SEN05196-01

ENGINE 1SHOP MANUAL

170E-5 Series

90 Repair and replacement of parts

Parts related to cylinder block
Part names related to cylinder block............................................................................................................... 2
Testing and inspection of cylinder block.......................................................................................................... 3
Part names related to crankshaft .................................................................................................................... 6
Testing and inspection of crankshaft............................................................................................................... 7
Part names related to connecting rod ............................................................................................................. 8
Testing and inspection of connecting rod........................................................................................................ 9
Replacement of flywheel ring gear................................................................................................................ 10
Replacement of crankshaft gear ....................................................................................................................11
Replacement of camshaft gear ..................................................................................................................... 12
Replacement of main bearing metal cap ...................................................................................................... 13
Replacement of connecting rod small end bushing ...................................................................................... 15
Replacement of cam bushing ....................................................................................................................... 16
Replacement of engine rear seal .................................................................................................................. 18
Repair of cylinder block top by grinding ........................................................................................................ 19
Repair of counterbore by grinding................................................................................................................. 20
Check and identification after repair by grinding ........................................................................................... 22
Gasket sealant application procedure........................................................................................................... 23
Repair of crankshaft by grinding ................................................................................................................... 26
Improvement of surface roughness of crankshaft journal ............................................................................. 31

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Part names related to cylinder block

1. Cylinder liner
2. Clevis seal
3. Cylinder liner O-ring
4. Cylinder block
5. Main bearing metal cap bolt
6. Main bearing metal cap
7. Camshaft bushing

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Testing and inspection of cylinder block

Unit: mm
Inspection item Criteria Remedy
Presence of crack (External dye check)
Crack
Cylinder head bolt hole etc. Replace cylinder
a See Fig. A block
Repair of contact of packing
Water leakage caused by corrosion
a See Fig. B
Standard value
Standard size Standard Replace cylinder
Clearance to cylinder liner Bore of Outside diameter clearance liner or cylinder
cylinder block of cylinder liner block
190.40 190.34 – 190.40 190.19 – 190.29 0.05 – 0.21
Inside diameter
Standard size Standard value Repair limit
90 90.112 – 90.222 90.251
Inside diameter of camshaft Replace camshaft
bushing Clearance to camshaft bearing bushing
Standard clearance Allowable clearance
0.077 – 0.217 0.284
Replace cylinder
a See Fig. C
Projection of cylinder liner liner or repair
Allowable range: 0.07 – 0.15 cylinder block
a See Fig. D
Presence of corrosion
Depth and bottom corrosion of Repair by cutting
Standard size Standard value
counterbore Add shim
14 14.00 – 14.05
Tolerance Repair limit
Distortion and wear of cylinder In all cylinder block Repair by cutting
head mounting face top of 1 cylinder Max. 0.09 0.15
Max. 0.05 0.10
Main bearing mounting hole a See Fig. E
diameter Standard size Standard value Repair limit
• Tighten main bearing metal 148
cap bolt to specified torque 148.000 – 148.025 — Replace cylinder
(Without bearing metal) block
Fit of main bearing metal cap a See Fig. F
and cylinder block
(Interference) Standard fit 0.080 – 0.159 (Interference)
a See Fig. G
Cylinder liner
Standard size Standard value Repair limit
Replace cylinder
205.965 – liner
Upper section 206.0 —
206.015
Inside diameter of counterbore
and outside diameter of 194.565 –
Lower section 194.5 —
cylinder liner flange 194.615
Cylinder block
Upper section 206.0 205.93 – 205.99 205.92 – 206.02 Replace cylinder
block
Lower section 194.5 194.48 – 194.54 194.46 – 194.57

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Illustrations related to testing and inspection table

Fig. A Fig. D

a: Packing portion f: Depth of counterbore

Fig. B Fig. E

b: Clearance g: Inside diameter

Fig. C Fig. F

c: Cylinder liner h: Fit

d: Cylinder block
e: Projection

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Fig. G

i: Upper section
j: Lower section

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Part names related to crankshaft

1. Crankshaft
2. Main bearing metal (upper)
3. Main bearing metal (lower)
4. Thrust metal

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Testing and inspection of crankshaft

Unit: mm
Inspection item Criteria Remedy
Crack Check for crack by magnaflux inspection Replace crankshaft
If damaged slightly,
Presence of damage in journal repair with oilstone
• Flaw
or by lapping.
• Seizure
Damage If seized, replace
• Discoloration
crankshaft
Damage of tap holes at front and rear ends Repair or replace
crankshaft
Clogging of oil hole Presence of clogged oil hole Repair
Standard value Repair limit Replace thrust
End play of crankshaft metal or replace
0.140 – 0.320 0.6 with oversize parts
Size Standard size Tolerance Repair limit
Standard 4.000 3.79
Replace thrust
0.25 US 4.125 3.92 metal or replace
Thrust metal thickness –0.07 with oversize
0.50 US 4.250 –0.12 4.04
crankshaft
0.75 US 4.375 4.17
1.00 US 4.500 4.29
Standard 108.00 107.91
0.25 US 107.75 107.66
Outside diameter of crankpin 0
journal 0.50 US 107.50 –0.022 107.41
Replace with
0.75 US 107.25 107.16 undersize parts or
1.00 US 107.00 106.91 replace crankshaft
Standard value Repair limit
Roundness of crankpin journal
0 – 0.010 0.015

