Win Progress.,Co - LTD (Pharkant Branch) : D13A Engine Receiving/Delivering Inspection Form

Win Progress.,Co.
Ltd (Pharkant Branch)

D13A Engine Receiving/Delivering Inspection Form
Customer Name Form no;
M/C Model Report no;
M/C Sr.no Receiving date
Engine Model Delivery date
Engine Sr.no Taking camera no
Working hour
Millage
Cause of problem
Action plan
Accessories Parts list
Quantity Part Condition Delivery

No Description STD Qty Remark
Receive Miss Good N.Good Qty
Engine left side
1 Breather pipe 1
2 preheat coil housing 1
3 EECU & fuel hoses 1
4 Fuel hoses from EECU 2
5 fuel filter housing 1
6 fuel hose from filter housing to Head 1
7 fuel hoses from feed pump to housing 2
8 Fuel return hose from Head 1
9 Steering pump & feed pump 1
10 Air Compressor 1
11 Delivery pipe from Air Compressor 1
12 Pneumatic hose (inlet) from Air Compresso 1
13 Engine Oil hose from air compressor 1
14 Water hose from Air Compressor 1
15 AVU valve 1
16 Pneumatic hose from AVU 1
17 Engine Mounting 1
18 Engine oil dipstick 1
19 Engine oil filler pipe 1
Engine right side
1 Exhaust Manifold 1
2 Turbo 1
3 E/O hose from turbo 1
4 E/O drain pipe from turbo 1
5 E/O fiter housing 1
6 Start Motor 1
7 E/O cooler 1
8 Coolant pipe from Oil cooler 1
9 E/O pipe from Oil cooler 1
Front side
1 Thermostat housing 1
2 Thermostat 1
3 Coolant pump 1
4 two belt tensioners 2
5 Fan Pulley 1
6 Fan Adaptor 1
7 Crankshaft pulley 1
8 Coolant pulley 1
9 Alternator 1
10 Air-con compressor 1
11 Idler pulley 1
12 Coolant pipe (suction) 1
13 Fan belt 1
14 Alternator belt 1
15 Engine Mounting 1
Rear side
1 Flywheel housing 1
2 Flywheel 1
3 Clutch plate assembly 1
Sensors
1 Coolant temp: sensor 1
2 Boost press; sensor 1
3 Can Speed sensor 1
4 Crank speed sensor 1
5 E/O press; sensor 1
6 Crankcase press; ensor 1
7 Feed press; sensor 1
8 Water in fuel sensor 1
9 E/O level & temp; sensor 1
10 Eng; wireharness 1
Customer Sign ---------------------------------- Inspector Sign ------------------------------

Customer Name ---------------------------------- Inspector Name ------------------------------
Win Progress.,Co.Ltd (Pharkant Branch)
D13A Engine Receiving/Delivering Inspection Form
Customer Name Form no
M/C Model Report no
M/C Sr.no Receiving date
Engine Model Component Model
Engine Sr.no Component Sr.no
Working hour Delivery date
Millage Taking camera no
Cause of problem
Action plan
Accessories Parts list

