automobile petrol engine overhaul sinhala

47
Petrol Engine Overhaul 1 mgq k Page Number 01) Micrometer Set hkq 5 - 6 02) Cylinder Gauge Set hkq 7 03) fmg%,a tka ðula hkq 8 04) jdykfha ÿu u.s ka foda I yÿkd.eksu 9 05) Compression Test 10 06) tka csula .e,ùug fya ;= 12 07) wjYH wdjq o yd WmlrK 13 08) tka ýu .,jk ms<s fj, 14 09) tka cs fï we;=<; fldgia .e,ùu 15 i. ms ia gka .e,ùu 16 ii. Gudgeon pin .e,ùu 17 iii. Crank Shaft .e, ùu 18 10) .e,jq fldgia ms ßis ÿ ls ßu 19 11) tka cs fuka .e,jq fldgia mßlaId ls ßu 20 - 32 i. Crank shaft tl ueks u 20 - 21 ii. Connecting Rod mßlaIdj 22 iii. is ,s kavr n`o mßlaIdj 23 iv. is ,s kav¾ fnda ¾ mßlaIdj 24 v. is ,s kav¾ fnda rh ueksu 25

Upload: upul-priyashantha

Post on 21-Apr-2017

4.351 views

Category:

Automotive


680 download

TRANSCRIPT

Petrol Engine Overhaul

1

mgqk

Page Number

01) Micrometer Set hkq 5 - 6

02) Cylinder Gauge Set hkq 7

03) fmg%,a tkaðula hkq 8

04) jdykfha ÿu u.ska fodaI yÿkd.eksu 9

05) Compression Test 10

06) tkacsula .e,ùug fya;= 12

07) wjYH wdjqo yd WmlrK 13

08) tkaýu .,jk ms<sfj, 14

09) tkacsfï we;=<; fldgia .e,ùu 15

i. msiagka .e,ùu 16

ii. Gudgeon pin .e,ùu 17

iii. Crank Shaft .e, ùu 18

10) .e,jq fldgia msßisÿ lsßu 19

11) tkacsfuka .e,jq fldgia mßlaId lsßu 20 - 32

i. Crank shaft tl ueksu 20 - 21

ii. Connecting Rod mßlaIdj 22

iii. is,skavr n`o mßlaIdj 23

iv. is,skav¾ fnda¾ mßlaIdj 24

v. is,skav¾ fndarh ueksu 25

Petrol Engine Overhaul

2

vi. Main Bearing mßlaIdj 26

vii. tkacska ysi w¿;ajeähdj 27

viii. Valve Seats mßlaIdlsßu 28

ix. Cam shaft mßlaId lsßu 29

x. Valve yd Spring mßlaId lsßu 30 - 31

xi. is,skav¾ ysi mßlaIdj 32

12) tkacsug o.rlo iúlsßu 33

i. Oil clearance 34

ii. Main Bearing iúlsßu 35 - 36

iii. msiagka iy msiagka j,¨ fhosu 37 - 38 - 39

iv. msiagka is,skavrhg we;=,alsßu 40

13) tkacska nfoys wfkl=;a fldgia iúlsßu 41

i. .Eialgh iy is,skavr ysi iúlsßu 42

ii. Cam shaft iúlsßu 43

iii. Rocker arm iúlsßu yd Oil seal fhoSu 44

14) jE,aj uq¾:kh ;eìu 45 - 46

i. Adjusting Valve Clearance 47

15) tkacsfuys ndysr fldgia ish,a,

isúfldg tkacsu mk.ekaùu 48 - 49

Petrol Engine Overhaul

3

Micrometer Set

fuu ñkqï WmlrKh u.ska ñ,sñgrfhka isfhka tlla ;rug

ksjeros f,i ueksh yel¡ fuh Micrometer tl fõ¡ fuu WmlrKfha

ueksh yels wju yd Wmßu ÿrla we;¡ tu m%uK fjkia WmlrK

lÜg,hla f,i fuh we;¡

1) 0 - 25mm 2) 25 - 50mm 3) 50 - 75mm 4) 75 - 100mm 5) 100 - 125mm 6) 125 - 150mm

fuu WmlrKfhka ñkqï lghq;= lsßug fmr fuys uQ,dxl fodAI

ksjeros lr.; hq;=h¡ t ioyd 25 - 50mm kï 25mm Rod tlo 50 -

75mm kï 50mm Rod tlo f,i l=v ñkqfï Rod tl Micrometer

tl w;rg oud Rachet tl ;o l< hq;=h (Rod tlg ;o ù lÜg

;=kla jefgkd yv wefik f;la) 50 - 75mm kï Main scale tl

50lgo Venire scale tl 0 f,i isák fia lrljd iod.; hq;=h¡

fuys ñkqï lghq;= lsßugkï ueksug wjiah foa ñkqu .ek o,

wjfndaOhla ;sìu myiqfjka fuu lghq;a; bgqlr.eksug iyh fõ¡

ueksug wjiah foa 20mm muK tlla kï uQ,dxl fodaI ksjeros lr.;a

0 - 25mm Micrometer tl f.k tu ueksug wjiah foa Micrometer

tl w;rg oud Rachet lrlj Main scale yd Venire scale tl

lshúu u.ska tu foa ksjerosj uek.; yel¡

Petrol Engine Overhaul

4

Main scale

Main scale = 12 = 0.50 Venire scale = 0.16 = 12.66

Venire scale Main scale 0.50

Main scale = 16 = 0

Venire scale = 35 fyd 36 f,i b;d

wdikak w.hg

.;hq;=h¡ = 16. (35 fyd 36)

Main scale = 7 = 0.50

Venire scale = 0.26 = 7.76

Petrol Engine Overhaul

5

Cylinder Gauge Set

fuu WmlrKh msiagka fnda¾ tfla f.úï iy ;e,sï

ueksu ioyd fhdod.ks¡ wmg wjYH 71mm m%udKfha fndarhla

ueksugkï t ioyd Cylinder Gauge tl72mm j,g tl,eia

lr.; hq;=h¡ ta ioyd 70mm Spacer tl iy 2mm Shim tl fhdo Cylinder Gauge tl,eia lr.; hq;=h¡ bkamiqj

