Project context
The engine was overhauled in a workshop in Papeete, with new engine internals installed and retained components inspected. Crankshaft machining, component reconditioning and measurement checks formed part of the overhaul scope.
Crankshaft and engine internals
- Crankshaft machining and installation with new bearings, including checks of the bearing housings, journals and assembled bearing bores
- New cylinder liners, pistons and connecting rods, together with bearings and bushes
- New camshaft bearings, bushes and tappet guides
- New rocker arms complete with bushes
- New oil-pump bushes and bearings for the coolant-pump, oil-pump and raw-water-pump idler gears
- Renewal of all oil relief valves
Cylinder heads and injectors
The cylinder heads and fuel-injection pumps were overhauled. The injectors were reconditioned with new nozzles and springs, and fuel-injection timing was set during assembly.
Cooling, turbochargers and auxiliary components
The raw-water and freshwater pumps and turbochargers were overhauled and fitted during the rebuild. The damper was stripped and inspected, the Geislinger assembly was stripped and inspected with its bearings renewed, and the thermostat was tested before installation.
Documented assembly checks
The assembly report records component measurements, fits and clearances throughout the rebuild:
- Crankcase main-bearing bores, bearing-cap screw projection, crankshaft journal dimensions and assembled bearing clearances
- Cylinder-liner fits and bores, piston crown and skirt dimensions, piston-to-liner clearances, ring gaps and piston projection at top dead centre
- Connecting-rod bores, big-end bearing dimensions, piston-pin and small-end bush fits
- Camshaft, tappet-guide, rocker-arm and oil-pump bearing fits, plus idler-gear bearing dimensions and axial clearances
Documented overhaul and assembly
The overhaul brought together new engine internals, reconditioned cylinder heads and fuel-system components, and overhauled cooling and turbocharger equipment. The build records document component identification, measurements and fitting checks across the crankshaft, cylinder assemblies, valve gear and auxiliary drives.