Fuel System & Mounting
1 Unit injector 6
2 Feed pump & Steering pump 1
3 Belt (Alternator) 1
4 Belt (Fan) 1
5 Pneumatic compressor 1
6 Air con compressor 1
7 Air con compressor mounting 1
8 Engine mounting front, left 1
9 Engine mounting front,right 1
10 Engine mounting rear, left 1
11 Engine mounting rear,right 1
12 Engine cushion front, left 1
13 Engine cushion front, right 1
14 Engine cushion rear, left 1
15 Engine cushion rear, right 1
Electrical system
1 Engine wireness 1
2 EECU 1
3 EI-Socket 1
4 Crank speed sensor 1
5 Cam position sensor 1
6 Boost press:&temp: sensor 1
7 Water in fuel sensor 1
8 Fuel press: sensor 1
9 Coolant temp: sensor 1
10 Coolant temp: switch 1
11 Engine oil level sensor 1
12 Engine oil press: sensor 1
13 Engine oil press: switch 1
14 Crankcase press: sensor 1
15 Thermostat 1
16 AVU 1
17 AVU socket 1
18 Fan speed socket 1
19 Alternator 1
20 Alternator socket 1
21 Starter motor 1
22 Starter relay 1
Cooling System
1 Bearing Housing (coolant pump) 1
2 Pipe (coolant pump to oil cooler) 1
3 Fan 1
4 Fan pulley 1
5 Cranshaft fan pulley 1
6 Fan (Adaptor) 1
7 Bearing mouting(fan pulley) 1
8 Belt tensioner 2
9 Idler pulley 1
Inlet & Exhaust System
1 Turbo 1
2 Eng oil pipe Turbo(in) 1
3 Eng oil pipe Turbo(drain) 1
4 Exhaust pipe (Turbo pipe) 1
5 Pipe (Turbo to CAC) 1
6 Hose (Turbo to CAC) 1
7 Breather pipe 1
8 Breather housing 1
9 Oil trap 1
10 Pneumatic pipe(AVU to EPG) 1
Lubrication System
1 Eng oil filter housing 1
2 Fuel oil filter housing 1
3 Eng oil dipstick 1
Transmission & Sterring System
1 Clutch plate assembly 1
2 Sterring delivery pipe 1
3 Sterring suction pipe 1
Customer Sign ----------------------- Inspector Sign --------------------

Customer Name ----------------------- Inspector Name --------------------
Win Progress Co.,Ltd(Pharkant Branch)
Engine Overhauling Check Sheet
Customer
D13A Cyliner Block
M/C Model S/N
Disassembly Engine Model S/N
Assembly WH Date
Unit=mm
Piston cooling nozzle NO.1 NO.2 NO.3 NO.4 NO.5 NO.6
Condition check(OK/NOK)
1st 111lbf.ft
Tighting torque for main bearing
2nd 120'
STD(mm) Limit(mm) Plane point 1 point 2 Comment
A
Diameter(Measure in 2 point and also
1
in 2 plane , so measure in 4 points)
[Tightening torque;1st=111lbf ft
B
2 A
B
STD=108.00 108.06 A
3
2nd=120degree]
1st OS=107.75 107.865 B

2nd OS=107.50 107.615 A
4
Main Bearing
3rd OS=107.25 107.365 B

4th OS=107.00 107.115 A
5
5th OS=106.75 106.865 B
A
6
B
A
7
B
STD 47.00 47.05
Thrust 1st OS 47.1 47.15
Bearing
Width 2nd OS 47.2 47.25
3rd OS 47.3 47.35
# Deflection at center 0.15
#Crank shaft radial clearance 0.01 - 0.15
#Crank shaft axial clearance 0.1 - 0.4
#Cam shaft radial clearance <0.05
#Cam shaft axial clearance <0.24
#Backlash (clearance) 0.05 - 0.17
Engineer/Mechanic Sign_ _ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Sign_ _ _ _ _ _ _ _ _ _ _ _ _

Engineer/MechanicName_ _ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Name_ _ _ _ _ _ _ _ _ _ _ _ _
Win Progress Co.,Ltd.(Pharkant Branch)
Customer
D13A Con-Rod
M/C Model S/N
Check Sheet
Engine Model S/N
Disassembly Date
Assembly Reference Service Report No.
1st 44 lbf.ft Remark: Make sure that numerical marking of
Tightening torque for connecting rod and bearing cap are in same side.
connecting bolts 2nd 90'
Unit=mm
Item Check Point STD Limit Point Plane Actual Clearance
A
1
pin diameter Limit of Clearance=0.10mm

B
1 99.00 99.07
A
2
B
Clearnce =Big end bearing dia-Crank shaft connecting

A
Diameter(Measure at 2point and 2planes)
1
B
2 99.00 99.07
A
2
B
A
1
B
Big End 3 99.00 99.07
A
2
B
A
1
Bearing B
4 99.00 99.07
A
2
B
A
1
B
5 99.00 99.07
A
2
B
A
1
B
6 99.00 99.07
A
2
B
A
1
B
1 57.00
A
2
B
A
Limit of Clearance=0.08mm
1
B
2 57.00
A
2
Clearnce =Small end bearing dia-piston pin dia
B
A
1
B
Small 3 57.00
A
End 2
B
A
1
Bearing B
4 57.00
A
2
B
A
1
B
5 57.00
A
2
B
A
1
B
6 57.00
A
2
B
Check the connecting rod parallel alignment to all connecting rods
Note! Same side piston arrow marking and conneting rod front marking.

