6. Maintenance Data
Part name Item Standard value
Engine parts
Cylinder head
Cylinder
Piston
Piston pin
Piston rings
Connecting rod
Crankshaft
Carbon deposition on combustion chamber wall
Deformation of mating faces and flaws
Corrosion of mating faces
Plugging of cooling water passages
Deposition on water jacket interior walls
Wear of bore : Measure bore by using cylinder gauge.
Seizing, and damage and wear of cylinder liner
Taper
Roundness
Deformation and damage of cylinder head mating faces
Engine anode
Outer diameter
Measure outer diameter at 9mm (0.35in)
above lower end of piston skirt.
(Measure at right angle to piston pin.)
· Piston clearance
Carbon deposition on piston crown and
in ring grooves
Flaws on sliding faces
Measure side clearance between piston
ring and ring groove.
Measure piston pin bore.
Piston pin clearance
Outer diameter
Ring end
gap
Top ring
Second ring
Oil ring
Small end bore
Big end oil clearance
Big end side clearance
Crankshaft runout: Support crankshaft at
journals of both ends by using V block.
Crank pin outer diameter
Main journal outer diameter
Metal bearing oil clearance
Crankshaft side clearance
61.00mm (2.4016in)
60.96mm (2.4000in)
0.020 - 0.055mm (0.00079 - 0.00217in)
Top ring 0.04 - 0.08mm (0.0016 - 0.0031in)
Second ring 0.03 - 0.07mm (0.0012 - 0.0028in)
Oil ring 0.05 - 0.15mm (0.0019 - 0.0059in)
0.002 - 0.012mm (0.00008 - 0.00047in)
16.00mm (0.6299in)
Ring gauge 61.000mm (2.40157in)
Top ring 0.15 - 0.30mm (0.0059 - 0.0118in)
Second ring 0.35 - 0.50mm (0.0138 - 0.0197in)
Oil ring 0.20 - 0.70mm (0.0079 - 0.0276in)
16.01mm (0.6303in)
0.015 - 0.041mm (0.00059 - 0.0161in)
0.10 - 0.25mm (0.0039 - 0.0098in)
To be less than 0.05mm (0.0020in)
at both ends and at the center.
29.98mm (1.1803in)
35.99mm (1.4169in)
0.012 - 0.044mm (0.00047 - 0.00173in)
0.1 - 0.3mm (0.004 - 0.012in)
Note : Measure ring end gap at
the top or bottom cylinder
bore that is worn little if
ring gauge is not available.
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