Clearance in crankpin journal 0.058 – 0.132 0.18 Replace connecting

rod bearing metal
Size Standard size Tolerance Repair limit
Standard 140.00 139.91
Outside diameter of crank 0.25 US 139.75 139.66
main journal 0
0.50 US 139.50 –0.025 139.41 Replace with
0.75 US 139.25 139.16 undersize parts or
replace crankshaft
1.00 US 139.00 138.91
Standard value Repair limit
Roundness of crankpin journal
0 – 0.010 0.015

Clearance in crankpin journal 0.076 – 0.152 0.20 Replace connecting

rod bearing metal
Standard Repair limit
Concentricity of
Bend of crankshaft all main journals Max. 0.15 0.15
(Total indicator reading)
Concentricity of
Max. 0.07 0.07
adjacent journals
Replace crankshaft
Standard size Tolerance Repair limit
Main bearing metal thickness
(at center) –0.038
4.0 3.90
–0.051
Outside diameter of rear
170 ±0.019 —
flange

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Part names related to connecting rod

1. Connecting rod bolt

2. Washer
3. Cap
4. Dowel pin
5. Bearing metal (lower)
6. Bearing metal (upper)
7. Rod
8. Small end bushing

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Testing and inspection of connecting rod

Unit: mm
Inspection item Criteria Remedy
Crack Check for crack by dye check or magnaflux inspection
a See Fig. H Replace connecting
Parallelism and twist of small Parallelism: 0.1 Twist: 0.25 rod
and large end holes of (After small end bushing is installed)
connecting rod a Deviation of center axis of piston pin hole 305 mm above center of
connecting rod on basis of crank pin hole
Standard Tolerance Standard Allowable Replace small end
size Shaft Hole clearance clearance bushing
Clearance between Surface roughness
connecting rod small end of inside of small
bushing and piston pin 0 +0.049
68 0.030 – 0.055 0.090 end bushing
–0.006 +0.030
Max. 1.6S
Standard size Tolerance
• Large end hole diameter +0.026
• Without bearing metal. 115
0
• Inside surface roughness of large
end hole: Max. 6.3S Standard Allowable Replace bearing
Connecting rod large end hole clearance clearance metal or connecting
diameter • Clearance to crankshaft bearing
(with bearing metal) rod
0.058 – 0.132 0.18
Even if dimensions of each part are within allowable limits, if any
clearance exceeds allowable clearance, replace parts (bearing metal etc.)
Size Standard size Tolerance Repair limit
Standard 3.500 3.41
0.25 US 3.625 3.54 Replace bearing
Bearing metal thickness –0.029 metal
0.50 US 3.750 –0.042 3.66
0.75 US 3.875 3.79
1.00 US 4.000 3.91
Replace bearing
Flaw on inside of or seizure of
bearing metal Presence of flaw and seizure metal or connecting
rod
Standard size Tolerance
Distance between large and Replace connecting
small end hole centers 305 0 rod
–0.05
Replace connecting
rod
a See Fig. J
Streak and bruise on I-portion • Presence of lateral streak If there is bruise,
of connecting rod • Presence of lateral grinding mark and bruise replace connecting
rod regardless of
size of bruise
a See Fig. K
Presence of fretting on mating face If fretting is felt with
Fretting on cap mating face • Mating face roughness: Max. 6.3 S nail, replace
• Fitted area of mating face: Min. 70% connecting rod
However, non-fitted area must not be in range of (f).
Scuffing on cap bolt seat surface Repair with oilstone

Scuffing on bolt seat surface Scuffing on bolt seat surface Replace bolt

Scuffing on washer surface Replace washer

Deformation of dowel pin
Damage of bolt
• Presence of deformation of dowel pin Replace connecting
• Presence of deformation of dowel pin hole rod
• Presence of crack and/or damage on threaded portion of bolt Replace bolt
• Presence of bend of bolt

a If all the items of this criteria (particularly the wave of the large end hole) cannot be measured after the
connecting rod is rebuilt, do not rebuild since the accuracy of the connecting rod large end hole after
rebuilding cannot be confirmed.
a Do not reuse the connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on it.

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Fig. H Replacement of flywheel ring gear

k Take care not to throw down the flywheel
and get hurt by mistake.

Removal of gear
q Make a notch at the tooth bottom of the gear
with a grinder and break the gear to remove
with a chisel.
k Take care in handling the grinder and
chisel.