D 13A Crankshaft Customer
M/C Model S/N
Check Sheet Engine Model S/N
Disassembly Working Hour Date
Unit=mm
A
1
B
Diameter 108.00 107.98
A
1 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
Diameter 108.00 107.98
A
2 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
Diameter 108.00 107.98
A
3 2
B
Main Bearing Journal
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
Diameter 108.00 107.98
A
4 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
Diameter 108.00 107.98
A
5 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
Diameter 108.00 107.98
A
6 2
B
Ovality(A-B) 0.08
Taper(1-2) 0.05
A
1
B
Diameter 108.00 107.98
A
7 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02


D13A Piston Customer
check M/C Model S/N
Sheet Engine Model S/N
Assembly Reference Service Report No
Unit=mm
Piston Crown Condition
Piston Scuff Condition
Item Check Point STD Limit Actual Comment
1st 0.4 0.7
1 2nd 1.1 1.7
Oil 0.35 0.7
1st 0.4 0.7
2 2nd 1.1 1.7
Oil 0.35 0.7
1st 0.4 0.7
3 2nd 1.1 1.7
Oil 0.35 0.7
Ring Gap
1st 0.4 0.7
4 2nd 1.1 1.7
Oil 0.35 0.7
1st 0.4 0.7
5 2nd 1.1 1.7
Oil 0.35 0.7
1st 0.4 0.7
6 2nd 1.1 1.7
Piston Oil 0.35 0.7
Ring 1st Tapered
1 2nd 0.09 0.14mm
Oil 0.05 0.1
1st Tapered
2 2nd 0.09 0.14mm
Oil 0.05 0.1
1st Tapered
3 2nd 0.09 0.14mm
Ring groove Oil 0.05 0.1
Clearance 1st Tapered
4 2nd 0.09 0.14mm
Oil 0.05 0.1
1st Tapered
5 2nd 0.09 0.14mm
Oil 0.05 0.1
1st Tapered
6 2nd 0.09 0.14mm
Oil 0.05 0.1
1 55.00
2 55.00
3 55.00
Piston Pin Diameter
4 55.00
5 55.00
6 55.00
The piston ring opening must be 120 degree to each other. Make sure the correct upper and button sid
piston ring.Refer service manual for more detail.
Engineer/Mechanic Sign_ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Sign_ _ _ _ _ _ _ _ _ _ _ _

Engineer/Mechanic Name_ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Name_ _ _ _ _ _ _ _ _ _ _ _
1st 0.7mm
2nd 1.7mm
D12D Engine Tightening Torques Specification Check Sheet
Customer
M\C Model S\N
Engine Model S\N
Working Hour- Date
Assembly √
Reference Service Report No-
No Description Torque Figure
1 Main bearings:
step 1 150 ±20Nm (110.6 ±15lbf ft)
step 2 120° ±5°
2 Connecting rod caps
step 1 20 ± 3 Nm
step 2 60 ± 3 Nm
step 3 (angle tightening) 90±5°
3 Bolt, piston cooling nozzle
24 Nm (17.7 lbf ft)
Note- Apply loctite in thread.
4 Thermostat housing
Step 1: 10 Nm (7.4 lbf ft)
Step 2: 30 Nm (22 lbf ft)
5 Timing gear plate
M8 bolts 28±4 Nm (20.65 lbf ft)
1. Drive gear, crankshaft 24±4 Nm (17.7 lbf ft)
2. Idler gear, outer bull gear
step 1 25 ± 3 Nm(18.4 lbf ft)
3. Idler gear, adjustable
step 1 35 ± 4 Nm(25.8 lbf ft)
4. Drive gear, camshaft
45±5 Nm(33.2 lbf ft)
step 1
5. Idler gear:
hex. socket screw 140±10 Nm(103.24lbf ft)
6. Drive gear,steering servo and fuel feed 100 ± 10 Nm(73.75 lbf ft)
pump.
7. Drive gear, air compressor 200+50/-0 Nm (147.5 lbf ft)
6 Timing gear cover, upper
Apply silicon in a 2 mm thick
Step 1: Secure the casing with bolts 1 and 2 4±1 Nm
Step 2: Tighten the bolts in numerical order 24±4 Nm (17.7 lbf ft)
7 Vibration damper
Step 1 35±5 Nm(25.8lbf ft)
Step 2 90 ± 10 Nm(66.4 lbf ft)
8 Flywheel(D13A)
Step 1: 60 ±5 Nm (44.3 lbf ft)
Step 2: 120±10°
9 Flywheel housing later version:

