Service manual
SERVICE
DATA
I
STANDARDS
AND
LIMITS
•
828
FOUR
MARINE
ENGINE
Component
CONNECTING
ROD
Small
End
Bore
Piston
Pin
and
Specified
Value
/
Standard
Repair
Limit
inches(mm)
inches(mm)
Small
End
Bushing
0.005
-
0.0015
(0.012
-
0.039)
0.0020
(0.05)
Bend
and
Twist
0.002
in
4
(0.05
in
100)
Side
Clearance
0.0094
-
0.0134
(0.239
-
0.340)
0.0157
(0.40)
Small
End
Bore
1.1816
-
1.1824
(30.012
-
30.033)
CONNECTING
ROD
BEARING
Oil
Clearance
...................
0.0014
-
0.0030
(0.036
-
0.076)
......
0.039
(0.10)
Available
Undersize
....
0.01. 0.02.
0.03
(0.255.
0.508.
0.762)
PISTON
Diameter
........................
3.7381
-
3.7399
(94.967
-
94.993)
Piston
Ring
Hole
Bore
..
1.1809
-
1.1814
(29.996
-
30.008)
Ring
Groove
Width
Top
..............................
0.0958
-
0.966
(2.433
-
2.453)
Second
.......................
0.0954
-
0.962
(2.423
-
2.443)
Oil
..............................
0.1887
-
0.1895
(4.793
-
4.813)
PISTON
RINGS
Piston/Liner
Clearance
....
O.0017
-
0.0028
(0.032
-
0.083)
Width
Top
..............................
0.0958
-
0.0966(2.433-2.453)
Second
......................
0.0954
-
0.0962
(2.423
-
2.443)
Oil
..............................
0.1887
-
0.1895
(4.793
-
4.813)
Thickness
Top
..............................
0.0930
-
0.938
(2.363
-
2.383)
Second
.......................
0.0930
-
0.938
(2.363
-
2.383)
Oil
..............................
0.1867
-
0.1875
(4.743
-
4.763)
Side
Clearance
Top
.............................
0.0020
-
0.0070
(0.050
-
0.180)
......
0.118
(0.30)
Second
......................
0.0016
-
0.0031
(0.040
-
0.080)
Oil
..............................
0.0012
-
0.0028
(0.030
-
0.070)
End
Gap
.............................
0.Q157
-
0.0240
(0.40
-
0.60)
........
0.0591
(1.5)
PISTON
PIN
Diameter
........................
1.1809
-
1.1811
(29.994
-
30.000)
Pin
to
Piston
Clearance
............
0 -
0006
(0
-
0.016)
CRANKSHAFT
Main
Joumal
diameter..2.9848
-
2.9853
(75.812
-
75.825)
Grinding
Limit
................................
2.955
(75.05)
Crankpin
Diameter.
.......
2.4060
-
2.4065
(61.112
-
61.125)
Processing
Diameter
.....................
0.030
(0.762)
End
Play
..........................
0.0055
-
0.0154
(0.140
-
0.390)
....
0.0157
(0.40)
Run-out
.....................................................................................
0.0020
(0.05)
Component
MAIN
BEARING
Specified
Value
/
Standard
inches(mm)
Repair
Limit
inches(mm)
Clearance
.........................
0.0020
-
0.0037
(0.059
-
0.090)
....
0.0047
(0.12)
Available
Undersize
....
0.01. 0.02.
0.03
(0.254.
0.508.
0.762)
CYlINDER
BLOCK
Warpage
Iimit
..................................
0.004
(0.10)
Cylinder
Liner
Inner
Diameter
........
3.7412
-
3.7422
(95.025
-
95.050)
..
0.0079
(0.20)
Protrusion
..............
-0.0040
-
-0.0000
(-0.101
-
-0.000)
Flywheel
to
Crankshaft
Run-out
...............................................
0.0079
(0.20)
FUEL
SYSTEM
Idle
Speed
......................................
600
-
650
rpm
Fuel
Injection
Pump
Plunger
diameter
......................
0.393
(10.0)
Gam
Lift
.......................................
0.08
(2.2)
Injection
Timing
..................................
O"
T.D.C.
Injector
Nozzle
Diameter
.................
0.031
(0.80)
Injection
Order
.................................
1 - 3 - 4 - 2
Injection
Pressure
.......
1920
+
71/-0
psi
(135
+
5/-0
kg/cm'
LUBRICATION
SYSTEM
Oil
Pressure
...............................
54
psi
(3.8
kg/cm')
Min
Safe
pressure
(idle)
.
.4.3
±
1.4
psi
(0.3
±
0.1
kg/cm')
Oil
Capacity
(sump)
......................
6.3
Qts
(6.0
L)
Oil
Pump
Outer
Rotor
and
Body
Clearance
........
0.0055
-
0.0100
(0.14
-
0.25)
......
0.0118
(0.30)
Rotor
Lobe
Clearance
.................
0.0016
-
0.0059
(0.04
-
0.15)
......
0.0118
(0.30)
Rotor
End
Float...
........
0.0016
-
0.0039
(0.04
-
0.10)
......
0.0059
(0.15)
Pump
Shaft
and
Body
Clearance
........
0.0024
-
0.0079
(0.06
-
0.15)
......
0.0039
(0.10)
STARTER
MOTOR
Depth
of
Brush
Undercut...
..............
0.019
(0.5)
........................
0.008
(0.2)
Height
of
Brush
.................................
0.669
(17)
..........................
0.236
(6)
Spring
Pressure
........................
.43
IbM
(3
kg/cm')
Commutator
0.D
.............................
1.523
(38.7)
......................
-0.039
(-1.0)
Pinion
Shaft
End
Play
.....................
0.0197
(0.5)
Engines
&
Generators
56