Press fitting of gear

1. Check the gear mounting face. If there is a
flaw, repair with an oilstone.
a: Parallelism: 0.1
b: Twist: 0.25 2. Heat the gear at the specified shrink fit temper-
1. Piston pin hole ature for a certain time.
2. Crank pin hole a Gear shrink fit temperature: Max. 200°C
(Below ring gear tempering temperature)
Fig. J Heating time: Min. 20 min

3. Press fit the gear with the chamfered side

directed toward the flywheel until its side con-
tacts the flywheel.

c: Inspection range
d: Streaks
e: Lengthwise direction

Fig. K

f: Inspection range

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Replacement of crankshaft gear 4. Using the drive tool, press fit the gear with the
timing mark out until its side contacts the
a Crankshaft gear replacement tools crankshaft flange.
Symbol Part No. Part name a Press fit the gear quickly before it cools
1 790-101-2800 Bearing puller down.
K
2 790-101-2300 Push puller

Removal of gear
q Make a notch at the tooth bottom of the gear
with a grinder, assemble tools K1 and K2, and
rotate the nut to pull out the gear.
a If the gear cannot be pulled out by the above
method, make a notch at the tooth bottom of
the gear with a grinder, heat the gear with a
gas burner, and drive out the gear with a cop-
per rod etc.
a Take care not to damage the crankshaft.

Press fitting of gear

1. Check the gear mounting face, key way and
flange surface. If there is a flaw, repair with an
oilstone.

2. Drive a new key into the key way of the crank-

shaft.

3. Heat the gear at the specified shrink fit temper-

ature for a certain time.
a Gear shrink fit temperature: Max. 170°C
Heating time: Min. 30 min

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Replacement of camshaft gear

k When setting the camshaft assembly on the
press stand, take care not to catch your fin-
gers between the press stand and the gear.

Removal of gear
Set the camshaft assembly on the press stand and
press the camshaft to pull out the gear.

Press fitting of gear

1. Check the gear mounting face, key way and
flange surface. If there is a flaw, repair with an
oilstone.

2. Drive a new key into the key way of the cam-

shaft.

3. Install the thrust plate.

4. Heat the gear at the specified shrink fit temper-

ature for a certain time.
a Gear shrink fit temperature: Max. 140°C
Heating time: Min. 30 min

5. Using the drive tool, press fit the gear with the
timing mark out until its side contacts the cam-
shaft flange.
a Press fit the gear quickly before it cools
down.

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Replacement of main bearing 5. While checking the inside diameter of main

metal cap
a When replacing the main bearing metal cap,
work on the semi-finished cap according to the
following procedure and install it.
Repair parts
Part No. Part name
6150-29-1210 No. 1, 2, 3, 4, 5, 7 main bearing metal cap
6150-29-1250 No. 6 main bearing metal cap
bearing metal cap (1), cut little by little.
a Cut to the degree that the boring bar tool
almost touches the inside of cylinder block
(2).
a Inside diameter of main bearing metal cap
q Machining dimension
Tolerance: 148 +0.025
0 mm
a Finished surface roughness: Max. 12.5S
a Do not cut the inside surface of the cylin-
der block.

Inside machining of main bearing metal cap

1. Remove the cylinder liner.

2. Install the replacement main bearing metal cap

to the cylinder block and tighten it to the speci-
fied torque.
a Match the notches of the cylinder block
and main bearing metal cap to each other.
2 Main bearing metal cap mounting bolt:
Apply engine oil to threaded portion
and seat.
a Tighten with the angle tightening wrench
at the 3rd time. Side machining of main bearing metal cap
3 Main bearing metal cap mounting bolt: (Machine only No. 6 main bearing metal cap)
Unit: Nm {kgm} 1. Insert cast iron bushing (3) and pass arbor (4)
Step Target Range through it.
1st time 284 {29} 270 – 299 {27.5 – 30.5}
2. Install facing tool (5) to the arbor.
2nd time 569 {58} 559 – 579 {57.0 – 59.0}
3. Cut main bearing metal cap (1) to the degree
3rd time 105° 90° +30°
0 that facing tool almost touches the cylinder
block surface.
3. Set the cylinder block mounting jig on the table
of the horizontal boring machine and install the
cylinder block by fitting its cylinder liner mount-
ing hole to the datum line of the jig.

4. Apply dial gauges to the inside of the 2 main

bearing metal caps at the longest pitch among
the caps to be used to center the arbor of the
boring machine.

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4. Cut the opposite side similarly.

a Thrust metal mounting surface roughness:
Max. 12.5S
a Do not cut the cylinder block.
a Dimensions of main bearing metal cap
q Dimension (R): Max. 0.5 mm
q Surface roughness of part (d):
Max. 12.5S
q Inside width (a) of main bearing metal cap:
0
56 –0.030 mm
q Outside diameter (b) of thrust metal
mounting face: 175 ± 0.2 mm
q Depth (c) of thrust metal mounting face:
2.5 ± 0.2 mm
q Dimension (R) of thrust metal mounting
face: Max. 0.5 mm
q Outside width (e) of main bearing metal
cap: 61 ± 0.5 mm

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Replacement of connecting rod Press fitting of bushing

small end bushing 1. Set the connecting rod to block (3) of tool L.

a Connecting rod small end bushing replace- 2. Install the bushing to push tool (1), set push
ment tool tool (4), and fix them with nut (2).
Symbol Part No. Part name a Match the oil holes of the bushing and
L 795-240-6401 Push tool (KIT) connecting rod to each other.