140 ± 20 Nm(103.24lbf ft)
M14 bolts
M10 bolts 48 ± 8 Nm(35.4 lbf ft)
M8 bolts 24±4 Nm (17.7 lbf ft)
10 Cylinder head:
step 1 100 ± 5 Nm
120±5°
step 2
step 3 90±5°
11 Stiffening frame
Step 1: Bolts 1-24 (in numerical order) 45±5 Nm (33 lbf ft)
Step 2: Bolts 1-24 (in numerical order) 60±5°
24 ± 4 Nm
12 Oil pan
Secure the oil sump with screws A and B 24±4 Nm (17.7 lbf ft)
Tighten the screws from the centre outwards 24±4 Nm (17.7 lbf ft)
Finish by check-tightening screws A and B 24±4 Nm (17.7 lbf ft)
Drain plug, oil sump 60 ± 10 Nm(44 lbf ft)
13 Bearing cap of camshaft
Step 1: 15 ±5 Nm (12lbf ft),90°±5°
>Bearing cap rocker arm shaft
Step 2: 60 ±5 Nm (44 lbf ft)
Step 3: 15 ±5 Nm (12 lbf ft) + 120°±5°
Step 4: loosen the bolts
Step 5: 15 ±5 Nm (12lbf ) + 120°±5°
>VEB 24 ±4 Nm (18 lbf ft)
14 Oil cooler
Step 1; Tighten the bolts in order 1,2,3,4 5±1 Nm(3.7lbf ft)
Step 2; Tighten the bolts inorder 1,2,3,4,1 27±4 Nm(20 lbf ft)
Oil cooler cover

screws C,D and tighten them to full torque 24 ±4 Nm (18lbf ft)
Tighten the cover screws from the centre 24 ±4 Nm (18lbf ft)
outwards (1-4),
Finish by check-tightening screws C and D 24 ±4 Nm (18lbf ft)
15 Oil filter housing

1. Thermostat valve, oil cooler 10±1.5 Nm(7.4 lbf ft)
2. Safety valve, block 50±5 Nm (37 lbf ft)
3. Overflow valve, full-flow filter 55±5 Nm (40.5 lbf ft)
16 Exhaust manifold (10±1.5 Nm)7.4 lbf ft

Step 1: Tighten bolts 1 and 4 52±4 Nm (38 lbf ft)
Step 2:Tighten bolts 3 and 2 (earlier version) 52±4 Nm (38 lbf ft)
(later version )
(later version) 48±4
52±4Nm
Nm(35.4
(38lbflbfft)ft)
Tighten bolts 1 and 4(earlier version) 48±4 Nm (35.4 lbf ft)
(later version ) 48±4 Nm (35.4 lbf ft)
17 Inlet manifold 24 ±4 Nm (18lbf ft)
Step 2:
24 ±4 Nm (18lbf ft)
18 Securing yoke, unit injector

