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166

8 INFORMATION ABOUT OVERHAULING

8.1 Recommendations for overhauls and tuning

 The information is laid out in sequence, according to operational requirements, and the intervention

methods have been selected, tested and approved by the manufacturer's

technicians.

 This chapter describes procedures for checking, overhauling and tuning units and/or individual

components.

NOT E : To easily locate specific topics, the reader should refer to the analytical index or chapter index.

 Before any intervention, the operator should lay out all equipment and tools in such a way as to

enable him to carry out operations correctly and safely.

 The operator must comply with the specific measures described in order to avoid errors that might

cause damage to the engine.

 Before carrying out any operation, clean the units and/or components thoroughly and eliminate any

deposits.

 Do not wash the components with steam or hot water. Use suitable products only.

 Do not use flammable products (petrol, diesel, etc.) to degrease or wash components. Use suitable

products only.

 Dry all washed surfaces and components thoroughly with a jet of air or special cloths before

reassembling them.

 Apply a layer of lubricant over all surfaces of all disassembled components to protect them against

oxidation.

 Check the integrity and state of wear of all disassembled components in order to ensure good

working condition of the engine.

 When indicated, some components are to be replaced in pairs or together with other parts (e.g.

crankshaft half-bearings/connecting rod, piston complete with rings and gudgeon pin, etc.).

 When indicated, some grinding operations are to be carried out in series (e.g. grinding of cylinders,

crankpins, journals, etc.).

Kohler KDI 1903 TCR Workshop Manual

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