3. Drive push tool (1) with the press to press fit

Pulling out of bushing
the bushing.
1. Set the connecting rod to block (3) of tool L.
a Since the bushing is semi-finished, its
inside diameter is small and the piston pin
2. Using push tool (1) and nut (2), drive out the
does not go through it.
busing with the press.
After press fitting the bushing, machine its
a After removing the bushing, remove sharp
inside with a reamer or a honing machine
edges and burrs from and clean the bush-
according to the maintenance standard.
ing mounting hole.
a After machining, remove all the chips from
the oil hole and oil groove.
a The inside surface roughness of the
machined bushing must be maximum of
1.6S.

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Replacement of cam bushing 3. Pulling out of No. 3, No. 4 and No. 5 bushings
1) Assemble bar (1), push tool (2), collar (3)
a Cam bushing replacement tools and guide (4).
Symbol Part No. Part name 2) While hitting bar (1), drive out the bushing
M 795T-621-1700 Push tool (KIT) from the cylinder block.

a Before replacing the cam bushing, remove the

plug at the rear of the cylinder block.

Removal
1. Pulling out of No. 1 and No. 7 bushings
1) Assemble push tool (2), collar (3) and bar
(1) of tool M.
2) While hitting bar (1), drive out the bushing
from the cylinder block.

4. After removing the bushing, remove burrs and

foreign matter from and clean the bushing
mounting hole.

Installation
a Cam bushing installation drawing

2. Pulling out of No. 2 and No. 6 bushings

1) Assemble bar (1), push tool (2), collar (3)
and guide (4).
2) While hitting bar (1), drive out the bushing
from the cylinder block.

1. Press fitting of No. 3, No. 4 and No. 5 bushings

1) 1) Install bar (1), push tool (2), collar (3)
and guide (4) to the bushing.
a When installing the bushing, direct its
cut-out portion toward the rear of the
block.
a Match the oil holes of the bushing.
2) Press fit the bushing until the oil holes of
th e c y l i n d e r b l o c k a n d b u s h i n g ar e
matched to each other.

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4. Measurement after bushing is press fitted

1) Using dial inside gauge (a), measure the
inside diameter of the bushing.

2. Press fitting of No. 2 and No. 6 bushings

1) Install bar (1), push tool (2), collar (3) and
guide (4) to the bushing.
2) Press fit the bushing until the oil holes of
th e c y l i n d e r b l o c k a n d b u s h i n g a r e
matched to each other.
a Match the oil holes of the bushing.
2) Measure the clearance between the bush-
ing and shaft. If it is out of the allowable
range or the shaft does not go through
smoothly, repair the inside of the bushing
with a reamer.
a After repairing the inside of the bush-
ing with a reamer, remove all the
chips from the oil hole and oil groove.
a Inside diameter of cam bushing:
f90 +0.222
+0.112 mm
a Clearance to camshaft journal:
0.077 – 0.217 mm

3. Press fitting of No. 1 and No. 7 bushings

1) Install bar (1), push tool (2) and collar (3)
to the bushing.
2) Press fit the bushing until the oil holes of
th e c y l i n d e r b l o c k a n d b u s h i n g a r e
matched to each other.
a Match the oil holes of the bushing.

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Replacement of engine rear seal
a Engine rear seal replacement tools
Symbol Part No. Part name
N 795-931-1100 Seal puller assembly
a When installing the Teflon seal (laydown lip
seal), check the wear condition of the shaft and
select the "standard seal" or "sleeved seal" to
install.
a If the crankshaft is worn to a degree of luster
(you can feel the wear with the cushion of your
finger and the wear depth is maximum of
10 µm) and there is no scratch, install the
"standard seal". In other cases, install the
"sleeved seal".
a The left one in the following figure is the "stan-
dard seal" and the right one is the "sleeved
seal".
Installation of rear seal (without sleeve)
Tighten pressing bolts (2) evenly to press fit rear
seal (b) until push tool (1) of tool N touches the
crankshaft end.
a Rear seal press fitting dimension (from shaft
end) (a): 20 mm
a After press fitting the rear seal, remove the red
sealant sticking to around the mounting hole.
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90 Repair and replacement of parts
Installation of rear seal (with sleeve)
a When installing, do not apply oil, grease, etc.
to the crankshaft surface and inside wall (c) of
the sleeve.
1. Set the sleeve and rear seal assembly (d) to
push tool (3) of tool N.
2 Inside wall of sleeve:
Gasket seal (LG-7)
2. Set the rear seal sleeve to the crankshaft end
and tighten 5 pressing bolts (4) (Stem length:
45 mm) evenly to press fit rear seal assembly
(d) until push tool (3) contacts the crankshaft.
3. Remove push tool (3) and install push tool (1).
a Replace the pressing bolts with the ones
the stem length of which is 35 mm.
4. Tighten the 5 pressing bolts evenly to press fit
rear seal assembly (d) until push tool (1) con-
tacts the crankshaft.
a Rear seal press fitting dimension (from
shaft end) (a): 20 mm
a After press fitting the rear seal, remove
the red sealant sticking to around the
mounting hole.
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Repair of cylinder block top by Grinding of top