First tightening:
step 1; 20 +5/-0 Nm(14.75lbf ft)
180°±5°
step 2 ;(angle tightening)
160°
step 3 ;Untighten the yoke bolt before
the second tightening until torque
Second is 10–15 Nm.
tightening:
step 4;. 20 +5/-0 Nm

step 5 ;(angle tightening) 90±5°
90±5°
19 Lock nut for adjusting screw,unit injector 52±4 Nm (38lbf ft)
Steering servo pump(fuel pump included) 24 ±4 Nm (18lbf ft)
Fuel pump (mounted on servo pump) 8 ± 2 Nm (6 lbf ft)
Connections, fuel system:

20
(A) .....
18±3 Nm(13.3lbf ft)
(B) .....
30±4 Nm(22.1 lbf ft)
(C)
(D) .....
..... 35±5 Nm(26 lbf ft)
40±5 Nm(29.5 lbf ft)
(E) ..... 48±5 Nm(35.4 lbf ft)
21 Preheater
10±2 Nm(7.4 lbf ft)
step 1.....
step 2..... 24 ±4 Nm (18lbf ft)
22 Front engine anchorage, cylinder block 275 ± 45 Nm(202.8lbf ft)

23 Front engine mounting, front engine pad 140 ± 25 Nm(103.24 lbf ft)
24 Front engine pad, vibration damper 48 ± 8 Nm(35.4 lbf ft)
25 Front engine pad, cross member 175 ± 30 Nm (129 lbf ft)
26 Rear engine mounting, flywheel housing 300 ± 45 Nm (221 lbf ft)
27 Rear engine mounting, rear engine pad 540 ± 90 Nm (398 lbf ft)
28 Rear engine pad, frame 140 ± 25 Nm (103.24 lbf ft)
29 Cover, crankshaft seal
Step 1: Tighten bolts 2 and 7 24 ±4 Nm (18lbf ft)
Step 2: Make sure the casing lies flush with engine block,checking
with a steel rule.(Version A)
Step 3: Tighten all bolts in order 1-8 24 ±4 Nm (18lbf ft) l
s
WIN PROGRESS CO.LTD (PHARKANT)
D13A Engine Head Disassemble Check Sheet
Customer Name Report no.
M/C Model Service date
M/C Sr.no Component model
SMR Component Sr.no.
Reason Of Overhaul Yes No Remark
Flushing?
Recondition?
Checking Parts Status
No Description Check Point Figure
Condition Good Repair N.Good
1 Preparation
(i)Prepare the tools as follow
General Tools
Allen Wrench-8mm,Wrench 14mm,Hammer
Special Tools
LT-176,9990176 ,11666043 ,11666041 ,LT-149 ,Magnetic ,9998263 or LT-139,LT-36,Pressure gauge
2 Mounting in work stand
Fixture(1) Bolt down on the cylinder head.
Lift up the cylinder head(2) and secure it in work stand(3).
3 Valves, removing
Install LT-149 in the copper sleeve and secure it in the holes with
unit injector's attaching bolts.
Press down the valve washer and remove the valve collets(4).
Remove the valve washer(5), springs(6) and valves(7).
Remove the remaining valves in the same way.
Remove the valve seals(8) and guide pins for the valve yokes.
Valve Collets Deform or Damage
Valve Washer Deform or Damage
Valve Spring Deform or Damage
Valve Wear or Damage
4 Valves Guide and Valve Seat, removing
Remove the Valve Guide(9).(By using Press)
Remove the Valve Seat(10).(By using Welding or Other)
Valve guide Wear or Damage
Valve seat Wear or Damage
5 Cylinder head, checking for leaks
Install LT-96 on the cylinder head's underside.
Install pressure plates.
Install the hole for the coolant temperature sensor.
Before pressure gauge 9996662 is used, it shall be checked
The pressure becomes 50 kPa (7.3 psi) (0.5 bar).
Hold the pressure for 1 minutes.
Increase the pressure to 150 kPa (21.8 psi) (1.5 bar).
Check after 2 minutes.
Head Surface Deform or Crack
Copper sleeve Leakage
6 Copper Sleeve, removing
Tap out the copper sleeve(11) with a 10 mm (0.394 in) drift.
Service person Sign_ _ _ _ _ _ _ _ Supervisor Sign_ _ _ _ _ _ _ _

