Page 353 of 513

ENGINE
MECHANICAL
Cylinder
head
recess
diameter
For
standard
insert
Intake
Cylinder
head
recess
diameter
mm
in
For
service
insert
For
standard
insert
Exhaust
For
service
insert
Interference
fit
mm
in
Intake
Exhaust
Replacing
the
valve
seat
insert
I
Old
valve
seat
insert
may
be
removed
by
boring
up
to
such
an
extent
that
the
valve
insert
is
collapsed
The
machine
depth
stop
should
be
set
so
that
boring
cannot
be
made
beyond
the
bottom
face
of
the
insert
recess
in
the
cylinder
head
2
Select
a
suitable
valve
seat
insert
and
verify
the
outside
diameter
3
Machine
the
recess
for
the
valve
seat
insert
on
the
cylinder
head
correctly
along
the
concentric
circle
to
the
valve
guide
center
so
that
the
valve
seat
insert
is
fitted
correctly
4
Heat
the
cylinder
head
to
a
temperature
of
1500
to
2000C
3020
to
3920
F
5
Fit
the
valve
seat
insert
ensuring
that
it
beds
on
the
bottom
face
of
the
recess
completely
6
The
valve
seats
newly
fitted
should
be
cut
or
ground
to
the
specified
dimensions
as
shown
in
Figure
EM
44
37
016
to
37
000
dia
1
4576
to
I
4564
dia
37
516
to
37
500
dia
I
4766
to
1
4754
dia
33
016
to
33
000
dia
1
2996
to
1
2990
dia
33
516
to
33
500
dia
1
3196
to
1
3190
dia
0
064
to
0
096
0
0025
to
0
0038
0
064
to
0
096
0
0025
to
0
0038
I
t
v
Al
r
A2
I
onl
J
J
n
llI
lltl
I
G
llW
6
UNIT
mm
in
Al
37
016
to
37
000
dia
1
4576
to
14570
dia
A2
33
016
to
33
000
dia
1
2996
to
1
2990
dia
0
34
7
to
34
5
dia
1
3659
to
1
3581
dia
O2
28
7
to
28
5
dia
I
1299
to
1
1221
dia
1
1
3
0
0512
2
1
8
0
0709
Fig
EM
41
Valve
seat
insert
EM
13
Page 354 of 513

ENGINE
CAMSHAFT
AND
CAMSHAFT
BEARING
Measuring
camshaft
bearing
clearance
Measure
inner
diameter
of
the
camshaft
bearing
and
outer
diameter
of
the
camshaft
journaL
If
camshaft
bearing
clearance
is
excessive
replace
the
cylinder
block
assembly
Limit
0
15mm
0
0059
in
Standard
o
oi
to
0
07mm
M012
to
0
0627
in
Fig
EM
42
Camshaft
bearing
check
1st
2nd
Oil
clearance
mm
in
3rd
4th
5th
1st
Inner
I
2nd
I
diameter
of
I
I
camshaft
3rd
bearing
mm
in
14th
I
15th
I
Standard
0
037
to
0
060
0
0015
to
0
0024
0
027
to
0
050
0
00
to
0
0020
0
040
to
0
063
0
0016
to
0
0025
0
027
to
0
050
0
0011
to
0
0020
0
037
to
0
060
0
0015
to
0
0024
43
833
to
43
843
i
7257
to
I
7261
43
323
to
43
333
l
7050
to
1
7060
42
836
to
42
846
1
6865
to
1
6868
42
323
to
42
333
1
6663
to
1
6667
41
258
to
41
268
1
6243
to
1
6247
Wear
limit
0
15
0
0059
1
1
1
1
Valve
timing
If
the
camshaft
has
no
apparent
damage
although
some
valve
troubles
have
been
detected
compare
valve
timing
data
with
the
valve
timing
diagram
to
ensure
that
beginning
and
ending
of
stroke
for
all
cylinden
are
complying
with
specified
advance
and
retard
figures
T
D
C
DIRECTION
OF
ROTATION
INTAKE
B
D
C
Fig
EM
43
Valve
timing
diagram
Unit
degree
a
b
e
f
d
c
248
248
14
54
12
56
Checking
camshaft
for
bending
Check
the
camshaft
camshaft
journal
and
cam
surface
for
bend
wear
or
damage
If
defective
condition
exceeds
the
limit
replace
the
defective
part
s
2
Apply
a
dial
gauge
to
the
center
journal
turn
the
camshaft
and
read
the
dial
gauge
Actual
bend
is
a
half
of
the
value
indicated
on
the
dial
gauge
Standard
Bend
limit
Camshaft
bend
mm
in
0
015
0
0006
0
05
0
0020
EM
14
Page 355 of 513

