service Repair No - 12.17.03.01

Remove
1. Remove engine and gearbox.
2. Remove cylinder head gaskets.
3. Remove crankshaft rear oil seal.
4. Remove engine sump.





5. Remove oil filter and discard.
6. Disconnect multiplug from oil pressure switch.
7. Remove crankshaft gear.
8. Remove and discard 16 bolts securing oil pump to cylinder block.
9. Release oil pump from locating dowels, remove oil pump and discard gasket.
10. Remove and discard crankshaft front oil seal from oil pump housing.





11. Remove bolt securing oil pickup strainer, remove strainer and discard '0' ring.





12. Remove 9 M8 bolts and 2 M6 bolts securing lower crankcase to cylinder block, release and remove lower crankcase.





13. Measure crankshaft end-float:
14. Position DTI gauge probe onto end of crankshaft as illustrated, push crankshaft away from DTI, zero DTI gauge, push crankshaft in the opposite direction and note reading on gauge.





15. Remove and discard 16 bolts securing bearing ladder to cylinder block.

NOTE: Short length bolts are fitted to the outer edge of the bearing ladder.

16. Release bearing ladder from dowels and remove from cylinder block.





17. Remove main bearing shells and 2 thrust washer halves from bearing ladder, keep in fitted order.





18. Remove LRT-12-144 cylinder liner clamps from cylinder block.





19. Remove 4 dowel bolts and remove big end bearing caps from No.1 and No.2 connecting rods. Keep bearing caps in order.

NOTE: Number stamped below bearing cap bolt is bearing bore size code. Number stamped on connecting rod is cylinder number and letter is weight code.

20. Release connecting rods from crankshaft.
21. Remove bearing shells from connecting rod and cap.
22. Rotate crankshaft, remove bolts securing remaining connecting rod bearing caps and remove bearing shells.
23. Remove crankshaft, remove main bearing shells and thrust washers from cylinder block.
24. With assistance, position cylinder block to enable each piston and cylinder liner to be removed.





25. Carefully push each piston assembly and cylinder liner from cylinder block.

CAUTION: Suitably identify each piston with its respective cylinder liner.





26. Remove piston assemblies from liners, keep liners in their fitted order.
27. Refit caps onto connecting rods, lightly tighten dowel bolts.
28. Piston rings-refit:
29. Fit oil control spring.
30. With 'TOP' or identification markings to top of piston, use an expander to fit piston rings in sequence; oil control, 2nd and top compression.

NOTE: The second compression ring is stepped.





31. Ensure rings are free to rotate, position compression ring gaps A and B at 120° to each other and away from thrust side. Position oil control ring gap C and spring gap D at 30° on opposite side of gudgeon pin axis





32. Cylinder liner bores: Measure wear and taper in two axis 65 mm from top of cylinder liner bore The cylinder liner grade is marked on outside diameter of liner.

CAUTION: Cylinder liners with excessively glazed, worn, scratched or scored bores must be replaced. DO NOT attempt to hone or remove glazing from bore. Ensure that if original liners are to be refitted, reference marks made during dismantling are not erased.





33. Cylinder liners have their bore/grade and step height determined at manufacture. The bore/ grade, red, blue (A) or (B), and step heights V or Z together with the cylinder liner part number and color code are marked on the external diameter of the cylinder liners. If cylinder(s) are to be replaced, the replacement liner(s) must have the same step height as the original liner(s). Both step heights are available in red (A) and blue (B) grades of cylinder liners.
34. Crankshaft big-end journal diameters: Check crankshaft big-end journal diameters and out of round. Renew crankshaft if outside tolerance.





35. Record big-end bearing journal code letters, located on the side of the rear crankshaft web. The first letter, reading from left to right, relates to number one big-end journal.





36. Record big-end bearing bore numbers, this will be 7, 8 or 9 located on the connecting rod bearing cap.
37. Big end bearings selection: Select required bearing shells general data section.