Micrometer tlla wdodrfhka Cylinder Gauge tfla Dial tl

71mm j,g 0 lr.; hq;=h¡ túg ueksfï lghq;a; lr.;

yel¡

Cylinder Gauge Dial tfla f,dl= lgqj jghla hkúg

l=vd lgqj tl mm hhs¡ úúO m%udKfha fndar ueksu ioy

m%uK lsysmhl Spacer yd Shim we;¡

Petrol Engine Overhaul

6

fmg%,a tkaðula hkq¡

tkacsula kï lerl=ï n,hla ksmojkakls¡ tkacsulg fhdok

bkaok u; yd tys ieleiau u; tkacska j¾. 2g fnfoa¡ tkï fmg%,a

tkacska iy ãi,a tkacska fõ¡

fmg%,a tkacsul l%shdldß;ajh fufiah¡

fmg%,a gexlsfha isg fmg%,a fmdïmhla wdodrfhka Carburetor hg

weoS tk fmg%,a jd;h;a iu. hï wkqmd;hlg ñY% ù Intake Manifold tl yryd Intake Valve tl újD; jk wjia;dfõ is,skavrh ;=<g weoS

hhs¡ tysos bkaok ñY%kh oykh ù ,efnk Yla;sfhka msiagkh T.D.C

isg B.D.C olajd .uka lrjhs¡ tu Yla;sh Connecting rod yryd

Crank Shaft tlg ,eì tu.ska Fly Wheel tl lrlefõ¡ tu Yla;sfhka

hï m%udKhla Fly Wheel tfla ;ekam;a fjhs¡ isõ myr tkacsul n,

myrla ,efnkafka myr ;=klg miqjh¡ fuu n, myr fkd,;a wjia;d

;=kysos Fly Wheel tfla ;ekam;a ú we;s Yla;sh u.ska tkacsu lrlefõ¡

Petrol Engine Overhaul

7

jdykfha ÿu u.ska fodaI yÿkd.eksu¡

ks,a ÿu

oil oykh ùu ksidh¡ thg fya;=j jkqfha Intake valve tfla Ths,a

iS,a ijq;a;= ùu ksid fyd msiagka Ring, msiagka is,sjq f.úu ksid

úh yel¡

l¨ ÿu

jd;h wvq ùu¡ fmg%,a jeä ùu¡ Compression ldkaÿ úu (msiagka

Ring, msiagka is,sjq f.úu) ksid úh yel¡

iqÿ ÿu

Advance / Retard úu ksid¡ (kshñ; wxYl .kfkaos Spark fkdùu) Timing belt j, fodAI¡

Petrol Engine Overhaul

8

Compression Test Dry Compression Test

1) Battery fydo ;;ajfha ;sfnoehs ne,su¡ 2) Drive belt fydo ;;ajfha ;sfíoehs ne,su¡ 3) j;=r " Ths,a ldkaÿ ;sfíoehs ne,su¡ 4) Petrol Engine tl l%shd ldß WIaK;ajhg tk;=re mk.kaj

;sìh hq;=h¡ 5) Air Cleaner tl .e,ùu¡ 6) Head bolt ksIamdlh os we;s w.hg ;o l, hq;=h¡ tkcsu

mk .ekaúug fkdyelskï ksIamdlh Cold wjia:dfõ os we;s

w.hg ;o l< hq;=h¡ 7) Valve Clearance mßCIdj¡ 8) tkacsu iagdÜ fkdúug j.n,d .eksu¡ Fuel cut ( Fuel cut off

solenoid l%shd úrys;) lsßu¡ 9) Ignition Cut cut (Distributor tlg we;s jh¾ .,jd bj;a

lsßu) 10) Spark plug ish,a, .e,úu¡ 11) Compression Test WmlrKh Spark plug iú ù ;snq

ia:dkj,g iïnkao lsßu¡

12) Accelerator tl fiñka Wmßu jrla m.d w;eßu¡

13) Stroke 5la 7la muk fudagrh l%shd;aul lsßu¡ 14) Compression WmlrKfha w.h lshjd .ekSu¡

4G32 Engine compression test result

Cylinder No 1 2 3 4

Pressur

Kg/cm

13 13 13 13

Petrol Engine Overhaul

9

Compression Test lsßug úfYaIs; WmlrKhla ndú;d lrhs¡ th Compression Gauge kï fõ¡

Compression Gauge

Compression gauge WmlrKfhka Spark plug iúfldg ;snq

;ekg iïnkao fldg mßlaId lsßfuos tys w.h nd¾ 10;a 16;a w;r

w.hl ;sìh hq;=h¡

m,uq msiagkfha Compression w.h yd fojk fyd wkla msiagka

j, Compression w.h w;r nd¾ 2g jvd jeä fjkila we;akï

tkacsfï Vibration we;¡

nd¾ 10g jvd wvq Compression w.hla ;sfíkï tkacsfï fodaIhla

we; (f.úula)¡ th Piston rings f.úula ksid úh yel¡ th ksjerosj

yÿkd.eksug Wet Compression text tllg hd hq;=h¡

Wet Compression text

Spark plug iúù ;snq ia;dkfhka is,skavrh ;=,g Ths,a

iaj,amhla oeñh hq;=h túg Piston rings w;rg Ths,a f.dia ;rul

Seal úula isÿfõ¡

kej;;a Compression gauge WmlrKh iïnkao fldg mßlaId

fldg ne,sh hq;=h¡ Compression w.h jeä úula we;kï Piston rings j, fodaIhla we;¡ tfia lsisÿ fjkila fkdjkafkakï fjk;a