ENGINE
MECHANICAL
Bendin9
limit
0
05mm
0
0020
in
Standard
0
of5mm
0
0006
in
or
less
Fig
EM
44
Camshaft
bend
check
Standard
height
of
cam
mm
in
36
45
to
36
55
I
435
to
I
439
Wear
limit
of
cam
height
mm
in
0
5
0
0197
Allowable
difference
in
diame
ter
maximum
worn
and
mini
mum
worn
parts
of
camshaft
journal
mm
in
0
03
to
0
07
0
0012
to
0
0028
Maximum
tolerance
in
journal
diameter
mm
in
0
1
0
0039
Camshaft
end
play
mm
in
0
02
to
0
08
0
0008
to
0
0031
CYLINDER
BLOCK
Check
the
cylinder
head
visually
for
defects
such
as
cracks
and
flaws
2
Measure
the
top
of
the
cylinder
block
cylinder
head
mating
face
for
warping
If
the
warp
exceeds
the
limit
correct
it
EM
15
Standard
Maximum
tolerance
Surface
flatness
less
than
mm
in
0
05
0
0020
0
1
0
0039
Distortion
limit
0
10mm
0
0039
in
Standard
0
05mm
0
0020
inLor
less
Fig
EM
45
Cylinder
block
surface
check
3
Measure
the
cylinder
bore
for
out
of
round
and
wear
with
a
bore
gauge
If
wear
or
out
of
round
is
excessive
rebore
the
cylinder
walls
by
means
of
a
boring
machine
Wear
limit
0
2mm
0
0079
Fig
EM
46
Measuring
the
cylinder
bore
4
When
wear
or
out
of
round
is
minor
and
within
the
limit
remove
the
step
from
the
topmost
portion
of
the
cylinder
by
the
use
of
a
ridge
reamer
or
other
similar
tooL
Page 356 of 513

ENGINE
How
to
measure
cylinder
bore
A
bore
gauge
is
used
Measure
the
cylinder
bore
at
tup
middle
Jnd
bottom
positions
in
A
and
B
directions
as
illustrated
in
Figure
EM47
and
record
the
measured
values
101o
1
50
1
9691
10013
94
EB
UNIT
mm
in
Fig
EM
47
Cylinder
bore
measuring
positions
Standard
Wear
limit
Cylinder
bore
mm
in
73
0S0
to
73
000
2
8760
to
0
2
0
0078
2
8740
Error
in
cylinder
bore
elliptic
taper
mm
in
less
than
O
OIS
0
0006
Difference
in
cylinder
bore
mm
in
O
OS
0
0020
0
2
0
0079
Boring
cylinder
When
any
of
the
cylinder
needs
boring
all
other
cylinders
must
also
be
bored
at
the
same
time
2
Select
an
oversize
piston
according
to
amount
of
wear
of
the
cylinder
EM
16
Piston
for
senrice
Outside
diameter
H
mm
in
STD
72
967
to
73
017
2
8727
to
2
8747
Piston
size
so
73467
to
73
517
2
8924
to
2
8994
oversize
100
73
967
to
74
017
2
9121
to
2
9140
oversize
ISO
74467
to
74
S17
2
9318
to
2
9337
oversize
3
By
measuring
piston
to
be
installed
at
piston
skirt
side
thrust
face
and
adding
the
mean
of
clearance
specification
the
finish
hone
cylinder
measurement
can
be
determined
EM126
Fig
EM
48
Measuring
the
piston
diameter
Page 357 of 513

