GENERAL INFORMATION

Disusun Oleh : Hari Krismanto

Dept. MKE/hari krismanto

WHY ENGINE NEED TO BE OVERHAULED

1. Engine power decrease due to the excessive gap between piston and cylinder liner, piston ring and valves worn
2. The excessive use of engine oil 3. The oil pressure reduces due to the clearance between bearing and crankshaft is too big 4. The oil is contaminated with water 5. Troubles in several parts of the engine that can not be overcome without being engine overhauled

Dept. MKE/hari krismanto

CYLINDER HEAD OVERHAUL

1. Remove intake and exhaust manifolds and valve cover. Cylinder head and camshaft carrier bolts (if equipped), 2. Remove rocker arm components or overhead cam components. Components must be installed in original location. 3. Cylinder head bolts be removed in proper sequence to prevent cylinder head damage.

Catatan : Mengencangkan merupakan kebalikan cara melepas

Dept. MKE/hari krismanto

VALVE REMOVAL
1. Mark valves for location. Using valve spring compressor, compress valve springs. 2. Remove valve locks. Carefully release spring compressor. 3. Remove retainer or rotator, valve spring, spring seat and valve

Dept. MKE/hari krismanto

TIMING CHAINS REMOVAL

1. Note timing mark. Timing chains must be installed so that timing marks on camshaft gear and crankshaft gear are aligned according to manufacturer 2. Remove timing sprocket gear bolt and remove timing chains

Dept. MKE/hari krismanto

PISTON & CONNECTING ROD REMOVAL

Note top of piston. Some pistons may contain a notch, arrow or be marked "FRONT". Piston must be installed in proper direction to prevent damage with valve operation.

Dept. MKE/hari krismanto

PISTON DAN CONNECTING ROD REMOVAL

1. Check that connecting rod and cap are numbered for cylinder location and which side of cylinder block the number faces. Proper cap and connecting rod must be installed together. Connecting rod cap must be installed on connecting rod in proper direction to ensure bearing lock procedure. Mark connecting rod and cap if necessary. 2. Pistons must be installed in original location.

Dept. MKE/hari krismanto

PISTON DAN CONNECTING ROD REMOVAL

1. Remove cap retaining nuts or bolts. Remove bearing cap. 2. Install stud protectors on connecting rod bolts. This protects cylinder walls from scoring during removal. 3. Ensure proper removal of ridge. 4. Push piston and connecting rod from cylinder. Connecting rod boss can be tapped with a wooden dowel or hammer handle to aid in removal.

Dept. MKE/hari krismanto

PISTON & CONNECTING ROD DISASSEMBLY

1. Using ring expander, remove piston rings. Remove piston pin retaining rings (if equipped). On pressed type piston pins, special fixtures and procedures according to manufacturer must be used to remove piston pins. Follow manufacturer's recommendations to avoid piston distortion or breakage. 2. Remove all carbon and varnish from piston. Using ring groove cleaner, clean all deposits from ring grooves. DO NOT attempt to clean pistons using wire brush

Dept. MKE/hari krismanto

CRANKSHAFT & MAIN BEARINGS

1. Ensure all main bearing caps are marked for location on cylinder block. Some main bearing caps have an arrow stamped on it which must face front of engine. Remove main bearing cap bolts and main bearing caps. 2. Carefully remove crankshaft.

Dept. MKE/hari krismanto

10

Arigato Gozaimashita

Dept. MKE/hari krismanto

11