Dadi. Engine 4G64 S4M. Service Manual — part 4
11-43
ENGINE
CYLINDER HEAD AND VALVE
DISASSEMBLY AND ASSEMBLY
Disassembly Procedure
1. connecting rod nut
2. connecting rod cap
3. connecting rod bearing
4. piston and connecting rod cluster
5. connecting rod bearing
6. first air ring
7. second air ring
8. oil ring
9. piston pin
10. piston
11. connecting rod
12. connecting rod bolt
All inside parts must be
coated with engine oil
6EN0526
G
F
A
E
D
E
C
C
B
A
B
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11-44
ENGINE
CYLINDER HEAD AND VALVE
Main Points in Disassembly
Disassembly of Connecting Rod Cap
(1)
Mark the cylinder No. on the side face of the larger end of the
connecting rod so as to ensure the correct assembly.
(2)
Put aside the dismantled connecting rod, connecting rod cap
and connecting rod bearing in order as per the cylinder No.
marked on.
Disassembly of Piston Pin
(1)
Insert the SST of compression bar from the side with arrow
mark at the piston top, then mount the guide block C at the end
of compression bar.
(2)
Keep the mark for forward face of the piston to face upwardly,
and mount the piston and connecting rod cluster on the base
seat (SST) of the assembler of piston pin.
(3)
Press the piston pin out with the pressure.
Notice:
Put aside the dismantled piston, piston pin and connecting
rod as per the cylinder No. marked on.
A
B
cylinder No.
DEN0050
Assembler for Piston Pin MD998780
pressing rod guide block B
conduit A=17.9mm
conduit A=18.9mm
conduit A=20.9mm
conduit A=21.9mm
guide block C
base seat
pressing rod
mark for forward
face
guide block C
base seat
mark for
f o r w a r d
face
7EN0390
7EN0431
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11-45
ENGINE
CYLINDER HEAD AND VALVE
Main Points for Mount
Mount of Piston Pin
(1)
Measure the following dimensions of the piston, piston pin
and connecting rod;
A) Length of inserting hole of the piston pin;
B) Width between the keyway
C) Length of piston pin
D) Width of smaller end of connecting rod.
(2)
Calculate the dimension L by substituting the letters in the
below formula with the measured dimensions:
L
[(A C)(B D)] / 2
(3)
Insert the SST of compression bar in the piston pin and mount
the conduit A at the end of compression bar.
(4)
Conduct the assembly in such way that the mark for forward
face on the piston is in the same direction with that of the
connecting rod.
(5)
Coat the engine oil on the outside diameter of the piston pin.
(6)
Encase the piston pin, connecting rod and conduit cluster
assembled as Step (3) in the piston pin hole at the side with
mark for forward face with conduit A.
(7)
Screw the guide block B in the conduit A and ensure the
clearance between the guide block B and the guide block A is
the value of the sum of L calculated in Step (2) plus 3 mm..
(8)
Maintain the state that the mark for forward face of piston
faces upwardly, and mount the piston and connecting rod
cluster on the base seat of the assembler of piston pin.
(9)
Press in the piston pin with pressure. If the pressure force is
less than the standard value, Change the piston pin and the
piston cluster, or/and change the connecting rod.
Standard value: 750
1750kg
A
piston
piston pin
connecting rod
A
B
C
D
7EN0432
3mm+L
guide block B
conduit A
7EN0433
compression bar
piston pin
mark for forward face
mark for
f o r w a r d
face
conduit A
conduit B
base seat
7EN0391
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11-46
(10)
Check whether the piston can rotate freely.
Mount of oil ring
(1)
Put the main ring of oil ring in the oil ring groove.
Remark:
1. The scraper blade and the main ring has the specified upper./lower
face.
2. The new main ring and scraper are colorful to identify its dimension.
(2)
Put in the upper scraper blade. When mounting the scraper blade,
press one end of the scraper blade in the piston oil ring groove, then
press the remaining part of scraper blade in the oil ring groove
shown as the figure by thumb.
Different from other piston ring, the use of ring pliers to expand the
scraper blade will break the scraper blade.
Notice:
Do not use the ring pliers to expand the scraper blade.
(3)
Mount the lower scraper blade in the same procedure of Step (2).
(4)
The scraper blade should be confirmed whether can rotate freely
to left and right after the mount.
Mount of First and Second Air Ring
(1)
The first air ring should be mounted after the second air ring is
mounted with the ring pliers.
Remark:
1. There is identification mark at the ring end.
Identification mark:
First ring
1R
Second ring
2R
2. Mount the piston ring and be sure the identification mark should face
upwardly to the top of the piston.