fodaIhla ksid úh yel¡

Petrol Engine Overhaul

10

tkacsula .e,ùug fya;=

tkacsfï YíOh fjkia ùu¡

ks,a mdg fyda l¨ ÿu msg ùu¡

tkacsu Over heat ùu¡

mk .ekaùfï wmyiqj¡

fmg%,a jeämqr oykh ùu¡

tkacska Ths,a wvq ùu¡

msiagka Rings j, fodaI¡

Crank shaft leäu fyda weo ùu¡

Petrol Engine Overhaul

11

wjYH wdjqo yd WmlrK

idudkH wdjqo fmÜáh

tkacsu .e,úu iy iúlsßug wjYH úfYaI wdjqo iy Wmlrk

Micrometer set

Cylinder gauge set

Dial gauge

Torque wrench

Straight edge

Connecting rod Test gauge

Valve spring tester

Plastic gauge

Petrol Engine Overhaul

12

tkaýu .,jk ms<sfj,

tkacsfï Ths,a bj;a lr.eksu¡

negß jh¾ .e,ùu¡

my; fldgia ms,sfj,ska .,jd.; hq;=h¡

1) Air cleaner 2) Carburetor

3) Inlet manifold

4) Exhaust manifold

5) Water tube

6) Fuel feed pump

7) High tension wires

8) Ignition coil

9) Distributor

10) Spark plug

11) Starter motor

12) Fan belt

13) Alternator

14) A/C compressor with bracket

15) Engine mount with bracket

16) Crank pulley with damper

17) Timing belt upper cover

18) Timing belt lower cover

Timing belt tl .e,ùug fmr Cam tl;a Crank tl;a Engine Bloke tfl;a fyda Belt tfl;a i,l=kq lr.;

hq;=h¡

19) Tensioner

20) Timing belt

21) Camshaft sprocket

22) Crank shaft sprocket

23) Water pump

24) Tappet cpver

25) Bell housing cover

Petrol Engine Overhaul

13

tkacsfï we;=<; fldgia .e,ùu¡

tkacsfï gemÜ ljrh m%:ufhka .,jd .; hq;=h¡ bkamiq my;

fldgia .,jd .; hq;=h¡

Rocker arm and shaft assembly

Cam shaft assembly

fuu fldgia .,jd .;a miq tkacska Hade tl .,jd .; hq;h¡

t ioyd Hade tfla w;s weK ueo isg fome;a;g l;sr yevhg

.,jd.; hq;=h¡

bkamiqj tkacska nfoa we;s¡

1. Front case assembly

2. Fly wheel

3. Rear plate

4. Rear oil seal case

hk fldgia .,jd .; hq;=h¡

Petrol Engine Overhaul

14

msiagka .e,ùu¡

tkacsfï tla tla msiagka fjk fjku .,jd msiagka j, yd

Connecting rod j, msiagka wxlh i,l=Kq lr.; hq;=h¡ tfukau

msiagka iúlr ;snq osYdj Bearing retaining lugs iúlr ;snq osYdjo

i,l=Kq lr.; hq;=h¡

Petrol Engine Overhaul

15

Gudgeon pin .e,ùu

tkacsfuka msiagka .e,jq miq msiagka w; weo ú woaoehs ne,sug

msiagkfhka msiagka w; .,jd .; hq;=h¡ fu ioyd Hydraulic press

tlla iy Piston pin setting tool kï úfYaI WmlrKhla nú;d lrhs

fõ¡ msiagka w; .e,úug fmr msiagkfha Rings ish,a,d .eúh hq;=h¡

tioyd ßka tlaiamekavrhla nú;d l< hq;=h¡ tfukau msiagka wf;a

msiagka wxlh i,l=Kq fldg weoaoeh n,sh hq;=h¡

Piston pin setting tool tfla Push rod tl msiagka mska tl ;=,g

w;=,a lsßu

fuu msiagkh yd Push rod tl Piston pin setting tool tfla

kshñ; wdldrfhka ;eìu

fuu tl,i Hydraulic press tl u; ;nd press lrk

w;r;=r msiagkh fomig fid,jd ne,sh hq;=h¡ msiagkh

fi,úfuos ;o .;shla wef;d;a kej; Hydraulic press tflka

.,jd kej; press l< hq;=h¡

Petrol Engine Overhaul

16

Crank Shaft .e, ùu¡

tkacsfï ish¨u msiagka .,jq miq Main bearing cap .e,jkq ,nhs¡

Bearing cap .e,ùfuos fomi isg ueog ueog ms<sfj,ska .,jd .;