grinding q Measure the corrosion quantity, wear quantity
and distortion of the cylinder block top. If any of
Grinding them has exceeded the allowable limit, grind
Remove the distortion and corrosion of the cylinder the top.
Unit: mm
block top by grinding within the tolerance of cylinder
block height (H). Standard size Repair limit
a If the cylinder block top is worn and corroded in Flatness of cylinder block
0.05 0.10
the shape of the head gasket and wear quan- top (in each cylinder)
tity (b) is 0.10 mm or more, grind the cylinder Cylinder block height (H) 489.0 ± 0.04 488.56
block top.
Cylinder block top
a If the cylinder liner contact surface of counter- surface roughness
Max. 12.5S
bore portion (a) is blackened and grained (par-
ticularly in the forward and backward directions
of the cylinder block) more than a half of the
contact width or the cylinder block top needs to
be ground, repair the counterbore portion.

When grinding with grinding stone

(Reference)
a Grinding speed: 1,650 – 1,950 m/min
a Table speed: 15 – 30 m/min
a Grinding depth by 1 grinding: 0.025 mm
a Cross feed for 1 grinding: 1 – 2 mm
a Grinding stone: A461V
a Grinding fluid: Water soluble grinding fluid

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Repair of counterbore by grinding q Machine only the hatched part of depth of

counterbore portion (e).
q After grinding the top of cylinder block (a), q Machining dimension of part (f): Max. 0.4 mm
measure the counterbore depth. If the result is q Machining dimension of part (g): Max. 0.7 mm
out of the standard dimension or the cylinder q Machining dimension of part (h):
liner (b) contact surface of the counterbore is 0 – Max. 0.06 mm
blackened and grained (particularly in the for- q Angle of part (i) to cylinder center (straight
ward and backward directions) more than a line): 90° +30'
0
half of the contact surface, repair within the q Remove burrs and sharp edges from the
allowable limit of counterbore depth (d). tapered portion etc.
q If the counterbore depth after the repair is q (j) is the cylinder center.
14.05 – 15.525 mm, adjust cylinder liner pro- q (l) is 0.2 – 0.4 mm.
jection (c) to 0.07 – 0.15 mm with shims.
Unit: mm
Standard size Repair limit

Counterbore depth (d) 14 +0.05

0 15.46

Cylinder liner projection (c) — 0.07 – 0.15

Counterbore surface
roughness Max. 12.5S

Grinding shape See figure below

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q Set the machining margin of counterbore por-

tion depth (d) so that the cylinder liner projec-
tion will be within the standard value.
q If counterbore portion depth (d) exceeds the
standard dimension and the counterbore por-
tion needs to be ground within the allowable
limit, set the machining margin so that 1 shim
(1) shown below will be used for 1 cylinder.

Shims for adjusting counterbore depth

(reference)
Weight
Part No. T t Remarks
(kg)
6162-29-2260 1.50 0.025 0.004
6162-29-2250 0.80 0.025 0.002
6162-29-2240 0.50 0.025 0.001
6162-29-2230 0.26 0.025 0.001
6162-29-2220 0.20 0.020 0.001
6162-29-2210 0.16 0.016 0.001

a Outside diameter (m) and inside diameter (n)

of shim (1) are as follows.
q (m): 205.5 ± 0.15 mm
q (n): 194.6 +0.030
0 mm

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Check and identification after q After repairing, stamp the contents of repair on
repair by grinding the cylinder block top (cast surface) (a).
a The flywheel side of the cylinder block is indi-
q After repairing by grinding, check the flat por- cated by the arrow.
tions around the water and oil holes on the cyl-
inder block top for flaw. Oversize head
gasket Shim Stamp
q Remove burrs and sharp edges sufficiently.
After grinding the top, if cylinder block height — — Unnecessary

Spare parts
q
(H) is larger than the standard dimension and Q — OS

used
within allowable limit (488.56 – 488.96 mm), be — Q SH
sure to use the oversize head gasket. Q Q SW
Unit: mm Stamp letter size shall be 5 – 10 mm.
Head gasket Part No. Plate thickness
Standard 6240-11-1811 2.0
Oversize 6240-19-1810 2.4

a The 2 letters of "OS" are stamped on the plate

for identification.

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Gasket sealant application

procedure
q When press fitting the cylinder liner again after
pulling it out, apply gasket sealant LG-6 to the
surface of the counterbore which will be con-
tact with the underside of the liner flange
according to the following procedure.
When using a shim to this part, apply the gas-
ket sealant similarly, too.

a The following gasket sealants commercially

available are equivalent to LG-6.
q THREEBOND, TB1215
q NIHON HERMETICS, SS-60F
When shim is used
q Thinly apply LG-6 to underside (e) of shim
(1) and fit the shim to the block deck.
q Apply LG-6 to gasket sealant application
area (a) similarly to the case when no
shim is used.

1. Wipe off dirt, oil etc. with cloths from the con-
tact surfaces of the cylinder block counterbore
and liner flange.

2. Apply LG-6 to gasket sealant application area

(a).
q The string diameter must be f2 – 3.
q Overlap length (b) of the starting and end-
ing points must be 6 ± 6 mm.
q (c) is the block top.
q (d) is the liner fitting portion.

