Tech:Engine/K-Series/TRD

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.

Cylinder block top surface

Warpage allowance - 0.02 mm

b. Boring.

To enlarge the cylinder bore from 75∅ to 79∅ perform the boring and honing.

The cylinder bore must be the minimum actual value of thrust direction in relation between 15 mm to 110 mm from the block top surface.

Caution

1. The piston diameter must be the maximum actual value at 7mm above the piston skirt in thrust direction at normal temperature (20°C).
2. After machining, perform the water test for 5 ~ 10 minutes at 2kg/cm².

c. Chamfering of the cylinder skirt.

Chamfer the cylinder skirt with an air grinder or file (2 ~ 3°)

d. Revise the bolts securing the oil filter and alternator bracket and thread to M10, P-1.25 to improve strength.

3. PISTON & PISTON RINGS

(1) Main modifications.

a. Piston

Revised the shape to provide a flat head.

b. Piston rings.

Will utilize a compression ring with the thickness of 1 mm.

The oil ring is of three piece type with the thickness of 2.5 mm.

c. Piston pin.

Revised the outer diameter of the piston pin from 18∅ to 20∅ to improve the strength.

(2) Required parts.

No.	Part No.	Description	Qty.
1	13011-KE004	Ring set, piston	4
2	13011-KE006	Piston w/pin	4

(3) Assembling procedures & assembling standards.

a. Fitting of piston with the cylinder block.

The minimum actual value of the cylinder bore in relation to the thrust direction at between 15 ~ 110 mm from the cylinder top surface and the difference (clearance) with the maximum actual value above 7 mm from the end of the piston skirt in thrust direction must accord to the List 8 upon assembly. (Refer to cylinder block paragraph.)

List 8

Item	Sports parts
Piston standard diameter mm	78.96 +0.02 -0
piston clearance mm	0.07~0.10

b. Weight difference of pistons.

The weight difference of each per one unit (including piston pin) must be within 2 grams.

c. Piston pin.

Heat the piston to 80°C in oil and further chamfer the end surface of the pin with an oil stone to smoothen then insert carefully without scratching the corresponding part.

List 9

Item	Sports parts
Piston pin bore mm	20 +0.012 -0
Piston pin outer diameter	20 +0.017 +0.005

Caution

It is satisfactory when the pin can be pushed into the piston with the thumb at 80°C.

d. Piston rings.

List 10

Item	Sports parts	S. T. D
Piston clearance mm	0.06~0.08	0.03~0.05

Item	Sports parts			S. T. D
	Compression ring		Oil ring	Compression rings		Oil ring
				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	0.15~0.35	0.20~0.90

Caution

To prevent vertical scratching of the cylinder bore with the compression ring ends, assemble after shamfering smoothly with an (ed: missing word, file?)

4. CONNECTING ROD, CRANKSHAFT & FLYWHEEL

====(1) Main modifications.

a. Connecting rod.

Revise the material to improve durability.

Also, the small end is of less bushing type.

b. Crankshaft.

Oil clearance is provided and dynamic balancing has been performed.

c. Flywheel.

Lightened the weight and dynamic balancing has been performed.

(2) Required parts.

No.	Part No.	Description	Qty.	Remark
1	13201-KE001	Rod sub-assy, connecting	4
2	90105-10030	Bolt, flywheel set	6	"O"

(3) Installing procedures & assembling standards.

a. Connecting rod.

For fitting the piston pin, apply oil onto the piston pin and it is excellent when it can be easily inserted at normal temperature.

List 11

Item	Sports parts	S. T. D
Connecting rod bolt tightening torque kg.cm	500	400~520
Clearance between piston pin & connecting rod mm	0.09~0.014	0.004~0.008
Bend limit (per 100 mm) mm	0.04	0.05
Twist limit (per 100 mm) mm	0.04	0.15

b. Crankshaft.

Adjust the clearances of the journals and crankpins.

List 12

Item	Racing specification	S. T. D
Journal oil clearance mm	0.05~0.07	0.016~0.040
Crankpin oil clearance mm	0.04~0.06	0.024~0.048
Journal thrust clearance mm	0.04~0.15	0.01~0.222
Bearing cap bolt tightening torque kg.cm	600	540-660
Roundness limit mm	0.008	0.01
Bend limit mm	0.02	0.03

c. Flywheel.

Discontinued the standard flywheel securing bolts (90105-01005) and lock plates and will utilize (2) (90105-10030).

Crankshaft x flywheel

Tightening torque - 800kg.cm

Caution

It is desirable to perform the dynamic balancing with the flywheel and crankshaft as a unit and the unbalancing volume must be within 2g.cm.

5. VALVE MECHANISM

(1) Main modifications.

a. Camshaft.

The valve timing and cam profiles are revised.

List 13

Part No.	Valve timing				Cam lift mm	Valve clearance mm	Cam top center
	A	B	C	D			E	F
13511-KE001	53	91	87	55	7.5	IN:0.35 EX:0.38	106	109
13511-KE003	35	70	70	35	7.4	IN:0.35 EX:0.35	110	110
13511-KE005	54	86	94	46	7.2	IN:0.3 EX:0.4	106	114
13511-KE051	36	64	70	30	6.8	IN:0.3 EX:0.3	104	110