Filed Under (Toyota Manuals) by admin on 21-06-2011

1) Disconnect negative battery cable. Remove air cleaner case
with air intake hose. Remove cruise control actuator. Remove clutch
release cylinder with hose attached and secure aside.
2) Remove starter. Disconnect necessary ground straps,
electrical connections and control cables from transaxle. Remove upper
transaxle mounting bolts from cylinder block.
3) Raise and support vehicle. Remove front wheels. Remove
lower engine covers. Drain transaxle fluid. Remove axle shafts from
transaxle. See appropriate AXLE SHAFTS article in AXLE SHAFTS &
TRANSFER CASES section. Remove stabilizer bar mount and bushing from

Crankshaft Durability of Rover K-Series Engine: Comparison of ENGDYN Analysis with Dynamic Measurements


Filed Under (BMW) by admin on 17-11-2010

The Rover K-Series engine has now been in production for over 10 years, initially of 1.4 L capacity. Since then 1.1L, 1.6L, 1.8L and 1.8L VVC (Variable Valve Control) have been introduced with an accumulative build of two million engines since 1989. The 1.8L engine is also built under official licence for Lotus and Caterham, and also in the MGF motorsport series. The K-Series is an attractive buy due to its reduced cost and low weight, which is a necessity for sport cars. This report aims to validate Ricardo ENGDYN software with respect to Rover K-Series 1.8 Litre VVC crankshaft durability. The software will be used to output the behaviour of the crankshaft under as realistic conditions as possible. The oil film thickness and bearing load characteristics of the crankshaft through the running range of the engine will be compared to results obtained from in-house software. The torsional and bending vibration output from ENGDYN will then be compared with results obtained from dynamic measurements. Finally, the crank stress and durability results from ENGDYN will be compared to strain gauge measurements at comparative points on the crankshaft. ENGDYN is a computer program used for analysing the dynamics of the engine, and in particular the crankshaft and its interaction with the cylinder block. In this analysis the software will be used to predict the time-domain response of the 3-dimensional vibration of the crankshaft coupled to the block by way of a non-linear oil film. When this loading and motion has been calculated the software can perform a fast Fourier transform to break down the time-domain response into its corresponding frequencies. This allows the results to be post-processed in the frequency domain. 2 Method of Analysis 2.1 Engine Specifications Configuration: in-line 4 Fuel: Gasoline Cylinder bore: 80 mm Piston stroke: 89.3 mm Swept volume: 1.8L Crankpin Peak Power: 107 KW @ 7000 rpm Peak Torque: 174 N/m @ 4500 rpm Engine running range: 750-7200 rpm 2.2 Component Modelling 2.2.1 Crankshaft To perform the analysis within ENGDYN two crankshaft models were created. These included a complete stiffness representation of the crank (excluding the crank nose hub and the flywheel), and a detailed model of the crank from main bearing 4 to main bearing 5, with mesh density increased around the fillets. ENGDYN can however perform crank analysis of any portion of the crank as long as the model incorporates at least two main journal bearings. Features such as bolt holes and oil drilling were omitted on both models, which were meshed using solid tetrahedral elements

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Bajaj Removing And refitting Automatic Cam Chain Tensioner


Filed Under (Bajaj) by admin on 31-10-2010

1. Remove the 2 Flanged Bolts securing the Tensioner Assembly. 2. Remove Tensioner Assembly from the engine block. 3. Unscrew and remove Lock Bolt. 4. Remove Pushrod, Ball & Retainer, Spring and “O” ring. Clean parts thoroughly and apply grease to the Balls & Retainer. Re-assembly procedure : 1. Place Spring on Pushrod and compress the spring beyond the hole in the Pushrod. 2. Insert a pin or wire into the hole in the Pushrod to hold the Spring in its’ compressed position. 3. Place Balls & Retainer onto Pushrod. 4. Insert Pushrod into the Tensioner body with the small flat on the Pushrod facing, and aligned with, the Locking Bolt hole. 5. Insert the Locking Bolt and tighten it against the small flat on the Pushrod to lock the Pushrod in the compressed position. Remove the pin that’s holding the Spring compressed. 6. Install the Tensioner assembly onto the cylinder block and install and tighten both Flanged Bolts. Be sure that the “O” ring has been installed at the base of the flange. 7.Looosen the Lock Bolt to release the Pushrod, then re-tighten the lock bolt

KAWASAKI KZ650 Slide Carburetor Tuning


Filed Under (Kawasaki) by admin on 31-10-2010

1. The float height has been checked and adjusted to factory specifications 2. The air cleaner filter is clean and not obstructed or blocked. 3. The rubber intake manifolds between the carburettor bodies and the cylinder block have no vacuum leaks caused by cracks or holes in the rubber 4. Initial Carburettor Mechanical Synchronization The following procedure shows how to mechanically synchronize carburettors so that a proper idle can be attained. Remove the carburettors from the engine. 1. Remove all top covers from the carburettors and loosen the throttle arm locknut. 2. Turn the throttle arm adjusting screw to allow for a slight clearance between the carburettor bore and the bottom of the slide. 3. Insert a piece of wire 0.8 – l.0 mm in diameter between the bottom of the slide and the carburettor bore. 4. Turn the throttle arm adjusting screw until the wire can just be moved in and out without noticeable friction or drag. i.e.. not too tight (drag) and not too loose (slop). 5. Tighten the throttle arm adjusting screw locknut without changing the adjustment and replace the top cover. NOTE: All 4 carburettors must be adjusted exactly the same, so do this procedure carefully and correctly. 6. With the carburettors fully assembled on the bench take a minute to double check your work. Check for missing screws, slide action, throttle plate function, in general anything out of the ordinary. 7. Now install the carburettor assembly in reverse order of its disassembly 8.