4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES 4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES 4.1 Complete Disassembly and Reassembly ............................................................................................. 4-2 4.1.1 Introduction........................................................................................................................................... 4-2 4.1.2 Special service tools .............................................................................................................................
4-3 4.1.3 Complete disassembly.......................................................................................................................... 4-8 4.1.4 Precautions before and during reassembly ........................................................................................ 4-12 4.1.5 Adjusting operation............................................................................................................................. 4-12 4.2 Cylinder Head: Disassembly, Inspection and Reassembly ................................................................
4-13 4.2.1 Components (2-valve cylinder head).................................................................................................. 4-13 4.2.2 Disassembly procedure ...................................................................................................................... 4-13 4.2.3 Reassembly procedure....................................................................................................................... 4-14 4.2.4 Servicing points ..................................................................................................................................
4-15 4.2.5 Parts inspection and measurement .................................................................................................... 4-19 4.2.6 Valve seat correction .......................................................................................................................... 4-23 4.2.7 Valve guide replacement .................................................................................................................... 4-24 4.2.8 Valve stem seal replacement..............................................................................................................
4-25 4.3 Gear Train and Camshaft ................................................................................................................... 4-26 4.3.1 Components ....................................................................................................................................... 4-26 4.3.2 Disassembly procedure ...................................................................................................................... 4-26 4.3.3 Reassembly procedure.......................................................................................................................
4-26 4.3.4 Servicing points .................................................................................................................................. 4-27 4.3.5 Parts inspection and measurement .................................................................................................... 4-30 4.3.6 Oil seal replacement (Gear case side) ............................................................................................... 4-32 4.3.7 Camshaft bushing replacement ..........................................................................................................
4-32 4.4 Cylinder Block..................................................................................................................................... 4-33 4.4.1 Components ....................................................................................................................................... 4-33 4.4.2 Disassembly procedure: ..................................................................................................................... 4-33 4.4.3 Reassembly procedure:......................................................................................................................
4-33 4.4.4 Servicing points .................................................................................................................................. 4-34 4.4.5 Parts inspection and measurement .................................................................................................... 4-38 4.4.6 Cylinder bore correction...................................................................................................................... 4-49 4.4.7 Piston pin bushing replacement..........................................................................................................
4-50 4.4.8 Oil seal replacement (Flywheel housing side) .................................................................................... 4-50 82E-5 – 98E-5 SERIES 4-1