170E-5 Series 23
SEN05196-01 90 Repair and replacement of parts

3. Press fit liner to the cylinder block. At this time, 7. Using liner driver (2), press fit the cylinder liner
apply rubber lubricant (RF-1) to the liner O-ring to the cylinder block.
and seal. a Squeeze out the gasket sealant applied to
a DS-50 manufactured by DAIDO CHEMI- the counterbore according to the following
CAL INDUSTRY is equivalent to RF-1. procedure.
a IF RF-1 is not available, apply a very little
amount of engine oil (SAE30) to the O-
ring and block contact surface of the seal
just before press fitting the liner.
a Evenly apply engine oil all over the cylin-
der block contact surface with the hand.

4. Apply a little amount of engine oil (SAE30) to

the liner O-ring, clevis seal and cylinder block
contact surface just before press fitting the
liner.
a Evenly apply the engine oil all over the cyl-
inder block contact surface with the hand.

8. Using the used head gasket, tighten the cylin-

der head temporarily.
3 Mounting bolt:
255 ± 10 Nm {26 ± 1 kgm}
a Tighten the head bolts in the order shown
below.

5. Insert the liner in the cylinder block, directing

stamp "GN" on its top forward and taking care
not to damage the O-ring.

6. Push in the liners with both hands, applying

your weight.
a If the liner is not inserted smoothly when
you apply your weight, check the cylinder
block for burrs and sharp edges since the
O-ring may be damaged.

24 170E-5 Series
90 Repair and replacement of parts SEN05196-01

9. Take out the cylinder head and wipe off the

gasket sealant projected from between the cyl-
inder liner and cylinder block.
a If the gasket sealant sticks to grommet (3)
of the head gasket, it deforms the grom-
met into a heart shape and can cause
coolant leakage into water hole (4).
Accordingly, wipe off the gasket sealant
thoroughly.
a Be sure to perform steps 8 and 9.

170E-5 Series 25
SEN05196-01 90 Repair and replacement of parts

Repair of crankshaft by grinding Pin journal oil hole (See figure below)
q Finish part (d) with sandpaper.
q When the crankshaft is worn, seized or dam- q Check part (e) extremely carefully since
aged slightly and needs to be repaired, grind it quenching crack tends to occur in that part.
to one of the following undersizes.
Undersizes: 0.25, 0.50, 0.75, 1.00 mm
q If the crankshaft is bent or worn unevenly, it
should not be repaired but should be replaced.
(Repairing the crankshaft requires high tech-
nologies)
q Finish fillet portion (R), shoulder portion (r) and
area (R) around the hole of the crankshaft with
extreme care.

Finish dimensions of fillet portion

0
(R): 6.5 –0.5 mm
Surface roughness: 1.6S

q Finish the main journal and pin journal accord-

ing to the following procedure.
Main journal oil hole (See figure below)
q Dimension of tapered part (a) of oil hole: 16 mm
q Angle (b) of tapered part of oil hole: 120°
q Surface roughness of oil hole top (c):
1.6S (Finished with sandpaper)
q Dimension of parts (R) at 2 places: 1 – 2 mm
q The outside surface roughness of the pin jour-
nal and main journal must be maximum of
0.6S.
Equipment necessary for grinding
q Magnaflux inspection machine
q Shore hardness tester
q Etching kit
q Crankshaft grinding machine
q Crankshaft polishing machine
q Surface roughness gauge
q Fillet (R) gauge

26 170E-5 Series
90 Repair and replacement of parts
Inspection before repair by grinding
Visual check
q Check for crack, damage, discoloration by sei-
zure, wear, etc. and judge if the crankshaft can
be repaired by grinding.
Hardness check of journal surface
Allowable range: 63 – 69 HS
Allowable limit: 63 HS
a If the hardness is below the allowable limit, dis-
card the crankshaft.
Check for twist
0
Tolerance of throw (a): 85 –0.15 mm
Allowable limit of horizontal displacement (differ-
ence in throw between No. 1 cylinder and rearmost
cylinder): 0.15 mm
Dispersion of throw (a) among cylinders: Max. 0.15
If any of the above items is out of the allowable
limit, discard the crankshaft.
q Dimension (b) is the stroke.
Check during and after repair by grinding
Check of fillet (R) portion
q Check that each fillet (R) portion is connected
to the journal shoulder smoothly.
q Using fillet (R) gauges [1] and [2], check that
"dimension (R)" is between the minimum value
gauge and maximum value gauge.
q (c) is the contact point of minimum value
gauge.
q (d) are the contact points of maximum value
gauge.
Fillet (R) Min. radius: 6.00 mm
Max. radius: 6.50 mm
170E-5 Series
SEN05196-01
Check for grinding burn mark by etching
q After repairing by grinding, check that there is
no grinding burn mark by etching inspection.
q If any burn mark is detected, grind about 0.02
mm again to the next undersize dimension.
Undersizes: 0.25, 0.50, 0.75, 1.00 mm
q After checking, neutralize and clean the
checked surface and apply rust preventive oil.
Magnaflux inspection
q Before using the repaired crankshaft, check it
by magnaflux inspection to ensure that it has
no crack.
q Extremely closely check journal fillet portion (a)
which is in the dangerous area of each web of
the crankshaft.
q After the magnaflux inspection, be sure to
demagnetize the crankshaft.
Measurement of bend (Measurement of align-
ment)
q Measure the bend of the ground crankshaft
and ensure that it is within the standard value.
q Measure the bend (alignment) at the following
4 places.
Tolerance of overall length alignment:
Max. 0.150 mm
Tolerance of adjacent alignment:
Max. 0.070 mm
Tolerance of front end alignment: Max. 0.04 mm
Tolerance of rear end alignment: Max. 0.03 mm
27
SEN05196-01 90 Repair and replacement of parts