ENGINE
MECHANICAL
5
M
co
El
co
I
ED
I
UNIT
mm
in
Fig
EM
49
Measuring
points
Outer
diameter
of
piston
skirt
measured
value
A
Piston
eylinder
clearance
B
0
023
to
0
043
mm
0
0009
to
0
0017
in
Boring
allowance
C
0
02
rom
0
0008
in
Cylinder
bore
to
be
machined
A
B
C
A
om
to
0
02
mm
0
0004
to
0
0008
in
4
Machine
the
cylinder
bore
to
the
determined
inner
diameter
Note
To
prevent
strain
due
to
cutting
heat
bore
in
order
of
2
4
3
or
cylinders
3
4
2
5
Do
not
intend
to
bore
in
one
time
but
cut
0
05
rom
0
0020
in
or
so
at
a
time
6
When
measuring
cylinder
bore
immediately
after
boring
note
that
the
cylinder
block
is
expanded
due
to
cutting
heat
7
Finish
the
treated
cylinder
bore
to
the
final
size
by
means
of
honing
8
Measure
the
finished
cylinder
bore
for
a
elliptic
or
tapered
part
9
Measure
clearance
between
the
piston
and
cylinder
This
clearance
can
be
checked
easily
by
using
a
feeler
gauge
and
a
spring
scale
EM
17
Feeler
gauge
0
03mm
0
0012
in
Pull
force
o
5to
5kg
11
to3
3
lb
i
Fig
EM
50
Piston
to
cylinder
clearance
check
Standard
clearance
rom
in
0
023
to
0
043
0
0009
to
0
0017
0
03
0
0012
Feeler
gauge
mm
in
Extracting
force
kg
Ib
0
5
to
1
5
1
1
to
3
3
Note
If
the
cylinder
bore
is
worn
beyond
the
wear
limit
use
the
cylinder
liner
Undersize
cylinder
liners
are
available
for
service
Interference
fit
of
cylinder
liner
Cylinder
block
0
8
to
0
9
mm
0
0315
to
0
0354
in
Cylinder
liner
for
service
400
undersize
Outside
diameter
mm
in
77
05
to
77
00
3
0330
to
3
0310
77
55
to
77
50
3
0530
to
3
0510
78
05
to
78
00
3
0730
to
3
0710
72
5
to
72
6
2
854
to
2
858
Inner
diameter
mm
in
72
5
to
72
6
2
854
to
2
858
450
undersize
72
5
to
72
6
2
854
to
2
858
500
undersize
Page 358 of 513

ENGINE
PISTON
PISTON
PIN
AND
PISTON
RING
Check
for
seizure
scratch
and
wear
Replace
as
required
o
10
e
O
I
l
Fig
EM
51
Piston
and
connecting
rod
assembly
2
Measure
side
clearance
of
each
piston
ring
and
ring
groove
with
the
piston
ring
installed
on
the
piston
Clearance
of
a
new
piston
and
piston
ring
should
be
as
follows
EM129
Fig
EM
52
Side
clearance
measurement
EM
18
Side
clearance
Standard
Wear
limit
mm
in
mm
in
Top
ring
0
04
to
0
Q7
02
0
0079
0
00
5
to
0
0027
2nd
ring
0
04
to
0
07
0
0015
to
0
027
0
2
0
0079
Oil
ring
0
04
to
0
08
0
0015
to
0
0031
I
0
2
0
0079
Ring
gap
Standard
Wear
limit
mm
in
mm
in
Top
ring
0
2
to
0
35
1
0
0
0394
0
0079
to
0
0138
2nd
ring
0
2
to
0
35
1
0
0
0394
0
0079
to
0
0138
Oil
ring
0
3
to
0
9
1
0
0
0394
0
01
8
to
0
0354
3
Place
the
ring
at
the
bottom
of
the
ring
traveled
part
of
cylinder
bore
in
which
it
will
be
used
Square
ring
in
bore
by
pushing
it
into
position
with
the
head
piston
Measure
gap
between
ends
of
ring
with
feeler
gauge
Gap
should
be
as
listed
above
Fig
EM
53
Ring
gap
measurement
Page 359 of 513

