Maintenance Data - TOHATSU TLDI MD 115A SERIES Service Manual

Service Data

6. Maintenance Data

Description
Cylinder Head
Cylinder
Piston
Piston Rings
Piston Pin
Crank Shaft
Connecting Rod
Reed Valve Stopper
Reed Valve
Engine Block
2-12
Item
Build up of carbon in combustion chamber
Distortion or damage on mating surface
Corrosion
Cooling water passage clogged
Mating surface scratches and wear
Seizure, cylinder liner damage, or wear
Deposits in water jacket
Engine anode
Diameter
<Measure the external diameter at a point 11.5mm
(0.45 in) above the lower edge of the piston skirt.>
Piston clearance
<The gap between cylinder and piston.>
Carbon build up on piston crown and in ring
grooves
Scratch on the sliding surface
Measure clearance between piston ring and ring
groove.
Measure piston pin hole diameter
Clearance between piston pin and pin hole
Ring end gap
Note: Measurement of ring end gap ; If ring gauge
is not available, use cylinder bore top or bottom
with small wear.
Outer diameter
Deflection
<Measure with both ends supported.>
Bearing external diameter
Oil seal scratches
Loose rod
Small end inner diameter
Small end area side gap
Lift height
Fails to close, is worn or damaged
Compression
Note: Remove all four spark plugs and measure
after warming with the throttle fully open.
Standard Values
0.03 mm (0.0012in) or less for scratches
0.03 mm (0.0012in) or less for distortion
0.03 mm (0.0012in) or less for scratches
0.03 mm (0.0012in) or less for distortion
φ88.02 mm <0.5 mm oversaize : φ88.52 mm>
φ3.4654 in <0.0197 in oversize : φ3.4850 in>
φ87.86 mm <0.5 mm oversize : φ88.36 mm>
φ3.4590 in <0.0197 in oversize : φ3.4787 in>
*Value with piston coating
0.15 - 0.21 mm (0.0059 - 0.0083 in)
*Value with piston coating
Top: 0.04 - 0.08 mm (0.0016 - 0.0032 in)
Second: 0.04 - 0.08 mm (0.0016 - 0.0032 in)
Third: 0.04 - 0.08 mm (0.0016 - 0.0032 in)
φ23.02 mm (φ0.9063 in)
0.015 - 0.025 mm (0.00059 - 0.00098 in)
Top: 0.25 - 0.40 mm (0.00098 - 0.0157 in)
Second: 0.25 - 0.40 mm (0.00098 - 0.0157 in)
Third: 0.25 - 0.40 mm (0.00098 - 0.0157 in)
φ23.00 mm (0.9060 in)
0.05 mm (0.0020 in) or less
Upper area of #1: φ40.0 mm (1.574 in)
Lower area of #4: φ40.0 mm (1.574 in)
φ28.00 mm (1.102 in)
0.20 - 0.55 mm (0.0079 - 0.0217 in)
9.2 - 9.4 mm (0.362 - 0.370 in)
0.9 Mpa (128 psi) [9.0 kg/㎠]
TLDI 115A 2007