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Petrol Engine Overhaul

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

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Petrol Engine Overhaul

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

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Petrol Engine Overhaul

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¡

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Petrol Engine Overhaul

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

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Petrol Engine Overhaul

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;¡

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Petrol Engine Overhaul

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¡

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Petrol Engine Overhaul

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,sj q 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¡

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Petrol Engine Overhaul

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 13 13 13 13
Kg/cm

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Petrol Engine Overhaul

Compression Test lsßug úfYaI;
s 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¡
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Petrol Engine Overhaul

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¡

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Petrol Engine Overhaul

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

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Petrol Engine Overhaul

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
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Petrol Engine Overhaul

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¡

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Petrol Engine Overhaul

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¡

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Petrol Engine Overhaul

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¡

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Petrol Engine Overhaul

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¡

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Petrol Engine Overhaul

.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¡

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Petrol Engine Overhaul

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 tllsk¡s 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

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Petrol Engine Overhaul

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 47.99 47.98 47.99 47.99 47.99 47.99 47.97 47.99 47.98
mm mm mm mm mm mm mm mm mm mm
BB 47.97 47.98 47.98 47.98 48 48 47.98 47.98 47.98 47.98
mm mm mm mm mm mm mm mm mm mm

Big end
journal 1 2 3 4
A B A B A B A B
AA 41.98 41.98 47.98 41.99 41.98 41.98 41.98 41.98
mm mm mm mm mm mm mm mm
BB 41.98 41.98 41.98 47.97 41.99 41.98 42 41.99
mm mm mm mm mm mm mm mm

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Petrol Engine Overhaul

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¡

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Petrol Engine Overhaul

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,skv a ¾ 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;¡

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Petrol Engine Overhaul

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 i DK 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¡ ksIm a dolh w.hka 3la os we;
71.25mm \ 71.50mm \ 71.75mm fõ¡

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Petrol Engine Overhaul

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 1 2 3 4
No
Position A B A B A B A B

AA + + + + + + + +
71.03 71.02 71.03 71.02 71.02 71.03 71.03 71
mm mm mm mm mm mm mm mm
BB + + + + + + + -
71.03 71.02 71.02 71.03 71.02 71.03 71.03 69.99
mm mm mm mm mm mm mm mm
CC + + + + + + + +
71.03 71.02 71.02 71.03 71.02 71.03 71.03 71
mm mm mm mm mm mm mm mm

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Petrol Engine Overhaul

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¡

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Petrol Engine Overhaul

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

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Petrol Engine Overhaul

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¡

26
Petrol Engine Overhaul

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

27
Petrol Engine Overhaul

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

28
Petrol Engine Overhaul

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¡

29
Petrol Engine Overhaul

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;sl r.; 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¡

30
Petrol Engine Overhaul

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

31
Petrol Engine Overhaul

Oil clearance

Plastic Gauge tl wdOdrfhka Oil clearance tl uek.; yel¡
Plastic Gauge lene,a,la Bearing shell tl w;rg oud ksIm
a dos;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¡

32
Petrol Engine Overhaul

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

33
Petrol Engine Overhaul

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

34
Petrol Engine Overhaul

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

35
Petrol Engine Overhaul

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¡

36
Petrol Engine Overhaul

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

37
Petrol Engine Overhaul

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¡

38
Petrol Engine Overhaul

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

39
Petrol Engine Overhaul

.Eialgh iy is,skavr ysi iúlsßu
tkacsfï fldgia w¨;ajeähdfõka miqj is,skavr 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

40
Petrol Engine Overhaul

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

41
Petrol Engine Overhaul

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¡

42
Petrol Engine Overhaul

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

43
Petrol Engine Overhaul

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

44
Petrol Engine Overhaul

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

1 2 3 4
I E I E I E I E
1st    X X  X X
2nd X X X   X  

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
45
Petrol Engine Overhaul

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
msygs d 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¡

46
Petrol Engine Overhaul

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¡

47