3. The dimension marks of piston ring are as follows:
6EN0 298
upper scraper blade
main ring
lower scraper blade
6EN1019
Dimension
Identification Color
Standard value
None
0.50mm larger
Red
1.00mm larger
Yellow
clearance of scraper blade
1EN0269
C
Dimension
Dimension mark
Standard value
None
0.50mm larger
50
1.00mm larger
100
ring pliers
7EN0452
identification mark
identification mark
direction mark
first ring
second ring
9EN0524
B
ENGINE
CYLINDER HEAD AND VALVE
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11-47
upper scraper blade
crankshaft
pulley side
openings of second and
main rings
lower balde
6ENO549
D
Mount of Piston and Connecting Rod Cluster
(1)
Coat enough engine oil on the piston, air ring and oil ring.
(2)
Adjust the openings of the air ring and oil ring (scraper blade
and the main ring) to the place shown in the figure.
(3)
Rotate the crankshaft until the crank pin locates the position of
the cylinder hole.
(4)
Threaded protective device should be adopted on the connect-
ing rod bolt before the insertion of the piston and connection
rod cluster in the cylinder. Carefulness is needed not to
damage the crank pin.
(5)
Insert the piston and connecting rod cluster in the cylinder
with the suitable press fitting SST for piston ring.
Notice:
There is a mark for forward face on the top of piston, which should
direct to the front of the engine (timing toothed belt side).
Mount of Connecting rod bearing
Where the bearing is needed to change, it should be selected and
mounted as per the following procedure.
(1)
Measure the outside diameter of the crank pin and determine
which group it belongs as per the following form, the crank-
shaft to be maintained should be marked at the position shown
in the figure with color paint to identify its dimension.
(2)
The identification mark of the connecting rod is printed at the
position shown in the figure.
Inside diameter of connecting rod; 48.000
48.015mm
(3)
Select the bearing from the group determined as per the Step
(1) and (2).
Bearing Selection, for example:
In case the outside diameter of the crank pin is measured as 44.
996mm, it belongs to the Group 1 in the above form. If the
repairing element for crankshaft needs to be changed, inspect
the identification color coated on the new crank pin. If the
color is yellow, the crank pin should belong to the first group,
therefore, the connecting rod bearing marked with
1
should be selected.
E
timing toothed belt
mark for forward face
1EN0247
NO.1
NO.2
NO.3
NO.4
6EN0700
6AE0115
identification mark
Crank pin
Connecting rod bearing
Yellow
44.995
45.000
1
Yellow
1.487
1.491
None
44.985
44.995
2
None
1.491
1.495
White
44.980
44.985
3
Blue
1.495
1.499
Identification
color
Outside
diameter
(mm)
Identification
mark
Identification
color
Thickness
(mm)
Group
ENGINE
CYLINDER HEAD AND VALVE
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11-48
Mount of Connecting Rod Cap
(1)
When mounting the connecting rod cap, align the marks made
in disassembly well, if mounting the new member without
mark, the anti-rotary gap shown in the figure should be
mounted at the same side
(2)
Be sure the axial clearance at the larger end of connecting rod
is suitable.
Standard value: 0.10
0.25mm
Limit value: 0.4mm
Mount of Connecting Rod Nut
Notice:
In case the cylinder head is mounted before the mount of
connecting rod cap, dismantle the spark plug and then
mount on the connecting rod cap nut.
(1)
The connecting rod bolts and nuts should be tightened with the
method of tightening bolt at plastic zone. Before reusing the
bolt, check whether the bolt is expanded. Inspection method:
tighten the nut to the threaded part of the bolt by hand until it
passes the full thread. In case the nut cannot be screwed down
to the bottom, it can be judged the threaded part of the bolt may
be protracted, change the bolt on such condition.
(2)
Coat the oil on the threaded part and the seat face of the nut
before tightening the nut.
(3)
Tighten the nut on the bolt by hand and then screw the nuts down
in turns so as to assemble the connecting rod cap correctly.
(4)
Tighten the nut with the torque of 20N.M.
(5)
Coat the paint mark on each nut head.
(6)
Make paint mark on the bolt at the position 90
100
forward from the paint mark at nut head.
(7)
Tighten the nut by a angle of 90
100, until the marks on
the nut and the bolt are in alignment.
Notice:
If the screwing angle is less than 90, the tightening
property specified is cannot be guaranteed. Therefore,
attention should be paid to the screwing angle when
tightening.
In case the nut is over tightened, (the screwing angle is
more than 100
), loosen it thoroughly, and then re-
tighten it from the Step (1).