hq;=h¡ bearing cap .,úfuos Cap wxlh yd Cap tl iújk osYdj

i,l=Kq fldg weoaoehs n,sh hq;=h¡ ke;skï i,l=Kq oud.; hq;=h¡

Crank Shaft tl .e,ùug fmr End play tl mßlaId lr ne,shhq;=h¡

Petrol Engine Overhaul

17

.e,jq fldgia msßisÿ lsßu

tkacsfuka .e,jq ish¨u fldgia fydoska msßisÿ l< hq;=h¡ rn¾

fldgia yer wksl=;a fldgia fiaosu ioyd äi,a fhdod.;a yel¡ rn¾

fldgia j;=frka mukla fidaohs¡ äi,a j,ska fiaÿ fldgiao j;=frka

fidaod composer tlla wdodrfhka yq,x w,a,d úh,d .; hq;=h¡

tkacsfuka .e,jq fldgia mßlaId lsßu

tkacsula .,jk w;r;=r;a .e,jq miqj;a ish¨u fldgia mßlaId lr

ne,sh hq;=h

weoùï

msmsÍï

wosl f,i f.ù heï

Main journal yd Big end

journal úYalïNh

hk fldgia uekSï lr ñkqu ,nd.ekSfuka fldgia j, ;;ajh ms,sno

ks.ukhlg meñk tjg ms,shï fhosh yel¡

Petrol Engine Overhaul

18

Crank shft tl ueksu

tkacsfuka .,jd.;a Crank shaft tfla Main journal yd Big end

journal úYalïNh uek.;a hq;=h¡ tu.ska fldmuk f.ù weoaoehs

n,d thg ms,shï fhosh yelsh¡ fuu ñkqï lrkqfha Micrometer

tllska fyda Venire caliper tllsks¡ ñkqï lghq;= lsßug fmr

ieuúgu Micrometer tfla uQ,dxl fodaI iod.; hq;=h¡

Mitsubishi Lancer 4G13 Petrol Engine tfla ksIamdos; Main

journal yd Big end journal úYalïNh¡

Main Journal Big End Journal

S.T.D S.T.D 48mm 42mm 0.25us 0.25us

0.50us 0.50us

0.75us 0.75us

Petrol Engine Overhaul

19

Mitsubishi Lancer 4G13 Petrol Engine

Inspection

Main

journal

1

2

3

4

5

A B A B A B A B A B

AA 47.98 mm

47.99 mm

47.98 mm

47.99 mm

47.99 mm

47.99 mm

47.99 mm

47.97 mm

47.99 mm

47.98 mm

BB 47.97 mm

47.98 mm

47.98 mm

47.98 mm

48 mm

48 mm

47.98 mm

47.98 mm

47.98 mm

47.98 mm

Big end

journal 1

2

3

4

A B A B A B A B

AA 41.98 mm

41.98 mm

47.98 mm

41.99 mm

41.98 mm

41.98 mm

41.98 mm

41.98 mm

BB 41.98 mm

41.98 mm

41.98 mm

47.97 mm

41.99 mm

41.98 mm

42 mm

41.99 mm

Petrol Engine Overhaul

20

Connecting Rod mßlaIdj

tkacsfuka .,jd.;a ish¨u Connecting rod mßlaId l< hq;=h¡

fu ioyd Connecting rod test gauge kï WmlrKh nú;d lrhs¡

msiagkfhka .,jd.;a Connecting rod j,g kej; Gudgeon

pin tl mukla Piston pin setting tool wdodrfhka kej; we;=,a lr.;

hq;=h¡ bkamiqj Connecting rod tl test gauge tl u; iúlr V

Gide tl t u; ;nd Measuring plate tl yd Test pin w;rg peeler

gauge tl we;=,a lr weoùï (Bend) yd weUßï(Twist) uek.; yel¡

ksIamdolh fuu weUßï (Twist) iy weoúï (Bend) j, Wmßu w.hla

oS we; t Wmßuhg jvd jeäkï w¨;a Connecting rod tkacsu ioyd

fhdod.; hq;=h¡

Petrol Engine Overhaul

21

is,skavr n`o mßlaIdj

is,skav¾ n`o u;=msg ;,fha weoùï mßlaId l< hq;=h¡ fu ioy

Straightedge yd Feeler gauge hk Wmlrk fhdod.ks¡

is,akav¾ nfoa u;=msgg (tkacska ysi iújk) yryd Straightedge

;nd Straightedge tl yd is,skav¾ nfoa u;=msg w;r we;sjk ysvi

w;rg Feeler gauge tl oud uek.eksu isÿlrhs¡ fuu weoùï j,g

ksIamdolhd Wmßu w.hla oS we;¡

Standard value 0.05mm

Limit 0.1mm

Grinding Limit 0.2mm

Cylinder block height 255.9 – 256.1mm

fuu w.hkag jvd jeä weohla mj;skï is,skavr n`o Face l<

hq;=h¡ bkamiqj fhdok Gasket fuu Face l< m%udKh;a tl;=lr

fhdod.; hq;=h¡ ke;skï Combustion chamber tl l=vd ú .eg¨

we;súug bv lv we;¡

Petrol Engine Overhaul

22

is,skav¾ fnda¾ mßlaIdj tkacsfuys we;s is,skav¾ fnda¾ l%shdldß;ajh;a iu. l%ufhka

f.ú hhs¡ fuu f.úï isÿjkafka Piston ring .uka lrkd m%foaYfhah¡

Piston ring .ukalrkd ÿrys ia:dk ;=klska Cylinder gauge kï

úfYAI WmlrKh wdodrfhka ñkqï ,nd.; hq;=h¡ is,skavrh f.ú

we;akï fnda¾ Wmlrkfhka Ok w.hl=;a ;e,sï we;akï iDK w.hl=;a

nefí¡ fuu w.hka ksIamdolh os we;s w.hka iyu. ieiosfuka fndrh

f.ù we;soehs ne,shy yel¡

Mitsubishi Lancer 4G13 Petrol Engine

STD 71.00mm

O/S1 0.25mm 71.25mm

O/S2 0.50mm 71.50mm

O/S3 0.75mm 71.75mm

O/S4 1.00mm 72.00mm

is,aka¾ ;=,ska jeäu f.úula we;s msiagka fndarh f;dard t wkqj iÿiq b,.

fnda¾ w.hg ish¨ is,skavrhka fnda¾ lrhs¡ ksIamdolh w.hka 3la os we;

