2. OTC
  3. 1205

OTC 1205 Operating instructions

  • Hello! I've reviewed the provided operating instructions for the OTC Wet Cylinder Sleeve Puller models 1204 and 1205. This document explains how to use the puller to remove cylinder sleeves, including adjustments, bridge installation, slide hammer usage. I am ready to answer your questions about the tool and its usage.
  • What is included in the OTC No. 1204 Wet Cylinder Sleeve Puller?
    What is included in the OTC No. 1205 Wet Cylinder Sleeve Puller?
    What safety precautions should I take when using the Wet Cylinder Sleeve Puller?
    How do you adjust the puller jaws?
Sheet No. 1 of 1
Issue Date: Rev B Sept 16, 2014
© Bosch Automotive Service Solutions LLC
Form No. 104842
Operating Instructions
for: 1204
1205
655 Eisenhower Drive
Owatonna, MN 55060 USA
Phone: (507) 455-7000
Tech. Serv.: (800) 533-6127
Fax: (800) 955-8329
Order Entry: (800) 533-6127
Fax: (800) 283-8665
International Sales: (507) 455-7223
Fax: (507) 455-7063
Website: www.otctools.com
Note:
• TheOTCNo.1204WetCylinderSleevePullerconsistsof
Items1and2asshown.
• TheOTCNo.1205WetCylinderSleevePullerconsistsof
Items1,2,and3.
Wet Cylinder Sleeve Puller
Operating Instructions
1. Remove the cylinder head and pistons from the engine according to
the vehicle service manual.
2. Working from the top of the cylinder block, adjust the puller jaws to the
approximate cylinder bore diameter. This is accomplished by turning
the threaded rod counter-clockwise to expand the jaws or clockwise
to reduce the jaw spread.
3. Position the puller in the cylinder so the jaws are below the bottom of
the cylinder sleeve liner. Turn the threaded screw counter-clockwise
approximately 2-1/2—3 turns. This allows the jaws to engage the
cylinder sleeve liner. While holding the tool in place with one hand,
allow the locking plate to drop down on top of the cylinder sleeve
liner. Secure in place with the locking plate nut.
Warning: Wear eye protection that meets
ANSI Z87.1 and OSHA standards.
4a. Tighten the locking plate nut against the
locking plate to hold the puller in place.
4b. Attach the slide hammer (Item 3) to the
puller and remove the cylinder sleeve liner.
See Figure 2.
4c. If the cylinder sleeve liner will not break
loose from the block, install the adjustable
bridge (Item 2) as shown in Figure 1. Tighten
the bridge nut against the bridge as shown
until the cylinder sleeve liner breaks loose
and protrudes above the block at least 1/2
in. Attach the slide hammer and complete
the pulling job.
No. 1205
4. Install the adjustable bridge (Item 2) as shown in
Figure 1. Tighten the bridge nut against the bridge
as shown until the cylinder sleeve liner breaks loose.
Continue tightening the nut to remove the sleeve from
the engine block.
No. 1204
Adjustable
Bridge Locking
Plate
Bridge
Nut
Locking
Plate Nut
Figure 1
Figure 2
/