Tech:Engine/K-Series/TRD: Difference between revisions
Jump to navigation
Jump to search
| Line 386: | Line 386: | ||
:Head the cylinder head to about 130°C, cool the valve seat ring with dry ice to shrink and fit. | :Head the cylinder head to about 130°C, cool the valve seat ring with dry ice to shrink and fit. | ||
:The intake valve seat ring must protrude into the combustion chamber 1 mm more than the exhaust. (Refer to Fig. 3- | :The intake valve seat ring must protrude into the combustion chamber 1 mm more than the exhaust. (Refer to Fig. 3-a & 3-b.) | ||
:Cylinder head x valve seat ring | :Cylinder head x valve seat ring | ||
| Line 404: | Line 404: | ||
{| class="wikitable" border="1" | |||
|colspan="2" |Contact surface angle || 45° | |||
|- | |||
|colspan="2"|Contact surface correction angles || 15° 45° 65° | |||
|- | |||
| rowspan="2" |Contact width || Intake mm || 1.2 +0.2 -0 | |||
|- | |||
| Exhaust mm || 1.2 +0.2 -0 | |||
|} | |||
;c. Valve spring seat portion machining. | |||
:Machine the valve spring portion 1.3 mm for recess from the standard surface (Refer to Fig. 3-a & 3-b.) | |||
;d. Port grinding. | |||
:Intake. | |||
:Perform the grinding by maintaining the standard shape. | |||
[[File:TRD_Fig4.png]] | |||
:Exhaust. | |||
:Grind the oblique lines of the Fig. 3-b. | |||
;e. Combustion chamber machining & cylinder head surface grinding. | |||
:When revising the combustion chamber shape, surface grind the cylinder head surface to obtain the compression ratio of 11.3 ~ 11.5 at the same time. | |||
[[File:TRD_Fig5.png]] | |||
:Combustion chamber capacity | |||
::As a unit - 22 ~ 23 cc | |||
::When assembled - 31 cc | |||
;f. Water jacket machining. | |||
:Depending on the grinding volume of the cylinder head, warpage may be produced from heat and installation of the cylinder head. | |||
:To countermeasure this, perform the argon welding on the water jacked before grinding the cylinder head surface (Refer to Fig. 5.) | |||
;Caution: | |||
:'''After machining the b, c and e, perform the water test for 5 ~ 10 minutes at 2 kg/cm²''' | |||
;g. Replacement of rocker supporting securing bolts. | |||
:To prevent damaging of the cylinder head threads, replace the rocker support securing bolts (90910-01005 x 6, 90116-08127 x 2) to (7), (8) stud bolts. | |||
===2. CYLINDER BLOCK=== | |||
====(1) Main modifications.==== | |||
Increased the cylinder bore from 75∅ to 79∅ (displacement from 1,166 -> 1,293 cc), grind the cylinder block top surface with a surface grinder. | |||
====(2) Required part.==== | |||
{| class="wikitable" border="1" | |||
! No. !! Part No. !! Description !! Qty. | |||
|- | |||
| 1 || 11495-SP001 || Plate plug (fuel pump hole) || 1 | |||
|} | |||
====(3) Machining procedures & assembling standards. | |||
;a. Surface grinding. | |||
:Due to the revision of the dimension above the pin of the piston, surface grind the cylinder block top surface. | |||
[[Category:K Motor]] | [[Category:K Motor]] | ||
Revision as of 04:46, 16 September 2012
I'll let TRD do the talking!!!
http://www.vhtracing.com/TRD_K_ENGINE_MANUAL.pdf (Dead link)
http://www.rollaclub.com/hosted/TRD-K-Engine-Manual.pdf (Mirror, 25MB)
Link by Taz_Rx
Transcription
Stage I
Without altering the displacement (1,166 cc), the pistons have been established to increase the compression ratio.
Cylinder Head Gasket, Piston & Piston Rings
(1) Main modifications
- a. Cylinder head gasket.
- Due to increase of compression ratio, the thickness upon assembling has been revised.
- b. Piston
- Without altering the displacement (75∅ 1,166cc), the compression ratio has been incrased.
- c. Piston rings.
- Two compression rings with thickness of 1 mm are utilized and the oil ring is of three-piece type with the thickness of 2.5mm.