71.25mm \ 71.50mm \ 71.75mm fõ¡

Petrol Engine Overhaul

23

is,skav¾ fndarh ueksu

1) fnda¾ tfla ksIamdos; w.h fidhd.; hq;=h¡ uekqj,a tl

wdodrfhka fyda jksh¾ le,smrhla is,skav¾ fndarfha by, Piston

ring .uka fkdlrk m%foaYhg oud uek.; yel¡

2) 4G13 petrol engine tfla fndarh 71mm fõ¡ fuu fndarh ueksu

iodyd Cylinder gauge tl 72mm tl,eia lr.; hq;=h¡

fuu.ska fndarfha ;e,sï iy f.úu folu tljr uek.; yels

fõ¡ Cylinder gauge tl 72mm tl,ia lr.eksu ioyd 70mm

distant spensr tl yd 2mm Shim tl fhdod Cylinder gauge

tl,i iod.; hq;=h¡

3) Micrometer (uq,dxl fodi ioy ;sìh hq;=h) tlla wdodrfhka

Cylinder gauge tl,i 71mm j,g Dial tl 0 lr.; hq;=h¡

4) fndarhg Cylinder gauge tl we;=,a fldg ia:dk ;=klska ñkqï

6la ,nd.; hq;=h¡

Sylinder

No

1

2

3

4

Position A B A B A B A B

AA + 71.03 mm

+ 71.02 mm

+ 71.03 mm

+ 71.02 mm

+ 71.02 mm

+ 71.03 mm

+ 71.03 mm

+ 71 mm

BB + 71.03 mm

+ 71.02 mm

+ 71.02 mm

+ 71.03 mm

+ 71.02 mm

+ 71.03 mm

+ 71.03 mm

- 69.99 mm

CC + 71.03 mm

+ 71.02 mm

+ 71.02 mm

+ 71.03 mm

+ 71.02 mm

+ 71.03 mm

+ 71.03 mm

+ 71 mm

Petrol Engine Overhaul

24

Main Bearing mßlaIdj

ish¨u Bearing caps fydoska msßisÿ l< hq;=h¡ bkamiq kshñ;

wxl yd osYdj n,d Bearing caps iúlr.;hq;=h¡ tu Bearing caps

iúlsßfuos fnhdßka m¨ rys;j iúl< hq;=h¡ fuu Bearing caps

kshñ; Torque tlg ;o l< hq;=h (Tightening torque 5.0– 5.5kgm).

bka miq Cylinder gauge tl wdodrfhka uõ fndarh (parent bore) f.ú

weoaoehs ne,sh hq;=h¡ tjd f.ú we;akï Line bore lr ksjeros l<

hq;=h¡

Petrol Engine Overhaul

25

tkacska ysi w¿;ajeähdj

tkacsfï ysi w¨;ajeähd lsßfïos tys we;s Valve ish,a, .,jd .;

hq;=h¡ Valve .e,ùug m%;ufhka Valve ish,a,f.au is,skav¾ wxl i,l=Kq

lr.; hq;=h¡ fuu Valve .,úu ioyd installing retainer lock kï

WmlrKh nú;d lrhs¡ Valve yd Springs ish,a, .,jd.;a miqj tjd

äi,a fyd Nqñf;,a oud fidod.; hq;=h¡ rn¾ fldgia j;=frka mula fiaosh

hq;=h ke;skï tajdg ydks úh yel¡ bka miq Valve guide f.ú we;aoehs

uek ne,sug ksIamdos;h os we;s w.hka yd iiod ne,sh hq;=h¡ tjd f.ù

we;akï w¨;a Valve tkacsu ioyd fhosh hq;= fõ¡

Standard Valve (Clearance) Limit Intake 0.02 – 0.05mm In 0.010mm Exhaust 0.05-0.09mm Ex 0.15mm

Petrol Engine Overhaul

26

Valve Seats mßlaIdlsßu

Valve Seats mßlaId lsßfïos Valve Seats kshñ; mßos

fkd;snqkfyd;a tu f.ú we;s Valve Seats kej; kshñ; fldaKhg

wkqj ilid.; hq;=h¡ fuf,i kshñ; fldaKhg w¨;ajeähd lsßu

ioyd úfYaYs; WmlrKhla we; th Valve seat vutter kï fõ¡ fuh

Wmfhda.s lrf.k w¨;ajeähd lghq;= lrkq ,efí¡

mßlaIdlr ilid.;a Valve ish,a, fhÿ wxl ms<sfj,g kej;

iúlr.; hq;=h¡ bkamiqj Valve uqyqk;a ksueosu isÿl, hq;=h (Valve

seat lapping)¡ bkamiqj ish¨u fldgia kej; fidaod Valve ksismßos

iúlr tjdfha ldkaÿ weoaoehs mßlaIdlr ne,sh hq;=h¡

Petrol Engine Overhaul

27

Cam shaft mßlaId lsßu

Engine head tflka Cam shaft .e,jq miq tys weoùï yd tys

Journal f.ú we;aoehs uek ne,sh hq;=h¡

Standard Limit Journal diameter 45.925-45.940mm Fuel pump driving cam diameter 38.1mm 37.6mm Cam height Standard Limit Intake 38.08mm 37.58mm Exhaust 39.15mm 38.65mm

Petrol Engine Overhaul

28

Valve yd Spring mßlaId lsßu

Valve spring wd;;sh mßlaId lsßu ioyd úfYaYs; WmlrKhla

jq Valve spring tester tl fhdod.ks¡ fuuTester tl u; spring tl

;nd yev,h ksIamdolh os we;s nrg my,g weosfïka yelsf,k spring

tfla Wi me;af;a we;s ñkqï máh u.ska lshjd .; hq;=h¡ bkamiq

ksIamdos;h oS we;s w.hka iu. tjd iiod ne,sh hq;=h¡

Valve spring height

Standard valve 44.6mm Limit 43.6mm Valve spring square less

Standard valve 2 ˚ or less

Limit 4 ˚

Valve spring height with 24.2kg load

Standard valve 37.3mm

Petrol Engine Overhaul

29

fuysos valve o ydks ú we;soehs mßlaId l< hq;=h¡ valve uyqk;a

f.úï valve l`o f.úï mßlaId l< hq;=h¡valve ydks ù we;akï valve

face grind lsßug fyda w¨;a valve fhosh hq;=fõ

je,aj w¨f;aka fhosug fmr Valve shim mßlaId l< hq;=fõ¡

f.ùï we;akï Valve seat cutters Wmfhda.s lr.ksïka iß,k whqßka

ilid.;hq;= fõ¡ msßisÿ lr.;a Valve j, uqyqk;a ksueoSu l< hq;=h

(Valve seat lapping)¡ bkamiqj Valve ish,a, wxl oeuq ms<sfj,g

iúlr ldkaÿúï we;aoehs mßlaId lr ne,sh hq;=h¡

Petrol Engine Overhaul

30

is,skav¾ ysi mßlaIdj

is,av¾ ysfia weoúï msmsßï weoaoehs mßlaId l< hq;=h¡ fu ioyd

Ndú;d lrk WmlrK kï fõ¡

Straightedge

Feeler gauge

Straightedge is,skav¾ ysi u; ;nd we;sjk ysvia ;=,g Feeler gauge tl oud ueksu isÿlrhs¡ fuys Wmßuhla ksIamdos;h os we;¡

