JOBSHEET O/H ENGINE

A. Alat dan bahan

1. Alat
- SST Penahan Pulley
- Kunci Double Hexagonal (10 dan 12)
- Kunci Socket Double Hexagonal (10)
- Caddy Tools
- Piston Ring Compressor
- Piston Ring Expander
- Oil Can
- Micrometer + Stand (0 - 25, 50 - 75)
- Jangka Sorong
- Dial Bore Gauge
- Fuller Gauge
- Plastic Gauge
- Kunci Momen
- Mistar Baja
- Manual Book

2. Bahan
- Oli Mesin
- Majun
- Nampan Plastic (5 pcs)
- APD
3. Media
- Engine Stand

B. Persiapan
- Pemeriksaan kelengkapan alat dan bahan
- Memeriksa Alat Ukur
- Pemeriksaan lingkungan kerja
- Pemeriksaan kelengkapan K3

C. Langkah Kerja
1. Membuka tutup kepala silinder
2. Melepas pulley
3. Melepas cover timing
4. Melepas timing chain
5. Melepas camshaft
6. Melepas kepala silinder
7. Melepas carter
8. Melepas piston
9. Memeriksa kerataan kepala silinder
10. Pengukuran diameter piston
11. Pengukuran diameter silinder
12. Pengukuran diameter crankpin journal
13. Pengukuran camshaft

D. Kriteria Penilaian
 Possible
Section Skor
Mark
1. Preparation (Persiapan) 9
2. Dismantling Timing chain (Melepas timing Chain) 13
3. Dismantling Cylinder Head (Melepas Kepala Silinder) 5,5
Dismantling Piston, Connecting Rod and Crankshaft
4. 5,5
( Melepas piston, batang piston dan poros engkol)
Cylinder Bore and Piston Measurement. (Mengukur
5. 17
diameter silinder dan piston)
Crankshaft and Bearing Measurement. (Mengukur
6. 16
poros engkol dan bantalan poros engkol)
Assembling Piston, Connecting Rod and Crankshaft
7. 10
(Merakit piston, batang poros engkol dan poros engkol)
8. Assembling Cylinder Head (Merakit kepala silinder) 10
Assembling Timing chain Cover and oil pan (Merakit
9. 14
penutup timing chain dan panci oli)
10.
Task Total 100

1. Preparation yes No Actual Comments

1.1 Use workshop manual (Gunakan 0,5 0

buku manual)

1.2 Checked all equipments. (cek 1 0

semua perlengkapan)

1.3 Checked all instructions (cek 1 0

semua perintah kerja)

1.4 Selected the correct tools. (Memilih 1 0

alat yang dibutuhkan)

1.5 Calibrate measuring tools. 1 0

(Melakukan kalibrasi alat ukur)

1.6 Used logical working procedur 1 0

(Menggunakan SOP)

1.7 Clean up the working area 1,5 0

(Membersihkan area kerja)

1.8 Clean up tools and Equitment 2 0

(Membersihkan peralatan)

Sub -Total 9 0
 2. Dismantling timing Chain yes No Actual Comments

2.1 Remove crankshaft bolt and pulley. 3 0

(Melepas baut poros engkol dan
puli)
2.2 Remove cover valve 2 0
2.3 Remove timing chain front cover ( 2 0

2.4 Remove timing chain 2 0

2.5 Remove timing chain tensioner 2 0
2.6 Remove Timing chain guide 2 0
Sub -Total 13 0

3. Dismantling cylinder head yes No Actual Comments

(Melepas selinder head)
3.1 Remove Camshaft (Melepas 0,5 0
Camshaft in dan ex)
3.2 Remove rocker arm (Melepas 0,5 0
rocker arm)
3.3 Remove cylinder head bolts in 2,5 0
correct order (Melepas baut kepala
silinder sesuai urutan)
3.4 Remove & kip cylinder head 1 0
( Melepas kepala silinder)
3.5 Remove cylinder head gasket. 1 0
(Melepas paking kepala silinder)
Sub -Total 5,5 0

4. Dismantling piston and connecting yes No Actual Comments

rod
4.1 Remove connecting rod cap 2,0 0
(Melepas tutup batang piston)
4.2 Remove piston (Melepas piston) 3,5 0
Sub -Total 5,5 0
 5. Cylinder Bore & Piston yes No Actual Comments
Measurement
5.1 Measure outer Diameter piston 2 0
no.1 (Mengukur diameter luar
piston no. 1)
5.2 Measure Inner Diameter Cylinder 5 0
no.1 (Mengukur diameter dalam
silinder no. 1)
5.3 Measure piston oil clearance 2 0
cylinder no.1 (Mengukur celah
silinder no. 1)
5.4 Roundness cylinder no.1 2 0
(Mengukur keovalan silinder no. 1)
5.5 Cylindricity no.1 (Mengukur 2 0
ketirusan silinder no. 1)
5.6 Measure Piston ring side clearance 2 0
no.1 (Mengukur celah sisi ring
piston no. 1)
5.7 Measure Piston end gap clearance 2 0
no.1 Mengukur celah ujung piston
no. 1)
Sub -Total 17 0