ENGINE
MECHANICAL
Note
8
When
the
piston
ring
only
is
to
be
replaced
without
the
cylinder
bore
being
corrected
measure
gap
at
the
bottom
of
the
cylinder
where
the
wear
is
minor
b
Oversize
piston
rings
are
available
for
service
50
100
150
oversize
4
Measure
the
piston
pin
hole
in
relation
to
the
outer
diameter
of
the
pin
If
wear
exceeds
the
limit
replace
such
piston
pin
together
with
the
piston
on
which
it
is
installed
Piston
pin
diameter
mm
in
17447
to
17452
0
6869
to
0
6871
65
23
to
65
48
2
5681
to
5
779
Piston
pin
length
mm
in
Piston
pin
hole
dia
meter
mm
in
17460
to
17453
0
6874
to
0
6871
5
Fitting
of
piston
pin
Determine
the
fitting
of
the
piston
pin
into
the
piston
pin
hole
to
such
an
extent
that
it
can
be
rmger
pressed
at
room
temperature
This
piston
pin
must
be
tight
press
fitted
into
the
connecting
rod
EM131
Fig
EM
54
Piston
pin
fitting
EM
19
g
1
EM132
Fig
EM
55
Measuring
piston
pin
diameter
Piston
pin
to
piston
clearance
mm
in
0
006
to
0
008
0
0002
to
0
0003
Interference
fit
of
piston
pin
to
connecting
rod
mm
in
0
020
0
0008
CONNECTING
ROD
If
a
connecting
rod
shows
any
scratch
or
score
mark
or
is
pitted
on
both
sides
of
the
thrust
face
and
the
large
end
correct
or
replace
it
EM133
Fig
EM
56
Connecting
rod
aligner
2
Check
for
bend
or
torsion
using
a
connecting
rod
aligner
If
bend
or
torsion
exceeds
the
limit
correct
or
replace
the
connecting
rod
Page 360 of 513

ENGINE
Standard
IMaXimum
Connecting
rod
bend
or
torsion
per
100
mm
or
3
94
in
length
mm
in
o
os
0
0020
0
07
0
0028
0
1
0
0039
bend
torsion
3
When
replacing
the
connecting
rod
select
the
rod
so
that
weight
difference
between
new
and
old
rods
is
within
S
gr
0
18
oz
in
unit
weight
4
Install
connecting
rods
with
bearings
on
to
the
corresponding
crank
pins
and
measure
the
thrust
clear
ance
If
the
measured
value
exceeds
the
limit
replace
such
connecting
rod
Stan
dard
Maximum
Big
end
play
mm
in
0
2
to
0
3
0
0079
to
0
Ql18
0
4
0
0IS7
l
8ig
end
plav
A
t
f
L
Fig
EM
57
Big
end
play
check
CRANKSHAFT
Check
the
crankshaft
journal
and
crank
pin
for
scars
biased
wear
and
cracks
Repair
or
replace
as
required
EM
20
27
00
to
27
05
1
063
to
1
065
19
1Ot01940
r
19
10t019
40
fO
752
to
0
764
Ii
10
75Z
to
0
764
I
c
1
r
1tf
1
I
J
X
I
34
97
to
35
03
t
11
377
to
1
379
49
951
to
49
964
dia
11
9666
to
1
96711
ALL
MAIN
BEARING
JOURNALS
Fig
EM
58
Crankshaft
Standard
Taper
out
of
round
of
crank
journal
and
crank
pin
mm
in
0
01
0
0004
44
961
to
44
974
die
11
7701
to
1
7706
ALL
CRANK
PINS
UNIT
ffim
in
Maximum
0
03
0
0012
2
Check
the
crankshaft
for
bend
If
the
bend
exceeds
the
limit
replace
the
crankshaft
Bending
limit
0
05mm
0
0020
in
Standaia
0
015mm
0
0006
in
or
less
Fig
EM
59
Crankshaft
bend
check