(2) Required parts.
| Description | Qty. |
|---|---|
| Gasket,cylinder head | 1 |
| Ring set, piston | 4 |
| Piston w/pin | 4 |
(3) Assembling standards.
| Item | Sports parts | S. T. D |
|---|---|---|
| Piston clearance mm | 0.06~0.08 | 0.03~0.05 |
| Item | Sports parts | S. T. D | ||||
|---|---|---|---|---|---|---|
| compression rings | Oil ring | Compression rings | Oil ring | |||
| No. 1 | No.2 | No.1 | No.2 | |||
| Clearance between ring & ring groove (mm) | 0.02~0.04 | ← | 0.015~0.06 | 0.03~0.07 | 0.02~0.06 | 0.015~0.06 |
| Gap clearance (mm) | 0.15~0.35 | ← | 0.20~0.90 | 0.15~0.35 | ← | 0.20~0.90 |
Stage II
Besides the boring of the cylinder block and correction of the valve seats contacting surfaces, parts have been established which are capable for assembling almost without any modification.
1. PISTON & PISTON RINGS
(1) Main modifications.
- a. Piston
- The oversize is 3mm (78∅) with the displacement of 1,261 cc.
- b. Piston rings
- Two compression rings with the thickness of 1 mm are utilized.
- The oil ring is of three-piece type with the thickness of 2.5 mm.
(2) Required parts.
| Description | Qty. |
|---|---|
| Gasket,cylinder head | 1 |
| Ring set, piston | 4 |
| Piston w/pin | 4 |
(3) Assembling standards.
| Item | Sports parts | S. T. D |
|---|---|---|
| Piston clearance mm | 0.07~0.10 | 0.03~0.05 |
| Item | Sports parts | S. T. D | ||||
|---|---|---|---|---|---|---|
| compression rings | Oil ring | Compression rings | Oil ring | |||
| No. 1 | No.2 | No.1 | No.2 | |||
| Clearance between ring & ring groove (mm) | 0.02~0.04 | ← | 0.015~0.06 | 0.03~0.07 | 0.02~0.06 | 0.015~0.06 |
| Gap clearance (mm) | 0.15~0.35 | ← | 0.20~0.90 | 0.15~0.35 | ← | 0.20~0.90 |
2. VALVE MECHANISM
(1) Main modifications.
- a. Camshaft
- The revise the valve timing, the cam profiles are revised.
- b. Valves
- To improve the intake and exhaust efficiency, the head diameters of the intake and exhaust valves have been enlarged.
- c. Valve springs.
- To prevent surging, revised from single to dual springs and the installed load is revised.
- d. Valve spring retainer & spring seat.
- Due to the revision of the valve springs from single to dual, the retainer and seat are newly established.
(2) Required parts.
| No. | Part No. | Description | Qty. | Remarks |
|---|---|---|---|---|
| 1 | 13511-KE003 | Camshaft | Either one | Overlap 70° |
| 13511-KE051 | Camshaft | Overlap 66° | ||
| 2 | 13711-KE051 | Valve, intake | 4 | Head dia. 37∅ |
| 3 | 13715-KE051 | Valve, exhaust | 4 | Head dia. 30∅ |
| 4 | 90501-42409 | Spring, compression (outer) | 8 | "O" |
| 5 | 90502-KE501 | Spring, compression (inner) | 8 | |
| 6 | 13734-KE051 | Seat, valve spring | 8 | |
| 7 | 13741-KE051 | Retainer, valve spring | 8 | |
| 8 | 90913-03005 | Lock, valve spring retainer | 16 | "O" |
(3) Assembling procedures & assembling standards.
Replace with the above parts.
3. INTAKE & EXHAUST SYSTEMS
(1) Main modifications
- a. Intake manifold.
- Matched with the carburetor throttle bore, enlarged the ports to reduce the intake resistance.
- b. Exhaust manifold.
- Revised the shape to improve the exhaust efficiency.
(2) Required parts.
| No. | Part No. | Description | Qty. | Remarks |
|---|---|---|---|---|
| 1 | 17104-KP751 | Manifold sub-assy. exhaust | 1 | |
| 2 | 17111-KE051 | Manifold sub-assy. intake | 1 | |
| 3 | 21911-TE001 | Gasket, carburetor | 8 | 40∅ |
| 4 | 21912-TE001 | Insulator, carburetor heat | 4 | 40∅ |
(3) Assembling procedures.
Replace with the above parts.
4. FUEL SYSTEM & ACCELERATOR LINKAGE
(1) Main modifications.
- a. Carburetor.
- Revised the throttle bore to match the specification for high speed driving.
- b. Accelerator linkage.
- Due to the revision of the carburetor, the shape of the linkage is revised.
(2) Required parts.
| No. | Part No. | Description | Qty. | Remarks |
|---|---|---|---|---|
| 1 | 21001-SP001 | Carburetor set | 1 | Dellorto DHLA40 x 2 |
| 2 | 78022-KE002 | Linkage set, accelerator | 1 |
(3) Assembling procedures.
Replace with the above parts.
STAGE III
1. CYLINDER HEAD
(1) Main modifications.