F
G
cylinder No.
anti-rotary gap
DEN0051
6EN0621
paint
marks
paint marks
90
100
6AE0298
ENGINE
CYLINDER HEAD AND VALVE
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11-49
Inspection
Piston Ring
(1)
Check whether the piston ring has damage, over abrasion
or breakage, if it has, change it, in the case of changing the
piston, the piston ring needs to be changed too.
(2)
Check the clearance between the piston ring and the piston
ring groove, if it is over large, change the piston ring or the
both parts.
Standard value: 0.02
0.06mm
Limit value: 0.1mm
(3)
Put the piston ring in the cylinder and locate it with the
crown face of the piston, then measure the opening clear-
ance with the feeler. If the opening clearance is over large,
change the piston ring.
Standard value:
First ring
0.250.35mm
Second ring
0.400.55mm
Oil ring
0.100.40mm
Limit value:
First and second ring
0.8mm
Oil ring
1.0mm
Play of Crank Pin (clearance gauge of plastic cord)
(1)
Clear away the oil on the journal and bearing of the
connecting rod thoroughly.
(2)
Cut the clearance gauge of plastic cord in the length that is
the same with the bearing width, and then put them on the
crank handle and parallel them with the axial center line.
(3)
Mount on the connecting rod cap carefully and tighten the
nut as per the specified torque.
(4)
Dismantle the connecting rod cap carefully.
(5)
Measure the max width of the flattened plastic cord with
the gauging ruler printed on the package bag of the clear-
ance gauge of plastic cord, thus obtaining the clearance
value.
Standard value: 0.02
0.05mm
Limit value: 0.1mm
5EN0066
press it in with piston
priston ring
opening clearance
5EN0548
1EN0246
clearance gauge of plastic cord
1EN0271
ENGINE
CYLINDER HEAD AND VALVE
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11-50
ENGINE
CYLINDER HEAD AND VALVE
CRANKSHAFT, CYLINDER BLOCK AND
FLYWHEEL
DISASSEMBLY AND ASSEMBLY
13
5
6
3
2
11N.m
132N.m
8.8N.m
4
11N.m
11
10
9
8
7
25N.m+90
~100
12
Smear the engine oil on
all moving parts
N
Disassembly Procedure
1. flywheel bolt
2. flywheel
3. rear cover plate
4. bell jar
5. rear oil seal cap
6. oil seal
7. main bearing cap bolt
8. main bearing cap
9. low bearing of crankshaft
10. crankshaft
11. bearing on crankshaft
12. thrust bearing of crankshaft
13. cylinder block
E
D
C
C
B
B
A
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11-51
ENGINE
CYLINDER HEAD AND VALVE
Inspection
Measurement for Crankshaft Play (clearance gauge of plastic
cord)
(1)
Clean the oil on the main journal and the inner race of bearing.
(2)
Mount the crankshaft.
(3)
Cut the clearance gauge of plastic cord in the length that is the
same with the width of bearing, then put them on the crankshaft
journal and ensure them are parallel with the axial center line.
(4)
Mount the main bearing cap carefully and tighten the bolts as
per the specified torque.
(5)
Tear down the main bearing cap.
(6)
Measure the Max width of the flattened plastic cord with the
gauging ruler printed on the package bag of the clearance
gauge of plastic cord, thus acquiring the clearance value.
Standard value: 0.02
0.04mm
Limit value: 0.1mm
Cylinder Block
(1)
Conduct a visual observation for deflects such as scoring, rust
and corrosion, etc. or conduct an inspection with the fluid
testing agent. In case the cylinder block has obvious deflect,
repair or change it.
(2)
Check the plane on cylinder block for warp with ruler and
feeler, and be sure there should be no washer scraps or other
alien materials on the surface.
Standard value: 0.05mm
Limit value: 0.1mm
(3)
In case the cylinder block has over large warp, change or
correct it within the permitted range.
Grinding limit: 0.2 mm
The max sum of thicknesses of the cylinder block and
cylinder head that is permitted to cut out is 0.2 mm.
Height of cylinder block (new): 290mm
(4)
Check whether the cylinder wall has scoring or the cylinder is
seized, in case the requirement is not met, correct (enlarge the
dimension) or change them.
(5)
Measure the inner cylinder and cylindricity of the cylinder
with the cylinder gauge, the cylinder should be corrected by
enlarging the diameter on condition the abrasion is serious,
and change the piston and piston ring. Measurement positions
are shown in the figure below.
