4. Disassembly, Inspection and Reassembly of Engines.............................. 59 4.1 Complete disassembly and reassembly................................................................................
59 4.1.1 Introduction ............................................................................................................................59 4.1.2 Special service tools...............................................................................................................60 4.1.3 Complete disassembly ...........................................................................................................65 4.1.4 Precautions before and during reassembly ............................................................................69 4.1.5 Adjusting operation.................................................................................................................69 4.2 Cylinder Head:
Disassembly, Inspection and Reassembly.................................................... 70 4.2.1 Components (2-valve cylinder head)......................................................................................70 4.2.2 Disassembly procedure:.........................................................................................................70 4.2.3 Reassembly procedure:
.........................................................................................................71 4.2.4 Servicing points......................................................................................................................72 4.2.5 Parts Inspection and measurement........................................................................................76 4.2.6 Valve seat correction ..............................................................................................................80 4.2.7 Valve guide replacement ........................................................................................................81 4.2.8 Valve stem seal replacement..................................................................................................82 4.3 Gear Train and Camshaft ......................................................................................................
83 4.3.1 Components...........................................................................................................................83 4.3.2 Disassembly procedure:.........................................................................................................83 4.3.3 Reassembly procedure:
.........................................................................................................83 4.3.4 Servicing points......................................................................................................................84 4.3.5 Parts inspection and measurement ........................................................................................87 4.3.6 Oil seal replacement (Gear case side) ...................................................................................89 4.3.7 Camshaft bushing replacement..............................................................................................89 4.4 Cylinder Block........................................................................................................................
90 4.4.1 Components...........................................................................................................................90 4.4.2 Disassembly procedure:.........................................................................................................90 4.4.3 Reassembly procedure:
.........................................................................................................90 4.4.4 Servicing points......................................................................................................................91 4.4.5 Parts inspection and measurement ........................................................................................95 4.4.6 Cylinder bore correction .......................................................................................................106 4.4.7 Piston pin bushing replacement ...........................................................................................107 4.4.8 Oil seal replacement (Flywheel housing side) ......................................................................107