Contents

1. Practice data .................................................................................... 2

2. Present determine and adjustment methods ................................. 5

3. Assembly procedure ........................................................................ 8

4. Engine assembly procedure .......................................................... 51

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1. Practice data
1.1. Engine specifications
Table 1: Engine Technical Parameters
No. Name Unit Value
1 Engine type SYM
2 No. of cylinders 4

3 Displacement cm3 1343

4 Bore x stroke mm 75 x 76
5 Firing order 1-3-4-2
6 Rotational direction Clockwise

1.2. Valve system

Table 2: Valve System Parameters
No. Name Unit Value
1 Type SOHC
2 No. of camshafts 1
3 No. of valves 4

4 No. of rocker arms 4

5 No. of pushrods None
6 Drive method Belt drive

7 Sensors None

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1.3. Ignition system
Table 3: Ignition System Parameters
No. Name Unit Value
1 Type Direct ignition
2 Sensors None
3 Spark plug 4

1.4. Fuel supply system

Table 4: Fuel Supply System Parameters
No. Name Unit Value
1 Type Gasoline IDI
2 Sensor None
3 Fuel type RON92
4

1.5. Lubricating system

Table 5: Lubricating System Parameters
No. Name Unit Value
1 Type
2 Pump Rotary pump
3 Engine oil No lubricating oil
4 Oil filter 1
5 Floating oil intake 1

3
1.6. Cooling system
Table 6: Cooling System Parameters
No. Name Unit Value
1 Type Forced circulation water
cooling
2 Pump 1

3 Sensors None

1.7. Powertrain system

Table 7: Powertrain System Parameters
No. Name Unit Value
1 No. of pistons 4
2 No. of piston rings 2 compression rings, 2
(compression rings, oil rings) oil scrapper rings/each
3 Piston pin piston
4

4 No. of connecting rods 4

5 Connecting rod bearings 4

6 Crankshaft 1

7 No. of main crankshaft journals 5

8 Crankpin 4

9 Flywheel 1
10 Counterweight 4

11 Web 4

12 Crankpin oil hole 7

4
 1.8. Measurement data
Table 8: Measurement parameters
No. Name Unit Value
1 Bore 1,2,3,4 74.52; 74.58; 74.60; 74.58
2 Compression ring gap 0.07; 0.08; 0.09; 0.08
3 Crankshaft thrust clearance 0.16

4 Initial valve clearance 0.24 (intake), 0.31 (exhaust)

5 Adjusted valve clearance Acceptable value (No

Adjusting)
6 Spark plug gap 0.85; 0.70; 0.82; 0.32

2. Present determine and adjustment methods

2.1. Present methods of determining the rotational direction of the practice
engine

We determine the rotational direction of engine by 2 methods:

Method 1: Check the arrow marked on the crankshaft pulley – which is clockwise

Method 2:

- Step 1: Rotate the pulley in clockwise direction

- Step 2: Observe the rocker arms on the first piston

- Step 3: Observe whether the exhaust valves close and intake valves open
(overlap)

- Step 4: In this practice model they did open and close, so we confirmed that the
rotational direction of the engine is clockwise

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2.2. Present methods of determining the firing order of the practice engine

- Step 1: Determine rotational direction of engine

- Step 2: Remove spark plugs and put 4 pieces of paper into spark plug positions

- Step 3: Rotate the crankshaft pulley and watch the order of the paper blown out

- Step 4: Firing order of this engine is 1-3-4-2

2.3. Present methods of determining the TDC's position of the practice engine

- Step 1: Determine rotational direction of engine

- Step 2: Remove spark plugs and cylinder head cover, determine location of
intake and exhaust valves

- Step 3: Rotate crankshaft pulley to the overlap angle of the first piston, now the
first piston is at TDC

- Step 4: Repeat step 3 to determine TDC of other pistons

2.4. Present methods of adjusting valve clearance of the practice engine

- Step 1: Determine rotational direction, firing order

- Step 2: Remove spark plugs, cylinder head cover

- Step 3: Rotate crankshaft pulley so that the first piston is at TDC on

compression stroke (both intake and exhaust valves are closed)

- Step 4: Check valve clearance by putting a feeler gauge in between the valve
and the adjustment screw

- Step 5: To adjust clearance, first choose the desired value of feeler gauge

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 - Step 6: Hold adjustment screw by a slotted screwdriver, loosen the locking nut

- Step 7: Put feeler gauge in between adjustment screw and valve

- Step 8: Tighten adjustment screw until feeling resistance when sliding feeler
gauge in clearance