Enlarge the intake and exhaust ports to improve the intake and exhaust efficiency. Also, due to the revision of the valves and valve springs, machined the valve spring seats portions and inserted the valve seat rings and valve guides.
| Item | Detail | Size & etc. |
|---|---|---|
| Intake valve | Replaced | Head dia. 38∅ stem dia. 6.6∅ |
| Exhaust valve | " | Head dia. 33∅ stem dia. 6.6∅ |
| Valve guide bushing (IN.) | " | Bore 6.6∅ |
| Valve guide bushing (EX.) | " | Bore 6.6∅ |
| Valve seat ring (IN.) | " | |
| Valve seat ring (EX.) | " | |
| Valve spring seat portion | Machined | Recess machining |
| Port shape | " | Grinding for enlarging |
| Combustion chamber shape | " | Capacity revised |
- Caution
- At the same time with the modification of the cylinder head, perform the surface grinding of the cylinder block top surface.
- (Refer to cylinder block paragraph.)
(2) Required Parts.
| No. | Part No. | Description | Qty. | Remarks |
|---|---|---|---|---|
| 1 | Head assy, cylinder | |||
| 2 | 11115-KE003 | Gasket, cylinder head | 1 | |
| 3 | 11131-KE002 | Seat, intake valve | 4 | |
| 4 | 11135-KE002 | Seat, exhaust valve | 4 | |
| 5 | 11121-KE001 | Bushing, valve guide (IN) | 4 | |
| 6 | 11125-KE001 | Bushing, valve guide (EX) | 4 | |
| 7 | 90520-12049 | Ring, shaft snap | 8 | "O" |
| 8 | 90116-KE001 | Bolt, stud | 2 | |
| 9 | 90116-KE002 | Bolt, stud | 6 |
(3) Machining procedures & assembly standard.
- a. Valve guide bushing replacement.
- Due tot he revision of the valve stem diameter, the valve guide is revised with a smaller bore (6.6∅) item.
- Valve guide bushing x cylinder head
- Fitting allowance - 0.018 ~ 0.035 mm (20°C)
- Caution
- The replacement of the valve guide bushing must accord to the repair manual procedures of the conventional engine. Also, after replacement, inspect the bushing bore and correct with a reamer if found defective.
- b. Valves seat ring replacement.
- Due to the revision of the valve head diameter, replace the intake and exhaust seat rings.
- Head the cylinder head to about 130°C, cool the valve seat ring with dry ice to shrink and fit.
- The intake valve seat ring must protrude into the combustion chamber 1 mm more than the exhaust. (Refer to Fig. 3-a & 3-b.)
- Cylinder head x valve seat ring
- Fitting allowance - 0.07 ± 0.01 mm.
- Caution
- Sufficent care must be taken so that there is no clearance between the ring seat and the cylinder block and also for inclination of the ring.
| Contact surface angle | 45° | |
| Contact surface correction angles | 15° 45° 65° | |
| Contact width | Intake mm | 1.2 +0.2 -0 |
| Exhaust mm | 1.2 +0.2 -0 | |
- c. Valve spring seat portion machining.
- Machine the valve spring portion 1.3 mm for recess from the standard surface (Refer to Fig. 3-a & 3-b.)
- d. Port grinding.
- Intake.
- Perform the grinding by maintaining the standard shape.
- Exhaust.
- Grind the oblique lines of the Fig. 3-b.
- e. Combustion chamber machining & cylinder head surface grinding.
- When revising the combustion chamber shape, surface grind the cylinder head surface to obtain the compression ratio of 11.3 ~ 11.5 at the same time.
- Combustion chamber capacity
- As a unit - 22 ~ 23 cc
- When assembled - 31 cc
- f. Water jacket machining.
- Depending on the grinding volume of the cylinder head, warpage may be produced from heat and installation of the cylinder head.
- To countermeasure this, perform the argon welding on the water jacked before grinding the cylinder head surface (Refer to Fig. 5.)
- Caution
- After machining the b, c and e, perform the water test for 5 ~ 10 minutes at 2 kg/cm²
- g. Replacement of rocker supporting securing bolts.
- To prevent damaging of the cylinder head threads, replace the rocker support securing bolts (90910-01005 x 6, 90116-08127 x 2) to (7), (8) stud bolts.
2. CYLINDER BLOCK
(1) Main modifications.
Increased the cylinder bore from 75∅ to 79∅ (displacement from 1,166 -> 1,293 cc), grind the cylinder block top surface with a surface grinder.
(2) Required part.
| No. | Part No. | Description | Qty. |
|---|---|---|---|
| 1 | 11495-SP001 | Plate plug (fuel pump hole) | 1 |
====(3) Machining procedures & assembling standards.
- a. Surface grinding.
- Due to the revision of the dimension above the pin of the piston, surface grind the cylinder block top surface.