6. Crankpin & Bearing Measurement yes No Actual Comments

7. Assembling
(No.1) piston & connecting yes No Actual Comments
6.1 rod
Measure Crank pin Outer Diameter 4 0
7.1 Assemble piston ring
No.1. (Mengukur in correct
diameter luar 3 0
setting.
crankpin(Merakit
no. 1) ring piston pada
6.2 posisi yang
Measure Crank benar)
pin Bearing Inner 4 0
7.2 Lubricate No.1.
Diameter components
(Mengukurbefore 2 0
assembling
diameter bantalan dalam crankpin
7.3 Assemble
no 1) piston to cylinder block 3 0
6.3 (Merakit
Measure piston kedalam
Oil clearance blok Pin.
Crank 2 0
8. silinder
(Mengukur) celah
Assembling oli crank
cylinder head pin) yes No Actual Comments
7.4
6.4 Assemble
Crank pin connecting rod & cap
roundness (Mengukur 2 0
8.1 (Merakit
Assemble cylinder headdan
keovalan batang
crank piston
pin) gasket 2 0
6.5 penutup)
Crank pin taper (Mengukur
(Merakit paking kepala silinder) 2 0
8.2 ketirusan cylinder
Lubricate crank pin)head bolt 1 0
6.6 Measure Connecting
(Melumasi baut kepala rodsilinder)
& play 2 0
8.3 Sub -Total
(Mengukur batang piston
Install Cylinder Head (Memasang dan jarak 10
2 00
main) silinder)
kepala
8.4 Sub -Total
Tighten cylinder head bolts in 16
3 00 With torque
correct order. (Mengencangkan
baut sesuai SOP
8.5 Assemble rocker arm & cover. 2 0
(Merakit rocker arm dan penutup)

Sub -Total 10
9. Assembling timing chain yes No Actual Comments

9.1 Assemble crank shaft timing gear 2 0

(Merakit gir poros engkol)
9.2 Assemble cam shaft timing gear & 2,5 0
timing chain (Merakit gir camshaft)
9.3 Install cam shaft timing gear bolt. 2 0 With torque
(Memasang baut camshaft)
9.4 Install timing chain tensioner. 2 0
(Memasang pengencang rantai)
9.5 Install timing chain cover. 2 0
(Memasang tutup rantai timing)
9.6 Assemble oil pan and gasket 1,5 0
(Memasang gasket panci oli)
9.7 Install crankshaft pully and bolt. 2 0 With torque
(Memasang pully poros engkol dan
baut)
Sub -Total 14 0
 Report Sheet

ENGINE MECHANICAL
a) Piston

Description Specification Actual Serviceable Unserviceable

No. 1 Piston Outer Diameter
(Diameter luar piston no. 1)

b) Cylinder bore

Description Specification Actual Serviceable Unserviceable

No. 1 Cylinder inner diameter A1:
(Diameter dalam silinder no. B1:
1) C1:
A2:
B2:
C2:
Roundness Cylinder No.1
(Keovalan silinder no. 1)
Cylindricity Cylinder No.1 A1:
( Ketirusan silinder no. 1) B1:

c) Piston ring

Description Specification Actual Serviceable Unserviceable

Piston 1 Side clearance (No.
1 compression ring) (Celah
sisi piston no. 1 (ring
kompresi no. 1)
Piston 1 Side clearance (No.
2 compression ring) (celah
sisi piston no. 1 (ring
kompresi no. 2)
Piston 1 End Gap (No. 1
compression ring) (Celah
ring piston no. 1 (ring
kompresi no. 1)
Piston 1 End Gap (No. 2
compression ring) (Celah
ring piston no. 1 (ring
kompresi no. 2)
d) Crankshaft
 Description Specification Actual Serviceable Unserviceable
Crankshaft & Play (poros
engkol dan jarak bebas)
No. 1 Crankshaft journal Outer A1:
Diameter (diameter luar jurnal B1:
poros engkol no. 1)
A2:
B2:
No. 1 Main Bearing Inner A1:
Diameter. (Diameter dalam B1:
bantalan utama no. 1)
A2:
B2:
Oil clearance (No. 1 cylinder)
(Celah Oli (silinder no. 1))
Crankshaft roundness
(Keovalan poros engkol)
Crankshaft taper (Ketirusan
poros engkol)

e) Crank Pin

Description Specification Actual Serviceable Unserviceable

Connecting rod & play
(batang piston dan jarak
main)
No. 1 Crank pin journal A1:
Outer Diameter (Diameter B1:
luar crank pin jurnal no. 1)
A2:
B2:
No. 1 Main Bearing Inner A1:
Diameter. (Diameter dalam B1:
bantalan utama no. 1)
A2:
B2:
Oil clearance (No. 1 cylinder)
(Celah Oli (silinder no. 1))
Crankpin roundness
(Keovalan crank pin)
Crankpin taper (ketirusan
crank pin)