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Workshop Manual KD 441_cod. 1.5302.865_2
Injector protusion
The end of nozzle A should protrude from the cylinder head plane :
Adjust with copper gaskets B with thickness of 0.5, 1 and 1.5 mm
Cylinder
Set a bore gauge to zero with a calibrated ring.
Check diameter at 1, 2 and 3; repeat the operation at the same points
after turning the bore gauge 90°.
If wear exceeds the max. given value by 0.05, bore the cylinder and fit
oversize piston and rings.
See table "Piston and cylinder dimensions" for cylinder diameter values.
Important
Protect the contact surfaces with lubricating oil, to prevent them
from rusting.
Caution – Warning
Do not manually hone the cylinder bore surfaces with emery
cloth or other means.
Cylinder roughness
The cross-hatch pattern should be at an angle of 45°-55°; lines
should be uniform and clear in both directions.
Average roughness must range between 0.35 ÷ 0.60 µm.
The cylinder surface which comes into contact with piston rings
should be machined with the plateau method.
Piston
Remove circlips and piston pin.
Measure diameter Q at the A distance from the skirt bottom (A=12
mm).
Replace the piston and piston rings if wear on the diameter is 0.05 mm
more than the minimum value given (see table).
Note: Oversize pistons of 0.50 and 1.00 mm are available.
Ø Cilinder
86.000÷86.015 85.905÷85.920
nd
ed_ rev. 01.
Overhauls and checking
mm
3.00 ÷ 3.50
Piston and cylinder dimensions (mm)
Ø Piston
5
Wear limit
0.08÷0.11
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