Service person Name_ _ _ _ _ _ _ _ Supervisor Name_ _ _ _ _ _ _ _
WIN PROGRESS CO.,Ltd.(Pharkant Branch) Check sheet 16 of 1
D13A Engine Head Assemble Check Sheet
Customer Report No.
Machine Model Service date
Machine Sr;No Component Model
Working Hour Component Sr;No.
Reason Of Overhaul Yes No Remark
Flushing?
Recondition?
Preparation
(i) Prepare the tools as follow
General Tools
Allen Wrench-8mm,Wrench 14mm,Hammer
Special Tools
LT-96,LT-176,9990176 ,11666043 ,11666041 ,LT-149 ,Magnetic ,9998261,9998251,9998262,9998254
LT-141 ,LT54-,LT-143,Pressure Gauge,Dial Gauge,Magnetic Stand
(ii)Clean the cylinder head and check for damage
(iii) Clean the engine head with cleaning solvent and dry with air.
(iv) Put the plastic or paper sheet on the work bench to prevent the parts damage
No Description Status Figure
1 Mounting in work stand
Fixture(1) Bolt down on the cylinder head.
Lift up the cylinder head(2) and secure it in work stand(3).
2 Valves Guide and Valve Seat, installing
Install the Valve Seat(4).(By using LT-141 and Press)
Install the Valve Guide(5).(By using LT-54 and Press)
Grind the Valve.
Measure the depth in the cylinder head (the distance between
the centre of the valve heads and the cylinderhead sealing surface).
Limit: inlet- (0.9-1.4)mm,Max 1.5mm. exhaust- (1.2-1.7)mm,Max 1.8mm
Measure the clearance of the valve guide and valve steam with the dial gauge.
Limit: inlet- (0.03-0.05)mm, exhaust- (0.04-0.06)mm
3 Copper Sleeve, installing
Note: Clean the cylinder head's walls for the copper sleeve
Lubricate the new copper sleeve's seal ring(6) and install it on the sleeve(7).
Place the copper sleeve on tool and lubricate the tap on the tool with oil.
Place the tool together with the copper sleeve in the cylinder head.
Make sure that the copper sleeve bottoms out in the cylinder head.
Flare the copper sleeve by screwing on the nut at the same time as
the spindle is held in place until the flaringtool is completely pulled through.
4 Cylinder head, checking for leaks
Install LT-96 on the cylinder head's underside.
Install pressure plates.
Install the hole for the coolant temperature sensor.
Before pressure gauge 9996662 is used, it shall be checked
The pressure becomes 50 kPa (7.3 psi) (0.5 bar). (Hold 1 minutes.)
Increase the pressure to 150 kPa (21.8 psi) (1.5 bar).Check after 2 minutes.
5 Valve Guide Seal and Valve Spring, installing
Install the Valve Guide Seal(8), and Valve(9).
Install the valve washer(11) on the spring.
Install the spring, or springs(12), depending on if it is an inlet valve
or an exhaust valve.
Note! The exhaust valves have double springs.
Install the valve collets (13).
Impact the Valve spring by rubber hammer.
Install the sealing plug in the hole for the unit injector.
Secure the tool in the hole for the unitinjector's attaching yoke.
Service person Sign_ _ _ _ _ _ _ _ Supervisor Sign_ _ _ _ _ _ _ _