Standard value 0.05mm Grinding Limit 0.02mm Cylinder head height 106.9 – 107.1mm

Measuring cylinder head flatness

fuysos is,skavß ysi weoúï ksIamdos;h os we;s w.hg jvd

jeäkï Face l< hq;= fõ¡ Face l<yels Wmßuhlao ksIamdos;hd os

we;¡ is,skav¾ ysfia l=vd isßula we;skï th Face lsßug wjiai

fkdfõ¡ weuß l=vq iaj,amhla úÿrejla u; oud fyd je,s lvodishla

iu;,d u;=msgl w,jd is,skav¾ ysi t u; 8 b,lalfï yevhg p,kh

lsßu u.ska l=vd fodaIhla ke;slr.; yel¡

;jo Cam okav rojd we;s Bearing inner circumference tlo

f.ù we;aoehs fyd ydks ú we;soehs ne,sh hq;=h¡ tfia ydks ú we;akï

is,skav¾ ysi w¨f;ak fhosh hq;=fõ¡

Petrol Engine Overhaul

31

tkacsug o.rlo iúlsßu

o.rlo w¨;ajeähd lr.eksfuka miqj tu m%udKhg .e,fmk

Main bearings iy Big end bearings f;drd.; hq;=h¡ msiagka wf;ys

uyfldka fnhdßka m¨fhdod wek ;olr.; hq;=h¡ bkamiqj uyfldka

fnhdßka fndarh yd uyfldka c¾k,h w;r we; f;,a jdish (Oil

Clearance) uek.; hq;=h¡ fuh uek.ekSug Plastic Gauge

lene,a,la nú;d lrhs¡ bkamiqj msiagka w;aa fnhdßka iys;j o.rlfoa

c¾k,a j,g iúlr tla tla msiagka wf;a me;s jdish uek ne,sh

hq;=fõ¡ tfiu tjdfha ksoyia N%ukho mßlaIdlsru l< hq;=h¡

Cecking side clearance

Oil clearance

Standard value 0.02-0.06mm Limit 0.15mm Big end side clearance 0.10-0.25mm Limit 0.4mm

Petrol Engine Overhaul

32

Oil clearance

Plastic Gauge tl wdOdrfhka Oil clearance tl uek.; yel¡

Plastic Gauge lene,a,la Bearing shell tl w;rg oud ksIamdos;hdos

we;s Torque tlg ;o l< hq;=h¡ bkamia kej;a .,jd Plastic Gauge

tl;a iu. we;s ñkqï fldgi f.k Bearing shell tl w;rg oeuq

Plastic fldgi iu. iiod tys w.h ,nd .;hq;= fõ¡

Petrol Engine Overhaul

33

Main Bearing iúlsßu

B;, i,l=kq bosßhg jkfiaa wxl ms<sfj,g is,skav¾ nog Main

bearing shells fhdod main bearing caps iúlr.; hq;=h¡ caps j,g

weK oud Tightening torque 5.0-5.5kgm hk m%uKh ;ol< hq;=h¡ bka

miqj o.rlfoa m%Odk c¾k,aj, úYaluNh yd tkacska nfoys m%Odk

fnhdßka fndarhka w;r f;,a jdish mßlaIdlr ne,sh hq;=h¡

Cecking crankshaft oil clearance

fuys Oil clearance ueksug ioyd Plastic gauge tl ndú;dlrhs¡

kej; fnhdßka m¨ .,jd o.rlo fhdod t w;rg Plastic gauge

lene,a,la oud kshñ; w.hg wjia:d ;qklos ueo isg fomig l;sr

yevhg weK ;o l< hq;=h

1) 300kgcm

2) 400kgcm

3) 500kgcm

Petrol Engine Overhaul

34

bkamiq kej; Cap .,jd Plastic gauge lene,a, uek Oil

clearance tl ,nd f.k mßlaIdlr n,d kej; weK oud fmr fiau

wjia:d ;=klos l;sr yevhg 500-550kgcm Wmßuhlg ;o lr

o.rlfoa me;sjdishd (End play) tl mßlaIdlr ne,sh hq;=h¡

Main bearing clearance - 0.02-0.07mm

Limit - 0.15mm

Crank shaft end play standard valve - 0.05-0.18mm

Limit - 0.25mm

Checking end play

Petrol Engine Overhaul

35

msiagka iy msiagka j,¨ fhosu

fmr wjia:dfj oS msiagka fndarh w¨;ajeähd lr m%udKhg

msiagka iy msiagka Rings f;dard.; hq;=h¡ bkamiq msiagkhg

Connecting rod tl Piston pin setting tool wdOdrfh kiúlr.;

