Yanmar 3JH4BE Service Manual page 11

4. Disassembly and Reassembly ...................................................................................... 71
4.1 Disassembly and reassembly precautions .............................................................................71
4.2 Disassembly and reassembly tools ........................................................................................72
4.2.1 General handtools........................................................................................................................... 72
4.2.2 Special handtools............................................................................................................................ 75
4.2.3 Measuring instruments.................................................................................................................... 78
4.3 Disassembly and reassembly ................................................................................................82
4.3.1 Disassembly.................................................................................................................................... 82
4.3.2 Reassembly .................................................................................................................................... 92
5. Inspection and Servicing of Basic Engine Parts .......................................................... 103
5.1 Cylinder block .......................................................................................................................103
5.1.1 Inspection of parts......................................................................................................................... 103
5.1.2 Cleaning of oil holes...................................................................................................................... 103
5.1.3 Color check procedure.................................................................................................................. 103
5.1.4 Replacement of cup plugs ............................................................................................................ 104
5.1.5 Cylinder bore measurement.......................................................................................................... 105
5.2 Cylinder head .......................................................................................................................106
5.2.1 Inspecting the cylinder head ......................................................................................................... 107
5.2.2 Valve seat correction procedure ................................................................................................... 108
5.2.3 Intake/exhaust valves, valve guides ............................................................................................. 109
5.2.4 Valve springs ................................................................................................................................ 111
5.2.5 Assembling the cylinder head ....................................................................................................... 112
5.2.6 Measuring top clearance............................................................................................................... 112
5.2.7 Intake and exhaust rocker arms.................................................................................................... 113
5.2.8 Adjustment of valve clearance ...................................................................................................... 113
5.3 Piston and piston pins .........................................................................................................114
5.3.1 Piston ............................................................................................................................................ 114
5.3.2 Piston pin ...................................................................................................................................... 115
5.3.3 Piston rings ................................................................................................................................... 115
5.4 Connecting rod ....................................................................................................................118
5.4.1 Inspecting the connection rod ....................................................................................................... 118
5.4.2 Crank pin metal............................................................................................................................. 119
5.4.3 Piston pin bushing......................................................................................................................... 121
5.4.4 Assembling piston and connecting rod ......................................................................................... 121
5.5 Crankshaft and main bearing ...............................................................................................122
5.5.1 Crankshaft..................................................................................................................................... 122
5.5.2 Main bearing ................................................................................................................................. 125