Standard value:
Inside diameter of cylinder: 86.50
86.53MM
Cylindricity:
0.01mm
clearance gauge of
plastic cord
6EN0703
6EN0623
9EN0074
12mm
center
bottom
6EN0553
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11-52
ENGINE
CYLINDER HEAD AND VALVE
thrusting
direction
piston diameter
6EN0554
6EN1557
Re-boring of Cylinder Diameter
(1)
The diameter for the enlarged piston should be determined
according to the max cylinder diameter.
Identification of piston diameter
Remark: Dimension mark is printed on the top of piston.
(2)
Measure the diameter of the cylinder to be used, the measure-
ment should be conducted in the thrusting direction shown in
the figure below.
(3)
Calculate the reparation dimension of the cylinder diameter
according to the outside diameter of the piston.
Reparation dimension = outside diameter of piston +
(clearance between piston and cylinder)
0.02 mm
(hone grinding)
(4)
Repair each cylinder to the dimension of reparation.
Notice:
When honing the cylinder, in order to prevent the error
caused by the increased temperature, conduct the reparation
as the order below: No.2
No.4 No.1 No.3
(5)
Hone the cylinder to its final diameter (piston diameter +
clearance between the piston and cylinder).
(6)
Check the clearance between the piston and the cylinder.
Standard value: 0.02
0.04mm
Remark:
When repairing the cylinder, the four cylinders should be in the
same dimension, do not only enlarge one cylinder.
Main Points of Mount
Mount of Thrusting Bearing of Crankshaft
(1)
Mount the thrusting bearing of crankshaft (2 sheets) on the 3rd
main shaft hole of cylinder block. Coat a little engine oil on the
surface of thrusting bearing to facilitate the mount.
(2)
The thrusting bearing side with groove should face to the
handle arm of the crankshaft.
dimension
Identification mark
Plus 0.50
0.50
Plus 1.00
1.00
A
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11-53
ENGINE
CYLINDER HEAD AND VALVE
No.3
No.2
No.1
No.4
No.5
6EN0705
identification mark for dimension of main bearing
No.1
No.2
No.3 No.4
No.5
identification
mark of main
bearing hole
dimension mark
of cylinder in-
side diameter
sub-face of cylinder
block
rear end face of cylinder
block
6EN1632
identification mark or color for crankshaft bearing
identification mark or color
6EN1096
groove
upper
lower
6EN1558
Mount of crankshaft bearing
(1)
Select the bearing that meets the dimension of crankshaft main
journal as per the form below.
B
Bearing Selection, for instance:
In case the identification color of the crankshaft main journal is
yellow, and the identification mark for main shaft aperture is
1, select the Bearings of No. 1,2, 4 and 5 with identification
mark
2 and identification color yellow or the No. 3
bearing with identification mark
1 and identification color
green.
In case there is no identification paint on the crankshaft, measure
the main journal and select the corresponding bearing as per the
measured value.
(2)
Mount the bearing with groove at the side of cylinder block.
(3)
Mount the bearing without groove at the side of main bearing
cap
0
1 Green
0 Black
Yellow 56.994
57.000
1
2 Yellow
1 Green
2
3 None
2 Yellow
0
2 Yellow
1 Green
None
56.988
56.994
1
3 None
2 Yellow
2
4 Blue
3 None
0
3 None
2 Yellow
White
56.982
56.988
1
4 Blue
3 None
2
5 Red
4 Blue
Combination of crankshaft main journal and
main shaft aperture
I d e n t i f i c a t i o n
marks and colors
for bearings of
Journal 1,2 and 5
Identification
marks and
colors for
bearings of
No 3 journal
Crankshaft main journal
Identification
mark of main
shaft aperture
Groups
Identifica-
tion color
Diameter
(mm)
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11-54
6EN0624
arrow mark
ENGINE
CYLINDER HEAD AND VALVE
9EN0477
paint marks
paint marks
90
100
6AE0299
6EN0625
Mount of Main Bearing Cap/ Main Bearing Bolt
(1)
Mount the main bearing cap with the arrow mark thereof
directing to the side of timing toothed belt.
(2)
Be sure the length of bolt is less than the limit value before
mounting the main bearing cap bolt. In case it is larger than the
limit value, change the bolt.
Limit value (A): 71.7 mm
(3)
Coat the engine oil on the threaded part and seat face of the
bolt.
(4)
Tighten the main bearing cap bolt with the torque of 25N.m as
per the specified sequence.
(5)
Make paint mark on each bolt head.
(6)
Screw down the paint mark at the position of the main bearing
cap by 90
100forward from the paint mark on bolt.