hq;=h¡ Connecting rod tl iúlsßfuos msiagkfha osYdj ms,sno

ie,ls,su;a úh hq;=h¡

msiagkhg Rings oeñug fmr msiagkh yd Rings me;s jdish

ne,sh hq;=h¡ fuh mßlaIdlßug Feeler gauge tl fhdod.ks¡

Side Clearance No. 1 Ring 0.03 - 0.07mm

No. 2 Ring 0.02 - 0.06mm

Limit 0.01mm

Cheking ring side clearance

Petrol Engine Overhaul

36

msiagkfhka .,dj.;a Ring f.k tjdfha End gap mßlaIdlr

ne,sh hq;=h¡ t ioyd Ring tlla f.k msiagka is,skavrhg oud

msiagkfhka Ring tl we;=,a lr.; hq;=h¡ bka miq msiagkh bj;g

f.k Ring tfl fl,jrj,a fol w;rg Feeler gauge tl oud End

gap uek.; yel¡ fuu uek.eksu is,skavrfha ia:dk ;=klska isÿlrhs

¡

End gap standard value

No 1 Ring 0.20 - 0.40mm

No 2 Ring 0.20 - 0.35mm

Oil Ring 0.20 - 70mm Limit

No 1 Ring 0.8mm

No 2 Ring 0.8mm

Oil Ring 0.1mm

bkamiqj msiagkh (msiagka Ring fkdue;sj) is,skavrh ;=,g oud

msiagkh yd is,skavth w;r we;s jdish uene,sh hq;=h¡ th 0.02mm –

0.04mm w;r w.hl úhhq;=h¡

Petrol Engine Overhaul

37

miqj tla tla msiagkhg iïmsvk j,¨ iy f;,a j,¨ Piston

ring expander tlla wdOdrfhka oud.; hq;=h¡ msiagkhg Rings

oeñfuos Ring tfla Wv me;a; ksiswdldrj n,d fhosh hq;=h¡ m,uq

Ring iy fojk Ring ksiswdldrj n,d fhosh hq;=fõ¡ m,uq Ring tfla

Ring gap tlg 180° úroaOj fojk Ring gap tl ;sìh hq;=h¡

Piston ring end gap position

Petrol Engine Overhaul

38

msiagka is,skavrhg we;=,alsßu

ish¨u msiagka j,g Connecting rod yd Ring iúlr.; hq;=h¡

bkamiq msiagka is,skavrhg we;=,al< yel¡ t ioyd msiagkfhka uola

is,akavrhg we;,alr (m,uq Ring tl wdikakhg muk) Piston ring

band kï úfYaI WmlrKh fhdodf.k Piston ring ;ofldg yl=̈ jd

msiagkh is,skavrh ;=,g we;=,afldg.; hq;=h¡ ,S ñglska ;Ügq lsßu

u.ska msiagkh we;=,a lsßu myiq lr.;yel¡ bkamiq kshñ; Big end

bearings oud weK ;ofldg.; hq;=h(Tightening torque 3.2 -

3.5kgm)¡ bkamiq o.rlo lrljd ne,sh hq;=h¡ fufi ish¨ msiagka

we;=fldg.; hq;hs¡ msiagkhla oud o.rlo lrljd ;o .;shlska

f;drj msiagkh ls%hd lrkjdo ne,sh hq;=h¡

fuysos msiagkfha B;,h ;sfnk osYdj tkacsfï bosß mig;a¡

Piston ring gap fol tlsfklg iudka;rj úreoaO osYdjg;a Thrust

side j,g fkdoeñug;a j. n,d.; hq;=h¡

Petrol Engine Overhaul

39

tkacska nfoys wfkl=;a fldgia iúlsßu

tkacsu .,jd w¨;ajeähdfõka miqj tkacsu iúlsßfïos w¨;a Oil

seal fhdod Front case, Rear oil seal case, Oil strainer iúfldg Oil

pan tlo iúlrkq ,enhs¡ tfukau Water pump, Rear plate bell

housing cover iúlr Fly wheel tlo mßlaIdlr n,d iúlr wek oud

kshñ; torque tlg ;ol, hq;=h¡

Fly wheel run out limit 0.13mm

Tightening torque 13 - 14Kgm

Checking fly whell

Petrol Engine Overhaul

40

.Eialgh iy is,skavr ysi iúlsßu

tkacsfï fldgia w¨;ajeähdfõka miqj is,skaavr nog wh;a

ish¨u fldgia iúlr wjidkfhaos .Eialgh ksjeros f,i iúlr.;

hq;=h¡ tkacsfï Hade tl Face lf<kï thg wod,j .Eialgfha

.klu fjkiafldg fhosh hq;=h¡ 4G13 tkacsfu kï 13 hk wxlh

.Eialgh Wv me;af;a fhdod we;¡ ke;skï Ths,a .uka.kakd udr.

ms,sno n,d .Eialgh ksjerosj oeñh hq;=h¡ .Eialgh oeñfïos lsisu

fohla wdf,am fkdl, hq;=h¡

is,skav¾ ysi is,skav¾ fndf,dla tl u; ;nd weK ueo isg

fome;a;g l;sr yevhg woshr ;=klg kshñ; w.hg ;ol, hq;=h¡

Head tightening torque

Cold : 7.0 - 7.5Kgm

Hot : 8.0 - 8.5Kgm

Cylinder head bolt tightening sequence

Petrol Engine Overhaul

41

Cam shaft iúlsßu

msßlaIdlr n,d Cam shaft tl iúlr hq;=fõ¡ Cam shaft

iúlr Thrust case tlo weK ksisf,I ;o lr Cam shaft tfla End

play mßlaaIdlr ne,sh hq;=h¡ tu End play jvd jeäkï Thrust case

tl w¨f;ka oeñug isÿfõ¡ tfia mßlaIdlr n,d leï okav is,skavr

ysig we;=,afldg Flange bolt iy Rear cover iúlrkq ,nhs¡

End play

Standard value : 0.05 - 0.20mm Limit : 0.4mm

Petrol Engine Overhaul

42

Rocker arm iúlsßu yd Oil seal fhoSu

Cam shaft iúlssßfuka wk;=rej Rocker arm tl,i .,jd

msßisÿfldg fldgia mßlaIdlr n,d iúl, hq;=h¡ fuys 1-3, 2-4

hkqfjka Rocer finger j, wxl fhdod we;s w;r tliudk yev we;sj

msysgd we;s Rocer finger s tu wxl u.ska yÿkd.; yel¡ óg wu;rj

Rocer arm assembly fol fjka fjka jYfhka Inlet valve yd

Exhaust valve side f,i fhdod weK kshñ; w.hg ;ol, hq;=h¡

Rocer arm isúlsßfuka wk;=rej Cam shaft tfla bosß

fl,jrg Oil seal tl iúlsßu isÿl, hq;=h¡ miqj Cam shaft tflao

weK ;olr.; hq;=h¡ óg wu;rj Crank shaft sporocket tlo oeñh

hq;=h¡ wk;=rej jE,aj iïmQ¾kfhka nqre,afldg jE,aj uq¾:kh ;nd

Timing belt iy Teìioner iúlsßu l,hq;=h¡

Petrol Engine Overhaul

43

jE,aj uq¾:kh ;eìu

tkacsfï ish¨u fldgia iúlr.;a miq jE,aj uq¾:dkh ;eìu

isÿlrhs¡ tkï Cam shaft sprocket tl ol=Kg lrljd tñ we;s

i,l=K is,skav¾ ysfiys we;s i,l=K iu. fl,ska ;nd.; hq;=h¡

tfiu Crank shft tl ol=Kg lrljd Crank sprocket tflys we;s

i,l=K Front case tfla we;s i,l=Kg fl,ska isák fia ilialr.;

