REPAIR INSTRUCTIONS, PART 2
Page 273
This is to ensure that the copper sleeve tapping
tool does not damage the piston due to tool
length.
Ensure the turning tool is well greased before
attempting to turn the flywheel.
4. Adjust the 9 mm tap so that it extends a
minimum of 25 mm or 1 inch (dimension A)
from the end of the tapping tool.
395
Figure 395 — Copper Sleeve Tapping Tool
This ensures that the tip of the copper sleeve is
tapped all the way through.
If the copper sleeve is not completely tapped
through to the opening of the tip, an end piece of
the tip can break off and fall into the cylinder
during removal.
5. Lubricate the tip of the 9 mm tap with
grease.
Applying grease will capture copper cuttings and
prevent them from falling down into the cylinder.
6. Thread the tap in small increments. Remove
the tap and wipe off the grease and copper
sleeve shavings. Apply fresh grease,
reinstall the tapping tool and thread more of
the copper sleeve. Continue this process to
thread the tap all the way through the copper
sleeve until no resistance is felt and the tap
turns freely. Tapping in small increments and
removing the shavings minimizes the
chance of shavings falling into the cylinder
and the sleeve turning in the cylinder head.
Ensure that the tap is completely through the
copper sleeve.
396
Figure 396 — Tapping Tool Installation
If threads are not cut completely through the tip of
the copper sleeve, the tip can break off and fall
into the cylinder. This can result in damage to the
cylinder, piston, valves or turbocharger.
7. Remove the tap and tapping tool.
8. Using the chip vacuum, remove any
remaining shavings from the copper sleeve.
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