Service person Name_ _ _ _ _ _ _ _ Supervisor Name_ _ _ _ _ _ _ _
Check sheet 17 of 1
_____
Engine Head Specification Check Sheet
D13A Cylinder Head Customer
M\C Model S\N
Check Sheet Engine Model S\N
Assembly Reference Service Report No
Unit=mm
Item Piston Check Point Wear limit Actual Clearance
1 Inlet 0.03-0.05
Exhaust 0.04-0.06
Inlet 0.03-0.05
Radial 2
Exhaust 0.04-0.06
Clearance of
Inlet 0.03-0.05
Valve Guide 3
Note Exhaust 0.04-0.06
-Valve Seal Inlet 0.03-0.05
4
must be Exhaust 0.04-0.06
removed Inlet 0.03-0.05
5
Exhaust 0.04-0.06
Inlet 0.03-0.05
6
Exhaust 0.04-0.06
STD limit Actual Clearance
Inlet 0.9-1.4 1.6mm
1
Exhaust 1.2-1.7 2mm
Inlet 0.9-1.4 1.6mm
The depth of 2
Exhaust 1.2-1.7 2mm
valves(center) Inlet 0.9-1.4 1.6mm
from the 3
Exhaust 1.2-1.7 2mm
cylinder head
Inlet 0.9-1.4 1.6mm
sealing 4
surface Exhaust 1.2-1.7 2mm
Inlet 0.9-1.4 1.6mm
5
Exhaust 1.2-1.7 2mm
Inlet 0.9-1.4 1.6mm
6
Exhaust 1.2-1.7 2mm
Dia,.C Depth,D Actual
Inlet 45 11.8±0.1
1 Exhaust 43 11.2±0.1
Inlet 45 11.8±0.1
2 Exhaust 43 11.2±0.1
Inlet 45 11.8±0.1
Valve seat's 3 Exhaust 43 11.2±0.1
position Inlet 45 11.8±0.1
4 Exhaust 43 11.2±0.1
Inlet 45 11.8±0.1
5 Exhaust 43 11.2±0.1
Inlet 45 11.8±0.1
6 Exhaust 43 11.2±0.1
Valve steam diameter must be 8mm-8mm( Inlet,Exhaust)
Inlet..... 24.5°± 0.2
A
Valve seat Exhaust..... 39.5°
angle Inlet..... 25°
B
Exhaust..... 40°
Valve guides Height above cylinder head's spring face: Inlet=24.5±0.2mm, Exhaust=24.5±0.2mm.
Clearance valve stem-guide ( Dry valve stem )
Inlet..... max 0.7 mm
Exhaust..... max 0.7 mm
Inlet 72-74mm
Length
unload
Valve springs exhaust(out) 72-74mm

ed
exhaust(in) 70-71mm
,
Engineer/Mechanic Sign_ _ _ _ _ _ _ _ _ _ Supervisior Sign_ _ _ _ _ _ _ _ _ _
Engineer/Mechanic Name_ _ _ _ _ _ _ _ _ _ Supervisior Name_ _ _ _ _ _ _ _ _ _
Customer
D13A Cyliner Block
M/C Model S/N
Assembly WH Date
Unit=mm
Piston cooling nozzle NO.1 NO.2 NO.3 NO.4 NO.5 NO.6
Condition check(OK/NOK)
1st 111lbf.ft
Tighting torque for main caps without bearing
2nd 120'
A
1
[Tightening torque;1st=111lbf ft
B
A
2
B
STD=113.00 113.06 A
3
2nd=120degree]
1st OS=112.75 112.865 B

2nd OS=112.50 112.615 A
4
Main Bearing
3rd OS=112.25 112.365 B

4th OS=112.00 112.115 A
5
5th OS=111.75 111.865 B
A
6
B
A
7
B
STD 47.00 47.05
Thrust
Bearing 1st OS 47.1 47.15
2nd OS 47.2 47.25
Width 3rd OS 47.3 47.35
# Deflection at center 0.15
#Crank shaft radial clearance 0.01 - 0.15
#Crank shaft axial clearance 0.1 - 0.4
#Cam shaft radial clearance <0.05
#Cam shaft axial clearance <0.24
#Backlash (clearance) 0.05 - 0.17

Win Progress Col,td
Engine overhaul check sheet
Customer
D13A Con-Rod
M/C Model S/N
Check Sheet
Engine Model S/N
Disassembly Date
Tightening torque for 1st 44 lbf.ft Remark: Make sure that numerical marking of connecting rod and
connecting bolts 2nd 90' bearing cap are in same side.
Unit=mm
Item Check Point STD
Limit Point Plane Actual Clearance
A
1
B
1 103.80 103.87
pin diameter Limit of Clearance=0.10mm

