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Tolerances and Wear Limits

The document lists tolerances and wear limits for various engine components of a Porsche 912 engine. It provides specifications for cylinder dimensions, piston and ring clearances, crankshaft details, camshaft specs, valve sizes and guides, oil pressure requirements, and tolerances for other parts like the flywheel, rocker arms, and oil pump gears. The specifications define acceptable ranges for new components as well as maximum wear limits before replacement is needed.

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376 views7 pages

Tolerances and Wear Limits

The document lists tolerances and wear limits for various engine components of a Porsche 912 engine. It provides specifications for cylinder dimensions, piston and ring clearances, crankshaft details, camshaft specs, valve sizes and guides, oil pressure requirements, and tolerances for other parts like the flywheel, rocker arms, and oil pump gears. The specifications define acceptable ranges for new components as well as maximum wear limits before replacement is needed.

Uploaded by

spdhiman
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Tolerances and wear Limits (Engine)

DAVES PORSCHE 912


Measuring point

Tolerance (new)

Wear Limit

1. Cylinder seat
depth in cylinder
head

9.500-9.600 mm
(0.374-0.378 in)

10.000 mmm
(0.3937 in)

2. Cylinder bore
ovality, B minus A

n/a

0.020 mm
(0.0008 in)

3. Piston to
cylinder clearance

0.041-0.059 mm
(0.0016-0.0023 in)

0.20 mm
(0.008 in)

4. Piston ring side


clearance

Ring 1 0.75-0.107
0.25-0.30
mm (0.0030-0.0042 mm (0.0098in)
0.0118 in)
Ring 2 0.45-0.072
0.25-0.30
mm (0.0018-0.0028 mm (0.0098in)
0.0118 in)

5. Piston ring side


clearance Oil ring

0.025-0.052 mm
(0.0010-0.0020 in)

0.25-0.30
mm (000980.0118 in)

6. Piston ring gap

0.15-0.30 mm
(0.0059-0.0118 in)

0.95
(0.0374)

7. Weight
5 g (0.176 oz)
differential between
pistons in one
engine

n/a

8. Weight
6 g (0.211 oz)
differential between
connecting rods in
one engine

n/a

9. Piston pin to
connecting rod
clearance

0.012-0.028 mm
(0.0005-0.0011 in)

0.042 mm
(0.0017 in)

10. Crank pin to


connecting rod
clearance

0.040-0.092 mm
(0.0016-0.0036 in)

0.130 mm
(0.0051 in)

11. Crankshaft to
a. Bearing 1. 0.028- 0.170 mm
main bearing
0.078 mm (0.0011- (0.0067 in)
clearance (bearings 0.0031 in)
installed)

b. Bearing 2 and 3.
0.046-0.100 mm
(0.0018-0.0039 in)

0.170 mm
(0.0067 in)

c. Bearing 4. 0.040- 0.170 mm


0.104 mm (0.0016- (0.0067 in)
0.0041 in)
12. Crankshaft
runout at Bearing 2
and 4 (Bearing 1
and 3 on V -blocks)

max. 0.020 mm
(0.0008 in)

0.030 mm
(0.0012 in)

13. Crankshaft to
crankshaft thrust
bearing

0.13-0.18 mm
(0.0051-0.0071 in)

0.3 mm
(0.0118 in)

14. Main bearing


journal ovality

0.020 mm
(0.0008 in)

15. Connecting rod


journal ovality

0.020 mm
(0.0008 in)

16. Crankcase
bores for main
bearings (dia)

a. Bearing 1-3
60.235-60.245 mm
(2.3715-2.3718 in)
b. bearing 4.
50.000-50.025 mm

(1.9685-1.9695 in)
17. Crankshaft
pulley runout

vertical. A max.
0.250 mm (0.0098
in)

B max. 0.250 mm
(0.0098 in)
18. Crankcase bore 24.020-24-041 mm 24.070 mm
for camshaft (diam) (0.9457-0.9465 in) (0.9476 in)
19a. Camshaft
bearing clearance

0.020-0.054 mm
(0.0008-0.0021 in)