- Step 9: Hold adjustment screw by a slotted screwdriver, tighten the locking nut

- Step 10: Repeat step 5 to 9 for other clearances

2.5. Present methods of aligning camshaft and crankshaft of the practice engine

- Step 1: Rotate camshaft pulley until intake and exhaust valves of the first

piston rest on cam lobes

- Step 2: Adjust valve clearance of first piston

- Step 3: Rotate camshaft pulley until intake valves of first piston start to open

and exhaust valves start to close. Then rotate one more revolution

- Step 4: Rotate crankshaft pulley to TDC position of the first piston

- Step 5: Mark the alignment of the belt and pulley for easier to assembly later

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3. Assembly procedure

3.1. Practice model:

Fig. Practice model

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Fig. Inspection Process with Materials and Preparing Necessary Tools

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3.2. Practise tools
1) Tool chest

Fig. Tool Chest JTC 165

2) Common tools

Fig. Pulley Puller

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Fig. Piston ring expander plier

Fig. 3-jaw puller

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Fig. Valve spring compressor plier

Fig. Piston ring compressor

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 Fig. Torque wrench

3) Mesuring equipment

Fig. Caliper

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 Fig. Dial indicator

Fig. Feeler gauge

Fig. Micrometer
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 3.3. Assembly procedures
Step 1: Remove all spark plug wires and spark plugs

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Step 2: Remove the cylinder head cover

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Step 3: Remove camshaft's pulley cover

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Step 4: Rotate the crankshaft to align the TDC's mark on pulley coinciding with the 00
mark on the engine front cover.

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Step 5: Check the aligning marks on the camshaft. Mark the position of the timing
belt for easier assembly

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Step 6: Remove the nut of the crankshaft

Step 7: Use the puller to remove the crankshaft's pulley

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Step 8: Remove the crankshaft cover

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Step 9: Loosen the nut of the belt tensioner

Step 10: Remove the timing belt spacer on the crankshaft.

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Step 11: Remove the belt tensioner

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Step 12: Remove the timing belt out of the camshaft's pulley

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Step 13: Use screwdrivers to remove the crankshaft's pulley

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Step 14: Remove the engine cover

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Step 15: Remove the ignition distributor

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Step 16: Remove the exhaust manifold cover. Remove the exhaust manifold.

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Step 17: Remove fuel rail

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Step 18: Remove the intake manifold

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Step 19: Remove the oil filter

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Step 20: Remove the oil pan

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Step 21: Remove the rocker arm shaft’s pin

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Step 23: Loosen the camshaft journal caps from the outside to the inside

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Step 23: Remove the rocker arm shaft’s cap

Step 23: Remove the camshaft

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Step 24: Remove cylinder head bolts.

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Step 25: Remove the cylinder head

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Step 26: Use valve spring compressor to remove the valve assy

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Step 25: Remove valve stem seals

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 Remove the piston-connecting rod assy
Step 1: Use SST to clean soot in the cylinder

Step 2: Mark the order on the connecting rod cap

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Step 3: Remove the rod caps and rod bearings

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Step 4: Remove the piston assy

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 Remove the Main bearing cap and Crankshaft

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 Arrange all part in an order

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 Measuring Procedure
1) Piston’s Bore 1,2,3,4

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2) Spark plug gap

3) Piston’s outer diameter

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4) Compression ring gap

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4. Engine assembly procedure
The assembly procedure of engine varies among manufacturers. However, it still complies
with the assembly rule: “disassembly first, assembly last” and vice versa.
 Install the crankshaft
Step 1: Install the journal bearings and thrust bearings

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Step 2: Place the crankshaft into the cylinder block

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Step 3: Install the journal caps

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Step 4: Install the piston-connecting rod assy into cylinder

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Step 5: Install the oil pan

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Step 6: Install the intake and exhaust valves

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Step 7: : Install the camshaft bearing caps and Crankshaft

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Step 8: Install the cylinder head gasket

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Step 9: Install the cylinder head

Step 10: Install the timing belt on the crankshaft's pulley

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Step 11: Install the crankshaft cover

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Step 12: Install the crankshaft pulley

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Step 13: Install the crankshaft belt which is connected with the alternator

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Step 14: Install the camshaft cover

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Step 15: Install the intake manifold

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Step 16: Install the fuel rail

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Step 17: Install the exhaust manifold and exhaust manifold cover

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Step 18: Install the cylinder head cover

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