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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
Summary of Contents for 3TNV Series
Page 1: ...4TNV106 4TNV106T 4TNV94L 4TNV98 4TNV98T 3TNV82A 3TNV84 T 4TNV84 T 3TNV88 4TNV88 ...
Page 31: ...1 General 1 4 Engine External Views 16 ...
Page 32: ...1 General 1 5 Structural Description 17 ...
Page 156: ...9 Starting Motor 9 1 2 Components 141 ...
Page 157: ...9 Starting Motor 9 1 3 Troubleshooting 142 ...
Page 172: ...9 Starting Motor 9 2 3 Troubleshooting 157 ...
Page 175: ...9 Starting Motor 2 Removal of magnetic switch Remove the M6 bolts 10mm 2 160 ...
Page 185: ...9 Starting Motor 3 Brush 1 Check wear of the brush and the brush spring force 170 ...
Page 194: ...10 Alternator 179 10 1 6 Troubleshooting ...
Page 195: ...11 Electric Wiring 180 11 ELECTRIC WIRING 11 1 Electric Wiring Diagram ...
Page 213: ......