Disassembly, Inspection And Reassembly Of Engines - Komatsu 82E Series Shop Manual

4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF
ENGINES
4.1 Complete Disassembly and Reassembly ............................................................................................. 4-2
4.1.1 Introduction ........................................................................................................................................... 4-2
4.1.2 Special service tools ............................................................................................................................. 4-3
4.1.3 Complete disassembly.......................................................................................................................... 4-8
4.1.4 Precautions before and during reassembly ........................................................................................ 4-12
4.1.5 Adjusting operation ............................................................................................................................. 4-12
4.2 Cylinder Head: Disassembly, Inspection and Reassembly ................................................................ 4-13
4.2.1 Components (2-valve cylinder head) .................................................................................................. 4-13
4.2.2 Disassembly procedure ...................................................................................................................... 4-13
4.2.3 Reassembly procedure....................................................................................................................... 4-14
4.2.4 Servicing points .................................................................................................................................. 4-15
4.2.5 Parts inspection and measurement .................................................................................................... 4-19
4.2.6 Valve seat correction .......................................................................................................................... 4-23
4.2.7 Valve guide replacement .................................................................................................................... 4-24
4.2.8 Valve stem seal replacement.............................................................................................................. 4-25
4.3 Gear Train and Camshaft ................................................................................................................... 4-26
4.3.1 Components ....................................................................................................................................... 4-26
4.3.2 Disassembly procedure ...................................................................................................................... 4-26
4.3.3 Reassembly procedure....................................................................................................................... 4-26
4.3.4 Servicing points .................................................................................................................................. 4-27
4.3.5 Parts inspection and measurement .................................................................................................... 4-30
4.3.6 Oil seal replacement (Gear case side) ............................................................................................... 4-32
4.3.7 Camshaft bushing replacement .......................................................................................................... 4-32
4.4 Cylinder Block..................................................................................................................................... 4-33
4.4.1 Components ....................................................................................................................................... 4-33
4.4.2 Disassembly procedure: ..................................................................................................................... 4-33
4.4.3 Reassembly procedure:...................................................................................................................... 4-33
4.4.4 Servicing points .................................................................................................................................. 4-34
4.4.5 Parts inspection and measurement .................................................................................................... 4-38
4.4.6 Cylinder bore correction...................................................................................................................... 4-49
4.4.7 Piston pin bushing replacement.......................................................................................................... 4-50
4.4.8 Oil seal replacement (Flywheel housing side) .................................................................................... 4-50
82E-5 - 98E-5 SERIES

4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES

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