Engine Component Dimensions And Wear - Kohler 4EOZ Service

10.5 Engine Component Dimensions and Wear

Part Description
Cylinder Liner
Bore: Bore: upper diameter upper diameter
below diameter
Note: It is not possible to rehone the liner because of the N t I i ibl
conical shape. We always suggest to exchange the
cylinder together with the piston and rings.
Piston
Crown diameter
st
1 compression ring groove height p g g
nd
2 compression ring groove height
Oil scrapper ring groove height
Diameter of the piston pin hole
Clearance between:
st t
groove/1 comp. ring height
nd nd
groove/2 /2 comp. ring height
groove/oil scrapper ring height / il
st st nd nd
1 1 and 2 d 2 compression ring gaps
oil scrapper ring gap oil scrapper ring gap
Note: The excessive clearances or gaps are because of
the abnormal wears of the cylinder liner, piston, and
rings. We always suggest to exchange the cylinder
together with the piston and rings.
Crankshaft
Journal diameter (D1) ( )
Journal diameter (D3) ( )
Journal diameter (D2)
Journal diameter : undersize of 0.25 mm (0.010 in.)
D1
D2
Journal diameter : undersize of 0.50 mm (0.020 in.)
D1 D1
D2 D2
Crankshaft gear diameter C k h ft di t
Diameter of crankshaft gear journal Diameter of crankshaft gear journal
Clearance: Clearance:
Con rod bearing and crankshaft journal diameter Con rod bearing and crankshaft journal diameter
Bushing and crankshaft journal diameter Bushing and crankshaft journal diameter
88 Section 10 Generator and Engine Disassembly/Reassembly
h h li b f h
g
i h i h
i h i ht
i i
Dimensions
Original
Max. mm (in.) Min. mm (in.)
81 900 (3 2244) 81.900 (3.2244) 81 880 (3 2236) 81.880 (3.2236)
82.030 (3.2295) 82.010 (3.2287)
81.967 (3.2270) ( ) 81.953 (3.2265)
2.120 (0.0835) ( ) 2.100 (0.0827)
2.070 (0.0815) 2.050 (0.0807)
4.040 (0.1591) 4.020 (0.1583)
22.010 (0.8665) 22.04 (0.8663)
0.145 (0.0057) 0.110 (0.0043)
0 092 (0 0036) 0.092 (0.0036) 0.060 (0.0024) 0 060 (0 0024)
0.065 (0.0026) 0 065 (0 0026) 0.030 (0.0012) 0 030 (0 0012)
0.500 (0.0197) 0 500 (0 0197) 0 300 (0 0118) 0.300 (0.0118)
0.500 (0.0197) 0 500 (0 0197) 0 250 (0 0098) 0.250 (0.0098)
40.080 (1.5780) ( ) 40.060 (1.5772)
35.023 (1.3789) ( ) 35.015 (1.3785)
40.030 (1.5760) 40.020 (1.5756)
39.830 (1.5681) 39.810 (1.5673)
39.780 (1.5661) 39.770 (1.5657)
39.580 (1.5583) 39 580 (1 5583) 39.560 (1.5575) 39 560 (1 5575)
39 530 (1 5563) 39.530 (1.5563) 39 520 (1 5559) 39.520 (1.5559)
22 000 (0 8661) 22.000 (0.8661) 21 970 (0 8650) 21.970 (0.8650)
22 029 (0 8673) 22.029 (0.8673) 22.008 (0.8665) 22 008 (0 8665)
0 060 (0 0024) 0.060 (0.0024) 0.030 (0.0012) 0 030 (0 0012)
0 050 (0 0020) 0.050 (0.0020) 0.020 (0.0008) 0 020 (0 0008)
Max. Limit
mm (in.)
82.000 (3.2283) 82 000 (3 2283)
82.130 (3.2335)
( ) --
( ) --
--
--
--
0.170 (0.0067)
0.140 (0.0055) 0 140 (0 0055)
0.110 (0.0043) 0 110 (0 0043)
1 000 (0 0394) 1.000 (0.0394)
1 000 (0 0394) 1.000 (0.0394)
( ) --
( ) --
--
--
--
--
--
--
--
0.110 (0.0043) 0 110 (0 0043)
0 080 (0 0031) 0.080 (0.0031)
TP-6137 5/03