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Tolerances and wear Limits (Engine)

DAVES PORSCHE 91

 Measuring point Tolerance (new) Wear Limit

1. Cylinder seat

depth in cylinderhead

9.5009.!00 mm

(0."#$0."#% in)

 10.000 mmm

(0."9"# in)

 

&. Cylinder 'oreoality * minus +

 n,a 0.0&0 mm(0.000% in)

 

". -iston to

cylinder clearance

 0.0$10.059 mm

(0.001!0.00&" in)

 0.&0 mm

(0.00% in)

 

$. -iston ring side

clearance

 ing 1 0.#50.10#

mm (0.00"00.00$&in)

 0.&50."0

mm (0.009%0.011% in)

 

ing & 0.$50.0#&mm (0.001%0.00&%

in)

 0.&50."0mm (0.009%

0.011% in)

 

5. -iston ring side

clearance /il ring

 0.0&50.05& mm

(0.00100.00&0 in)

 0.&50."0

mm (0009%0.011% in)

 

!. -iston ring gap 0.150."0 mm(0.00590.011% in)

 0.95(0.0"#$)

 

#. Weight

dierential 'etweenpistons in one

engine

 5 g (0.1#! o) n,a

%. Weight

dierential 'etween

connecting rods inone engine

 ! g (0.&11 o) n,a

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 9. -iston pin toconnecting rod

clearance

 0.01&0.0&% mm(0.00050.0011 in)

 0.0$& mm(0.001# in)

 

10. Cran2 pin toconnecting rod

clearance

 0.0$00.09& mm(0.001!0.00"! in)

 0.1"0 mm(0.0051 in)

 

11. Cran2shat tomain 'earing

clearance ('earingsinstalled)

  a. *earing 1. 0.0&%0.0#% mm (0.0011

0.00"1 in)

 0.1#0 mm(0.00!# in)

 

'. *earing & and ".0.0$!0.100 mm

(0.001%0.00"9 in)

 0.1#0 mm(0.00!# in)

 

c. *earing $. 0.0$0

0.10$ mm (0.001!0.00$1 in)

 0.1#0 mm

(0.00!# in)

 

1&. Cran2shatrunout at *earing &

and $ (*earing 1and " on 3 'loc2s)

 ma4. 0.0&0 mm(0.000% in)

 0.0"0 mm(0.001& in)

 

1". Cran2shat tocran2shat thrust

'earing

 0.1"0.1% mm(0.00510.00#1 in)

 0." mm(0.011% in)

 

1$. Main 'earing

 ournal oality

  0.0&0 mm

(0.000% in)

 

15. Connecting rod

 ournal oality

  0.0&0 mm

(0.000% in)

 

1!. Cran2case

'ores or main'earings (dia)

 a. *earing 1"

!0.&"5!0.&$5 mm(&."#15&."#1% in)

 

'. 'earing $.

50.00050.0&5 mm

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(1.9!%51.9!95 in)

 1#. Cran2shat

pulley runout

 ertical. + ma4.

0.&50 mm (0.009%in)

 

* ma4. 0.&50 mm

(0.009% in)

 

1%. Cran2case 'oreor camshat (diam)

 &$.0&0&$0$1 mm(0.9$5#0.9$!5 in)

 &$.0#0 mm(0.9$#! in)

 

19a. Camshat'earing clearance

 0.0&00.05$ mm(0.000%0.00&1 in)

 0.1&0 mm(0.00$# in)

 

19'. Camshat endplay at thrust end

 0.0$00.0%0 mm(0.001!0.00"1 in)

 0.100 mm(0.00"9 in)

 

19c. Camshat

center 'earingrunout (camshat

mounted oncenters)

 0.0&0 mm (0.000%

in)

 0.0&5 mm

(0.0010 in)

 

&0a. Timing gear

run out (gear 'oltedand pinned to

camshat)6 Lateralrunout

 ma4. 0.100 mm

(0.00"9 in)

 

&0'. Timing gear

runout6 7ear*ac2lash

 0.0150.0$0 mm

(0.000!00.001! in)

 

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 &0c. Timing gearrunout6 3ertical

runout

 0.0&5 mm (0.0010in)

 0.0$0 mm(0.001! in)

 

&1a. 8lywheel6Lateral runout

measured at starterring (+)6

 ma4. 0."00 mm(0.011% in)

 

&1'. 8lywheel6Lateral runout

measured in clutchplate recess (*)6

 ma4 0.0$0 mm(0.001! in)

 

&1c. 8lywheel63ertical runout

measured at starterring (C)6

 ma4 0.0&0 mm(0.000% in)

 

&1d. 8lywheel63ertical runout

measured in clutch

dis2 recess ()6

 ma4 0.100 mm(0.00"9 in)

 

&1. 8lywheel6

:n'alancemeasured with

cran2shat

ma4 0.5 cmg (0.0!9

o,in)

 

&1e. 8lywheel6iameter o oil

sealing surace athu' (;)6

 59.000!0.100 mm(&."5%"&."!!1 in)

 59.#00 mm(&."$0" in)

 

&1. 8lywheel6epth o recess to

we' (8)6

 !."!.%5 mm(0.&$%00.&!9# in)

 

&1g. 8lywheel6 We'

thic2ness (7)6

 !."!.%5 mm

(0.&$%00.&!9# in)

 min $.%00

mm (0.1%90in)  

&1h. 8lywheel6

Width o oil sealingarea (

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pressure whencompressed to $1

mm length

?, "." l's)

 &5e. 3ale >pring

pressure whencompressed to "0.1

mm length

 9# ?, &.5 2p (&1"

?, 5.5 l's)

 

&!. 3ale clearancein cold engine

 inta2e60.10 mm (0.00$ in)

 

e4haust60.15 mm (0.00! in)

 

a. oc2er +rm inside diameter61!.0001!.01%

(0.!&990.!"0!)

 1!.1$5(0.!"1")

 

shat outside

diameter615.9%$15.9#"

(0.!&9"0.!&%9)

 15.9!5

(0.!&%5)

 

arm to shat

clearance60.01!0.0$5

(0.000!0.001%)

 0.0#0

(0.00&%)

 

&%. 3ale Liter 'ore in cran2case(diam)61&.0001&.01%

(0.$#50.$#"1)

 1&.0!0(0.$#$%)

 

diameter6

11.9!!11.9%$(.$#110.$#1%)

 11.9$5

(0.$#0")

 

to cran2case 'oreclearance6

0.01!0.05&(0.000!0.00&0)

 0.100(0.00"9)

 

&9. /il -ressure warm engine idle

(min)60.5 atm (#." psi)

 

warm engine at&500 -M (min)6

 &.0 atm (&9psi)

 

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".0 atm ($$ psi)

 "0. /il -ump -ump gears e4tend

'eyond housing (nogas2et)6

0.0!0.1&5 (0.00&$0.00$9)

 

Thic2ness o

compressed gas2et(+)60.1! (0.00!")

 

7ear end play withgas2et and coer

installed (*)60.0"50.10 (0.001$

0.00"9)

 0.&0(0.00#9)

 

7ear 'ac2lash6

0.0"00.0%0(0.001&0.00"1)

 

"1. >pring orpressure relei

ale in cran2case

and timing gearcoer

 8ree length6!! mm (&.! in)

 

>pring pressure

when compressed to$9 mm6

$.# 2p ?, #@ (10.$l's ?, #@)

 

>pring wire cross

section (diam)61.$ (0.55)

 

"&. /il -ressureswitch opens at

pressure o6

 0."0.! atm ($.$%.%psi)

 

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