(7)
Tighten each bolt by 90
100in the above specified se-
quence until the paint marks on the bolts are in alignment with
that on the main bearing cap.
Notice:
If the screwing angle is less than 90, the tightening
property specified is cannot be guaranteed. Therefore,
attention should be paid to the screwing angle when
tightening.
In case the nut is over tightened, (the screwing angle is
more than 100
), loosen it thoroughly, and then re-
tighten it from the Step (1).
(8)
Ensure the crankshaft can rotate smoothly after the main
bearing cap is well mounted, and inspect the axial clearance.
In case the axial clearance exceeds the application limit value,
change the No.3 crankshaft thrusting bearing.
Standard value; 0.05
0.18mm
Limit value: 0.25mm
C
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11-55
ENGINE
CYLINDER HEAD AND VALVE
MD990938
MD998376
6EN0709
6EN0626
Mount of Oil Seal
Mount of Rear Oil Seal Cover
Specified sealant
Brand: Genuine Mitsubishi brand sealant MD970389 or the
equivalents.
Notice:
(1)
The rear oil seal cover should be mounted quickly on the
condition the sealant is not dry (
15 min).
(2)
Keep the sealing area free from the lubricant and coolant for
1 hours or so after the mount.
D
E
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11-56
ENGINE
AC GENERATOR
AC GENERATOR
1
6
5
4
2
3
7
8
9
10
11
12
13
DISASSEMBLY AND ASSEMBLY
Disassembly Procedure
1.
generator pulley
2.
rotor assembly
3.
rear bearing
4.
bearing block
5.
front bearing
6.
front cap
7.
stator assembly
8.
retaining plate
9.
adjustor and brush stand
10. brush
11. ring
12. rectifier assembly
13. rear cap
A
A
A
B
9EN0187
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11-57
ENGINE
AC GENERATOR
6EN1774
1EN0300
rectifer
soldering joint
DEL0009
6EN0603
6EN0604
NOTES FOR DISASSEMBLY
SEPARATION OF STATOR AND FRONT CAP
(1)
Insert the screwdriver into the gap between front cap and stator
to separate the front cap from the stator.
(2)
If it is hard to separate them, lightly hit the front cap with a plastic
hammer and prize it with screwdriver at the same time.
NOTES:
Don't insert the screwdriver too deep lest the stator winding
is damaged.
DISASSEMBLY OF GENERATOR PULLEY AND ITS FAN
(1)
With the pulley end upwards, disassemble the pulley after fixing
the rotor with a bench clamp.
NOTES:
Do not damage the rotor.
DISASSEMBLY OF STATOR ASSEMBLY, ADJUSTOR
AND BRUSH STAND
(1)
Knock down the stator with an electric iron (180
250W), such
operation should be finished within 4 seconds lest heat is con-
ducted to the diode.
(2)
While disassembling rectifier from adjustor, burn off the part
welded to the rectifier with the electric iron.
Ensure not to conduct the heat generated by the electric iron
to the diode for a long time.
Do not let the diode pin overburden forces.
CHECK
ROTOR
(1)
Check whether the rotor winding is switched into conduction and
confirm conduction exists between the slip-rings. Measure the
resistance of the rotor. If the resistance is too low, it means the
circuit is shorted . If there exists non-conduction or short circuit,
replace the rotor assembly.
Standard value: 3
0.5
(2)
Grounding of rotor winding. Check if it is insulated between the
slip-ring and iron core, if not, replace the rotor assembly.
A
B
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11-58
ENGINE
AC GENERATOR
3EN0208
3EN0209
7EL0011
7EL0012
7EL0012
STATOR
(1)
Conduct on stator examination over the stator and confirm
whether the conduction exists with the lead-wire of the winding,
if not, replace the stator assembly.
(2)
Check the grounding of stator winding. Confirm whether con-
duction exists between the winding and stator iron core, if yes,
replace the stator assembly.
RECTIFIER
(1) Check the positive rectifier
Check whether conduction exists between the positive rectifier
and the wiring terminals of stator windings with a multimeter. If
conduction exists in two direction , the diode is breakdown, the
rectifier assembly should be replaced.
(2)
Check the positive rectifier
Check whether conduction exists between the negative rectifier
and the wiring terminals of stator windings. If conduction exists
in two direction, the diode is breakdown, the rectifier assembly
should be replaced.
(3)
Check diodes group (3 diodes)
Connect the two ends of the diode to the ammeter, check whether
these three diodes are switched into conduction.
If conduction doesn
t exists bidirectioinally, the diodes are
damaged, and the radiator assembly should be replaced.
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