hq;=h¡

i,l=Kq ksisf,i ia:dk.; lr.;a miq Timing belt tl .,jk

wjia:dfõos oud.;a i,l=Kq wkqj fhdod Cam shaft sprocket w;r yd

Crank shaft sprocket w;r iïnkaOlr Tensioner jï w;g lrljd

( Side toward water pump) iúl,hq;=h¡ bkamiqj Tensioner

isreudre wKh uola nqre,afldg Timing belt tl ksis f,i iliaúu

ioyd Cam shaft sprocket uola jï w;g lrljd Tensioner tflys

weKh ksis f,i ;ol, hq;=h¡ bkamiq Crank shaft tl jg folla

lrljd uqyq¾:k i,l=Kq ksjerosj ;sfnoehs mßlaIdlr ne,sh hq;=h¡

bkamiqj Timing belt tflys ksoyia nqre, (Tension) ilia l< hq;=h

Petrol Engine Overhaul

44

Timing belt tflys Tension iSreudre lsßu ioyd Tensioner

tfla iúlr we;s weKh nqre,afldg Crank shaft fyd Cam shaft tl

olqKq mig lrljd Front case tfla i,l=Kkska oe;s ;qkla bosßfhaka

Crank shaft sprocket i,lqK ia:dk.; fldg Timing belt tfla

wd;;sh ksjerosj ;sfíoehs mßlaIdlr ne,sh hq;=h¡ kshñ; wd;;sh

jkafka Tensioner bolt tflys ysfiys m<,ska ¼ úh hq;h¡

Timing belt tl iúlr wjidkfhaos jg fol ;=kla Crank shaft tl

lrljd i,l=Kq msysáu yd wd;;sh h,s;ajrla mßlaIdlr ne,sh hq;=h¡

bka wk;=rej Timing belt cover iúlr Crank shaft pully, Damper pully iúlr kshñ; w.hg ;ol< hq;=fõ¡

Tightening torque : 7 - 10kgm

Petrol Engine Overhaul

45

Adjusting Valve Clearance Valve clearance ;eìu ioyd Crank shaft tl ol=Kg

lrljñka m,uq is,skavrh ;=, n,myr wdrïN jkfia .eksug

y;rjk is,skavrh Over lap l< hq;=h¡ fuu wjia:dfõ Cam shaft

sprocket i,l=K yd Cylinder head i,l=K iumd; jkq,efí¡

fuu m,uq wjia:dfõ jE,aj mr;rhka iSreudr l< yelafla my;

oelafjk jE,ajhkah

fojk wjia:dfõ y;rjk is,skavrh n,myr wdrïN jkfia

.eksug Crank shaft tl ol=Kg jghla lrljñk m,uq is,skavrh

Over lap l< hq;=h fuu fojk wjia:dfjysos my; oelafjk

jE,ajhkaf. jE,aj mr;rhka iSreudr l< yelsh¡

Valve clearance

Standard value cold endine Intake 0.07mm Exhaust 0.17mm

Standard value on hot engine Intake 0.15mm Exhaust 0.25mm

Adjusting valve clearance

1 2 3 4

I E I E I E I E 1st X X X X

2nd X X X X

Petrol Engine Overhaul

46

tkacsfuys ndysr fldgia ish,a, isúfldg tkacsu

mk.ekaùu

tkacsfï jE,aj mr;rh ieliSfuka miqj .,jk ,o ish¨u

ndysr fldgia tlska tl ms,sfj,ska tkacsug iúlr.; hq;=h¡ fï wkqj

fldgia iúlsßfïos Distributor tlo uqyq¾:kh ;nd iúlsßu jeo.;ah¡

cj,k uq¾:kh ;eîu ioyd m%:ufhka Crank shaft tl ol=Kg

lrljñka m,uq is,skavrh iïmSvk myr wjidkfha msiagkh uqÿka

iSudjg ilialr.; hq;=h¡ tkï 4jk is,skavrfha Valve over lap

wjia:dfõos Crank pully mark tl T.D.C mark tlg iumd; jkfia

ilid.; hq;=h¡ bkamiqj Distributor tl f.k tys wkafvys we;s

i,l=K ksismßos ilid tkacsug iúlr.; hq;=h¡ bkamiqj negßfha isg

cj,k mßm;h iïmQ¾k lr.; hq;=h¡ Distributor body isreudrelr

mq,s.=jla mksk wjia:dj ilid th iaÓrj weKh u.ska ;olr.;

hq;=h¡ bkamiqj Distributor cap tl iúlr t fudfydf;a Rotor tl

msysgd we;s ia:dkh 1 jYfhka i,ld Rotor lrlefjk osYdj wkqj

oyk ms<sfj,g Spark plug wires (High tension wires) iïnkaO

l,hq;=fõ¡

Petrol Engine Overhaul

47

óg wu;rj Spark plug gap ilid iúlsÍuo jeo.;a fõ¡

Spark plug gap : 075mm

ish,a, ksisf,i bgqlsÍfuka miqj tkacsfï ish¨ fldgia ksjerosj

iúfldg we;soehs kej; jrla fydoska mßlaIdlr n,d tkacsug f;,a

iy f¾äfhagrhg c,ho fhdod tkacsu mk.kajd ne,sh hq;=h¡