Grinding of main journal Grinding of pin journal

a Grind all the main journals to the same under- a Grind all the pin journals to the same under-
size. size.
a When grinding, leave the polish finishing mar- a When grinding, leave the polish finishing mar-
gin of 0.007 – 0.008 mm. gin of 0.007 – 0.008 mm.

Undersize dimensions of main journal Undersize dimensions of pin journal

Unit: mm Unit: mm
Size Standard size Tolerance Size Standard size Tolerance
Standard 140.000 Standard 108.000
0.25 US 139.750 0.25 US 107.750
0 0
0.50 US 139.500 0.50 US 107.500
–0.025 –0.022
0.75 US 139.250 0.75 US 107.250
1.00 US 139.000 1.00 US 107.000

Roundness, cylindricality (TIR) and surface Roundness, cylindricality (TIR) and surface
roughness of main journal roughness of pin journal
Roundness: 0.010 mm Roundness: 0.010 mm
Cylindricality: 0.010 mm Cylindricality: 0.010 mm
Surface roughness: 0.6S Surface roughness: 0.6S

Grinding of thrust surface (#6) Grinding of sides of main journal and pin journal
a It is not always required to grind the thrust sur- q When repairing worn surfaces (c) of main jour-
faces of the front and rear to the same under- nal (a) and pin journal (b), limit the grinding
size dimension. quantity to the minimum.
a If the thrust surface was repaired by grinding, q (d) is thickness of worn surface.
ensure that the end play of the crankshaft is q Width of crankpin journal
within the allowable range. Standard: 72 +0.074
0 mm
(See the section of general assembly) Allowable limit: 72.074 mm
Undersize dimensions of thrust surface q Width of main journal (#6 only)
Unit: mm Standard: 64 +0.5
0 mm
Rear thrust surface Allowable limit: 64.56 mm
Standard 0.25 OS
Standard size 64 +0.050
0 64.25 +0.050
0
Standard
Front thrust

Repair limit 64.060 64.310

surface

Standard size 64.25 +0.050

0 64.50 +0.050
0
0.25 OS
Repair limit 64.310 64.560

q Squareness of thrust surface (TIR)

Permissible deviation: 0.04 mm

28 170E-5 Series
90 Repair and replacement of parts
Dressing of grinding stone
q Dress the grinding stone for each journal.
q Grinding stone dresser
Grooving angle (a): 75° ± 1°
Tip diameter (b): 0.38 ± 0.25 mm
Use a cylindrical copper rod of the above form
having an industrial diamond embedded in its
tip.
q Adjust the grinding stone edge to the arc of the
fillet with the grinding stone modifying device.
Test and correct the grinding stone edge by
grinding a piece of wood on trial, while check-
ing with gauges.
Prevention of grinding burn
q Apply the flange grinding method.
q Use all the width of the grinding stone.
Avoid grinding the boss surface.
q Apply cooling oil sufficiently.
q Set the standard peripheral speed of the grind-
ing stone to 2,000 m/min when the crankshaft
rotation speed is 50 rpm.
170E-5 Series
SEN05196-01
Finishing of surface
q Surface roughness standard
Journal surface (c): 0.6S
Thrust surface and fillet portion (d): Max. 1.6S
Front seal insertion portion (e) (Range of 32 –
85 mm from end): 1 – 2S (Finished with sand-
paper)
End portion (f) (Range of 32 mm from end):
3.2S
q Polish finishing margin: 0.007 – 0.008 mm
Work after repair by grinding
q Ensure again that each dimension is as speci-
fied.
q Clean each part thoroughly and apply rust-pre-
ventive oil.
q When storing the crankshaft for a long period,
support it on 3 points or keep it erected with a
sling.
Balancing (Reference)
Avoid performing repair that may affect the crank-
shaft balancing.
q Allowable limit of unbalance: 110 gcm
Limits for reading balance accurately
Bend of crankshaft: 0.150 mm (TIR)
Rotation speed of crankshaft: Max. 325 rpm
q When balancing, perform the following correc-
tions.
Rear key way: 66 gcm
Reamed hole: 119 gcm
q Correct the balance by drilling holes in or grind
the counterweight, if necessary.
Repair quantity limit of counterweight: 56 g
Drilling direction: Radial direction
Number of holes: Max. 6
Hole diameter: 19 mm or 23 mm
Hole depth: Max. 50 mm
Distance between hole and side: Min. 3 mm
Distance between holes: Min. 5 mm.
29
SEN05196-01 90 Repair and replacement of parts

Measuring procedure for bend and outside

diameter of journal portion
1. Measure the bend on the basis of the #1 and
#7 journals. Apply the dial gauge to the journal
to be measured, set the dial to 0 at the top, and
rotate the crankshaft 1 turn and read the mini-
mum and maximum values.

