Engine - Overhaul Instructions: Engine: Caulking

Operation Number(s):

Fig 1: Bearing Housing, Cylinder Block And Intermediate Section

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On engines manufactured of aluminum the camshaft bearing housing (1) cylinder block (2) and the intermediate section (3) may be caulked.

NOTE: The cylinder heads that are chill-cast may not be caulked.

Each individual case is assessed as to whether caulking can be carried out or not depending on the location of the oil leakage.

Fig 2: Identifying Center Punch And Rounded Tips

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Caulking involves in the event of leakage knocking the material together using a special caulking tool.

Two caulking tools are required. Use center punches (1). Grind down the tips so they become round. One is to be ground so the rounded tip (A) is 2 mm. The other is ground so the rounded tip (B) is 4 mm.

NOTE: Use the protective goggles supplied with the leak tracing kit.

Use: Isopropanol, 1161721

Use an UV light to localize the pore. Carefully wash round the pore with Isopropanol. Check with a UV light that all the oil has been removed.

Fig 3: Identifying Tool Angle And Pores

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WARNING: Use protective goggles.

If the pore is small, it is sufficient to place the tool (2 mm) directly on the pore and hit it with a copper or plastic hammer. If the pore is larger, angle the tool (2 mm) and drive the material in a circle toward the pore (2). If there is a lip around the pore, caulking (tool 4 mm) should be carried out in a spiral form toward the pore (3).

Fig 4: Driving Material Toward Pore Using 2 mm Tool

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Drive the material toward the pore (1) using the 2 mm tool. Seal using the 4 mm tool (2).

Use: Isopropanol, 1161721

Wash with Isopropanol. Check with a UV lamp that there is no oil around the leakage point.

Test drive for 45 minutes as set out below to reach an oil temperature of about 80°C.

Allow the engine to idle for 20 minutes.
Test drive the car for 15 minutes.
Allow the engine to idle for a further 10 minutes.

Check using a UV light that the sealed area no long leaks. If leakage remains, repeat the caulking.