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Detailed procedures for cylinder block and liner maintenance and replacement.
Procedure for measuring cylinder liner wear using a dial indicator.
Detailed procedure for fitting cylinder liners, including measurements and alignment.
Instructions for removing and installing the crankshaft rear end seal.
Overview of repair procedures related to the cylinder head.
Step-by-step guide for safely removing the cylinder head from the engine.
Steps for machining damaged valve seats using specialized cutters or grinders.
Instructions for installing valves, springs, and split collets correctly.
Procedure for installing the cylinder head on 309, 311, and 411 engines, including torque specs.
Steps for fitting the cylinder head on 611 and 612 engines, including tightening sequences.
Procedure for checking and reconditioning valve tappets, push rods, and rocker arms.
Steps for removing, inspecting, and replacing the camshaft and its gears.
Procedure for checking and adjusting valve clearances for various engine models.
Procedures for removing, checking, replacing gears, and installing the crankshaft.
Instructions for removing, checking, and replacing connecting rods, pistons, and rings.
Procedure for removing the crankshaft from the engine, including oil draining and component removal.
Instructions for removing and installing crankshaft drive gears.
Procedure for installing the crankshaft, including bearing shells and torque specifications.
Steps for removing the connecting rod and piston assembly from the cylinder.
Procedure for checking connecting rod bearing clearances and replacing bearings.
Methods for inspecting the connecting rod for deflection and wear.
Procedure for inspecting piston rings for side clearance and replacing them.
Visual inspection of the piston and pin, checking for cracks and measuring diameter.
Steps for fitting the connecting rod, piston rings, and piston into the cylinder.
Instructions for fitting the gear housing, including backlash adjustment.
Procedure for installing the coolant pump, including gasket replacement and system filling.
Procedure for installing the turbocharger, ensuring proper lubrication and alignment.
Procedure for bleeding air from the fuel system using the hand pump.
Procedure for checking the injection pump timing using a check pin and timing marks.
Instructions for adjusting injection pump timing based on retard or advance.
Procedure for mounting the injection pump, including lubrication and torque settings.
Procedure for adjusting engine idling speed for the injection pump.
Procedure for adjusting engine idling speed for the injection pump.
Instructions for mounting the injection pump on engines with a right-side compressor.
Procedure for checking and adjusting the injection timing for the Bosch "P" pump.
Detailed instructions for disassembling, cleaning, checking, and reassembling injectors.
Procedure for installing injectors into the engine, including sealing and torque.
General