Service manual
SERVICE
DATA
I
STANDARDS
AND
LIMITS
-
828
FOUR
MARINE
ENGINE
Component
Specified
Value
I
Standard
Repair
Limit
inches{mm)
inches{mm)
COMPRESSION
I
TIMING
Cylinder
Compression
.............
.427
psi
at
200
rpm
....................
384
psi
Pressure
(30.0
kg/cm')
(27.0
kg/cm')
Difference
between
...........................
.42.7
psi
Cylinders
(Max)
(3.0
kg/cm')
VALVE
TIMING
Intake
Valve
Opens
......................
17·
BTDC
Intake
Valve
Closes
....................
.47·
ABDC
Exhaust
Valve
Opens
..................
51·
BBDC
Exhaust
Valve
Closes
..................
13·
ATDC
CYLINDER
HEAD
Surface
Distortion
..............................
See
Text
..........................
0.004
(0.1)
Intake
Valve
Seat
Angle
........................
.45·
Exhaust
Valve
Seat
Angle
......................
30·
Intake
Valve
Seat
Width
..................
0.079
(2.0)
........................
0.004
(0.1)
Exhaust
Valve
Seat
Width
...............
0.079
(2.0)
........................
0.004
(0.1)
Valve
Clearance
..........................
0.012
(0.30)
[cold]
(Intake
&
Exhaust)
VALVES
Valve
Head
Diameter
(Intake)
............................
1.59
-1.60
(40.4
-
40.6)
(Exhaust)
.......................
1.47
-
1.48
(37.40
-
37.60)
Valve
Head
Thickness
(Intake
&
Exhaust)
.........
0.059
(1.5)
...
0.039
(1.0)
Dverall
Length
(Intake)
....................................
.4.508
(114.5)
(Exhaust)
.................................
.4.512
(114.6)
Valve
Stem
O.D.
Intake
..........................
0.353
-
0.354
(8.955
-
8.980)
......
0.351
(8.904)
Exhaust...
.....................
0.352
-
0.353
(8.935
-
8.960)
......
0.350
(8.884)
Valve
Guide
Protrusion
from
Cylinder
Head
.............................
0.65
(16.5)
Cylinder
Inner
Dia
.......
0.355
-
0.356
(9.018
-
9.040)
Stem
to
Guide
Clearance
Intake
.......................
0.0015
-
0.0033
(0.038
-
0.085)
..
O.OOSO
(0.127)
Exhaust...
...................
0.0023
-
0.0041
(0.058
-
0.105)
....
0.0050
(0.127)
Valve
Contact
Width
.........................
0.079
(2.0)
Valve
Face
Angle
Intake
..............................................
.45·
Exhaust
.............................................
30·
Dimension
L
(Sinking)
....................
1.890
(48.0)
......................
1.949
(49.5)
Valve
Spring
(Outer)
Wire
Diameter.
...........................
0.117
(4.5)
Outer
Coil
Diameter
..................
1.496
(38.0)
Free
Length
...............................
2.193
(55.7)
......................
2.083
(52.9)
Fitting
Length
............................
1.587
(40.3)
Fitting
Load
................
71.43
-75.401b
(32.4
-
34.2Kg)
..
66.36Ib
(30.1
Kg)
Squareness
...........................................................................
0.054
(1.37)
Spring
Constant...
.............
121Ib1in
(2.16Kg/mm)
Component
Valve
Spring
(Inner)
Specified
Value
I
Standard
inches{mm)
Wire
Diameter
............................
0.138
(3.5)
Outer
Coil
Diameter
..................
1.083
(27.5)
Repair
Limit
inches{mm)
Free
Length
...............................
1.736
(44.1)
......................
1.654
(42.0)
Fitting
Length
............................
1.488
(37.8)
Fitting
Load
................
26.68
-
29.321b
(12.1
-13.3Kg)
..
24.921b111.3
kg
Squareness
...........................................................................
0.049
(1.25)
Spring
Constant...
.............
113Iblin
(2.02Kg/mm)
TIMING
GEARS
Backlash
Between
Gears
in
Mesh
.............
0.0003
-
0.0005
(0.01
-
0.14)
........
0.012
(0.3)
Idler
Gear
Bushing
Clearance
Between
Bushing
and
Shaft.
..............
0.001
-
0.010
(0.03
-
0.07)
..........
0.0078
(0.2)
ROCKER
ARM
Rocker
Arm
Bore
............
0.625
-
0.626
(15.876
-
15.896)
Rocker
Arm
Shaft
Outer
Diameter
.......
0.6234
-
0.6244
(15.835
-
15.860)
Clearance
...................
0.0006
-
0.0024
(0.016
-
0.061)
....
0.0028
(0.07)
TAPPET
Outer
Diameter
..............
0.5600
-
0.5610
(14.224
-
14.249)
Bore
in
Cylinder
Block
..
0.5630
-
0.5640
(14.288
-14.319)
Clearance
In
Cylinder
Block
Bore
........
0.0015
-
0.0037
(0.039
-
0.095)
....
0.0039
(0.10)
VALVE
CAMSHAFT
Joumal
Diameter
No.
1
(Front)
...........
2.0437
-
2.0449
(51.910
-
51.940)
No.2
......................
2.0339
-
2.0351
(51.660
-
51.690)
No.3
........................
2.0240
-2.0250
(51.410
-
51.440)
No.4
(Rear)
............
2.0142
-
2.0154
(51.160
-
51.190)
Wear
Limit...
.......................................................................
0.0003
(0.008)
Cam
Elevation
Intake
and
Exhaust
................
1.6767
(42.580)
................
1.6728
(42.478)
Camshaft
End
Play
..........
0.0008
-
0.0071
(0.020
-
0.180)
....
0.0118
(0.30)
Camshaft
Run-Out
....................................................................
0.08
(0.0031)
Camshaft
Support
Bore
No.1
(Front)
...........
2.0473
-
2.0485
(52.000
-
52.030)
No.2
......................
2.0374
-
2.0386
(51.750
-
51.780)
No.3
........................
2.0280
-2.0290
(51.500
-
51.530)
No.
4(Rear)
.............
2.0177
-
2.0189
(51.250
-
51.280)
Oil
Clearance
...................
0.0024
-
0.0047
(0.060
-
0.120)
....
0.0057
(0.145)
Backlash
Between
Gears
..
0.0039
-
0.0067
(0.10
-
0.17)
......
0.0118
(0.30)
IDLER
GEAR
Boss
Bore
......................
1.8898
-1.8908
(48.000
-
48.025)
Boss
Bore
Limit
................
0.0079
-
0.0118
(0.20
-
0.30)
Bushing
Inner
Diameter
........
1.7327
-1.7336
(44.009
-
44.034)
Outer
Diameter
.......
1.8915
-1.8925
(48.043
-
48.068)
Spindle
Length
.......................
1.1398
-
1.1437
(28.95
-
29.05)
Outer
Diameter
.......
1.7303
-1.7313
(43.950
-
43.975)
Spindle
and
Bushing
Clearance
.........
0.0013
-
0.0033
(0.034
-
0.084)
....
0.0059
(0.15)
End
Play
............................
0.0059
-
0.0118
(0.15
-
0.28)
Engines
&
Generators
55