2. Measure the outside diameter of the main jour-

nal in directions (X) and (Y) at 2 places ((1)
and (2)) and that of the pin journal in directions
(X) and (Y) at 2 places ((1) and (2)) with a
micrometer or an air micrometer.

30 170E-5 Series
90 Repair and replacement of parts SEN05196-01

Improvement of surface 3. Check the surface roughness with the stan-

roughness of crankshaft journal dard piece.
a Measure the surface roughness of the
q If the surface roughness of the crankshaft jour- journal by comparing it with the standard
nal does not satisfy the standard value, piece.
improve it. Surface roughness standard (Pin journal
a Before starting polishing, brush the oil holes of and main journal)
the crankshaft and blow air into them. Journal surface: Max. 0.8S
Round part: Max. 3.2S

Improvement of journal surface roughness
When improving with special polishing
machine
q Use the special polishing machine shown
below.
4. Check the surface roughness. If it does not
satisfy the standard, make round polishing with
the sandpaper #500 again between both ends.
a After improving the surface roughness, be
sure to brush the oil holes and blow air
into them.
a Ensure that there is no flaw or bruise on
the journal portion and the round part of
each fillet.
If there is any flaw or bruise, polish again
from step 1.

1. Set the workpiece rotation speed to 40 – 50

rpm and use sandpaper of #320 (belt type).
Make round polishing of each journal between
both ends with the sandpaper in the dry state
without using honing oil.
Move the sandpaper smoothly without stop-
ping at a place.

2. Replace the sandpaper with one of #500.

Apply honing oil to the journal surface. Make
round polishing with the sandpaper between
both ends of the journal, while operating
machine handle (1) to vibrate the sandpaper
by the play.
Move the sandpaper smoothly without stop-
ping at a place.

170E-5 Series 31
SEN05196-01
When using clamp jig for polishing (When spe-
cial polishing machine is not available)
q Use the clamp jig shown below.
1. Use the crankshaft grinding machine and pol-
ish under the following condition.
Sandpaper: #800
Cutting oil: Honing oil
Rotation speed of crankshaft: 40 rpm
2. Set the polishing time to about 6 minutes for
each journal. Polish by moving the clamp jig in
the axial direction of the journal between both
ends of the play (about 5 mm) between the
clamp jig and journal width.
After finishing honing the journal, replace the
sandpaper with new one.
When honing the pin journal, set it to the cen-
ter of rotation for safety.
32
90 Repair and replacement of parts
Assembly and using procedure of clamp jig
1. Assemble the clamp jigs for the pin journal and
main journal as shown in the following figure.
2. Cut off sandpaper of #800 to the shapes (a)
and (b) shown below.
q (a) is for the pin journal and its size is as
follows.
L: 205 mm, W: 95 mm
q (b) is for the main journal and its size is as
follows.
L: 255mm, W: 88 mm
a Make slits (c) 20 mm long on both sides of
the sandpaper at intervals of 10 mm and
cut off one part at each end (d).
170E-5 Series
90 Repair and replacement of parts SEN05196-01

3. Insert 2 pieces of upper and lower sandpapers

(a) or (b) prepared in step 2 into slits (e) and fix
their ends with tape (f).

4. Fold slit portion (d) of the sandpaper along the

round part of the clamp jig.

5. Hold the journal with the clamp and fix the

lever ends with rubber tube (g) etc.

Measurement of surface roughness

Surface roughness standard
q Check with the surface roughness tester that
the surface roughness of the main journal and
pin journal is within the standard of 0.6S.
q If tester is not available, lightly rub the journal
in the axial direction with sandpaper of #1500
and observe the surface through a 30x power
magnifier. If the cross lines made with the
sandpaper are connected, the surface rough-
ness is within the standard value.
q If the cross lines are not connected, the journal
surface is rougher. In this case, polish again.

Cleaning after improving surface roughness

q After improving the surface roughness, be sure
to brush the oil holes and blow air into them.
q Ensure that there is no flaw or bruise on the
journal portion and the round part of each fillet.

170E-5 Series 33
SEN05196-01 90 Repair and replacement of parts

Clamp jig parts drawing (for pin journal)

Plate (Use 2 pieces for 1 jig)

Handle (Use 2 pieces for 1 jig)

34 170E-5 Series
90 Repair and replacement of parts SEN05196-01

Clamp jig parts drawing (for main journal)

Plate (Use 2 pieces for 1 jig)

Handle (Use 2 pieces for 1 jig)

170E-5 Series 35
SEN05196-01

KOMATSU 170E-5 Series engine

Form No. SEN05196-01

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)

36