A
2
B
A
Clearnce =Big end bearing dia-Crank shaft connecting

1
B
2 103.80 103.87
A
2
B
A
1
B
3 103.80 103.87
connectin A
2
g rod B
without A
bearing 1
B
4 103.80 103.87
A
2
B
A
1
B
5 103.80 103.87
A
2
B
A
1
B
6 103.80 103.87
A
2
B
A
1
B
1 57.00
A
2
B
A
Limit of Clearance=0.08mm
1
B
2 57.00
A
2
B
Clearnce =Small end bearing dia-piston pin dia
A
1
B
3 57.00
Small End A
2
B
A
Bearing 1
B
4 57.00
A
2
B
A
1
B
5 57.00
A
2
B
A
1
B
6 57.00
A
2
B
Check the connecting rod parallel alignment to all connecting rods
Note! Same side piston arrow marking and conneting rod front marking.
D 13A Crankshaft Customer
M/C Model S/N
Check Sheet Engine Model S/N
Unit=mm
A
1
B
Diameter 99.00 98.98
A
1 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
A
2 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
Big End Bearing Journal
A
1
B
A
3 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
A
4 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
A
5 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
A
6 2
B
Ovality(A-B) 0.08
Taper(1-2) 0.05

Customer
D13A Cam Shaft
M/C Model S/N
Assembly WH Date
Unit=mm
A
1
B
A
2
B
A
3
B
A
4 70 70.1
Cam Bearing
B
A
5
B
A
6
B
A
7
B
A
1
B
A
2
B
A
Diameter of cam shaft
3
B
A
4 70 69.98
B
A
5
B
A
6
B
A
7
B


Win Progress.,Co - LTD (Pharkant Branch) : D13A Engine Receiving/Delivering Inspection Form

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Win Progress.,Co.

Ltd (Pharkant Branch)

Accessories Parts list

Quantity Part Condition Delivery

Customer Sign ---------------------------------- Inspector Sign ------------------------------

Accessories Parts list

Quantity Part Condition Delivery

Customer Sign ----------------------- Inspector Sign --------------------

1st OS=107.75 107.865 B

3rd OS=107.25 107.365 B

Engineer/Mechanic Sign_ _ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Sign_ _ _ _ _ _ _ _ _ _ _ _ _

pin diameter Limit of Clearance=0.10mm

Clearnce =Big end bearing dia-Crank shaft connecting

Engineer/Mechanic Sign_ _ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Sign_ _ _ _ _ _ _ _ _ _ _ _ _

Engineer/Mechanic Sign_ _ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Sign_ _ _ _ _ _ _ _ _ _ _ _ _

Engine Overhauling Check Sheet

Engineer/Mechanic Sign_ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Sign_ _ _ _ _ _ _ _ _ _ _ _

9 Flywheel housing later version:

Oil cooler cover

15 Oil filter housing

16 Exhaust manifold (10±1.5 Nm)7.4 lbf ft

18 Securing yoke, unit injector

step 4;. 20 +5/-0 Nm

Connections, fuel system:

22 Front engine anchorage, cylinder block 275 ± 45 Nm(202.8lbf ft)

Service person Sign_ _ _ _ _ _ _ _ Supervisor Sign_ _ _ _ _ _ _ _

Service person Sign_ _ _ _ _ _ _ _ Supervisor Sign_ _ _ _ _ _ _ _

Valve springs exhaust(out) 72-74mm

1st OS=112.75 112.865 B

3rd OS=112.25 112.365 B

Engineer/Mechanic Sign_ _ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Sign_ _ _ _ _ _ _ _ _ _ _ _ _

pin diameter Limit of Clearance=0.10mm

Clearnce =Big end bearing dia-Crank shaft connecting

Engineer/Mechanic Sign_ _ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Sign_ _ _ _ _ _ _ _ _ _ _ _ _

Engineer/Mechanic Sign_ _ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Sign_ _ _ _ _ _ _ _ _ _ _ _ _

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