3.4 Troubleshooting by measuring compression pressure ..........................................................62 4. Disassembly and reassembly ........................................................................................64 4.1 Disassembly and reassembly precautions .............................................................................64 4.2 Disassembly and reassembly tools ........................................................................................65 4.2.1 General hand tools..........................................................................................................................
65 4.2.2 Special hand tools........................................................................................................................... 68 4.2.3 Measuring instruments.................................................................................................................... 71 4.2.4 Other material .................................................................................................................................
75 4.3 Disassembly and reassembly ................................................................................................77 4.3.2 Reassembly .................................................................................................................................... 89 4.3.1 Disassembly.................................................................................................................................... 77 5.
Inspection and servicing of basic engine parts ............................................................104 5.1 Cylinder block .......................................................................................................................104 5.1.1 Inspection of parts......................................................................................................................... 104 5.1.2 Cleaning of oil holes...................................................................................................................... 104 5.1.3 Color check procedure..................................................................................................................
104 5.1.4 Replacement of cap plugs ............................................................................................................ 105 5.1.5 Cylinder bore measurement.......................................................................................................... 106 5.2 Cylinder head .......................................................................................................................107 5.2.1 Inspecting the cylinder head .........................................................................................................
108 5.2.2 Valve seat correction procedure ................................................................................................... 109 5.2.3 Intake/exhaust valves, valve guides ............................................................................................. 110 5.2.4 Valve springs ................................................................................................................................ 112 5.2.6 Measuring top clearance...............................................................................................................
114 5.2.5 Assembling the cylinder head....................................................................................................... 113 5.2.7 Intake and exhaust rocker arms.................................................................................................... 114 5.2.8 Adjustment of valve clearance......................................................................................................
115 5.3 Piston and piston pins ..........................................................................................................116 5.3.1 Piston............................................................................................................................................ 116 5.3.2 Piston pin ...................................................................................................................................... 117 5.3.3 Piston rings ...................................................................................................................................
118 5.4 Connecting rod .....................................................................................................................121 5.4.1 Inspecting the connection rod....................................................................................................... 121 5.4.2 Crank pin metal............................................................................................................................. 122 5.4.3 Piston pin bushing.........................................................................................................................
124 5.5 Crankshaft and main bearing ...............................................................................................125 5.4.4 Assembling piston and connecting rod ......................................................................................... 124 5.5.1 Crankshaft..................................................................................................................................... 125 5.5.2 Main bearing ................................................................................................................................. 127