0.120 mm
(0.0047 in)

19b. Camshaft end


play at thrust end

0.040-0.080 mm
(0.0016-0.0031 in)

0.100 mm
(0.0039 in)

19c. Camshaft
center bearing
runout (camshaft
mounted on
centers)

0.020 mm (0.0008
in)

0.025 mm
(0.0010 in)

20a. Timing gear


max. 0.100 mm
run out (gear bolted (0.0039 in)
and pinned to
camshaft): Lateral
runout

20b. Timing gear


runout: Gear
Backlash

0.015-0.040 mm
(0.00060-0.0016 in)

20c. Timing gear


runout: Vertical
runout

0.025 mm (0.0010
in)

0.040 mm
(0.0016 in)

21a. Flywheel:
max. 0.300 mm
Lateral runout
(0.0118 in)
measured at starter
ring (A):
21b. Flywheel:
Lateral runout,
measured in clutch
plate recess (B):

max 0.040 mm
(0.0016 in)

21c. Flywheel:
max 0.020 mm
Vertical runout,
(0.0008 in)
measured at starter
ring (C):
21d. Flywheel:
Vertical runout,
measured in clutch
disk recess (D):

max 0.100 mm
(0.0039 in)

21. Flywheel:
Unbalance,
measured with
crankshaft

max 0.5 cmg (0.069


oz/in)

21e. Flywheel:
Diameter of oil
sealing surface at
hub (E):

59.000-60.100 mm 59.700 mm
(2.3583-2.3661 in) (2.3403 in)

21f. Flywheel:
Depth of recess to
web (F):

6.3-6.85 mm
(0.2480-0.2697 in)

21g. Flywheel: Web 6.3-6.85 mm


thickness (G):
(0.2480-0.2697 in)

21h. Flywheel:
Width of oil sealing
area (H):

9.250-10.250 mm
(0.3642-0.4035 in)

21i. Flywheel:
Matching starter
ring gear teeth
22a. Valve stem

min 4.800
mm (0.1890
in)

max. 2.000
mm (0.0787
in)
9.990-9.978 mm

9.940 mm

diameter: intake
valve

(0.3933-0.3928 in)

(0.3701 in)

22b. Valve stem


diameter: exhaust
valve

9.970-9.958 mm
(0.3925-0.3920 in)

9.940 mm
(0.3701 in)

23a. Valve guide to 10.025-10.040 mm 10.070 mm


valve stem
(0.3947-0.3953 in) (0.3965 in)
clearance. a) Valve
guild inside
diameter
23b. Valve guide to 0.035-0.060 mm
valve stem
(0.0014-0.0024 in)
clearance. b) Intake
valve clearance in
bore

0.120 mm
(0.0047 in)

23c. Valve guide to 0.055-0.080 mm


valve stem
(0.0022-0.0031 in)
clearance. c)
Exhaust valve
clearance in bore

0.120 mm
(0.0047 in)

24a. Valve Seat:


1.25 +/- 0.15
Intake seat width a) (0.0492 +/- 0.0059
in)

24b. Valve Seat:


Exhaust seat width
a)

1.55 +/- 0.15


(0.0610 +/- 0.0059
in)

24c. Valve Seat:


Lateral Runout of
valve head to seat

0.010 (0.0004 in)

25a. Valve Spring


length
decompressed

47 mm (1.85 in)

25b. Valve Spring


length installed,
intake

41 mm (1.61 in)

25c. Valve Spring


length installed,
exhaust

40.5 mm (1.59 in)

25d. Valve Spring

36 +/- 1.5 kp (79

pressure when
compressed to 41
mm length

+/- 3.3 lbs)

25e. Valve Spring


97 +/- 2.5 kp (213
pressure when
+/- 5.5 lbs)
compressed to 30.1
mm length

26. Valve clearance intake:


in cold engine
0.10 mm (0.004 in)
exhaust:
0.15 mm (0.006 in)
27a. Rocker Arm

28. Valve Lifter

29. Oil Pressure

inside diameter:
16.000-16.018
(0.6299-0.6306)

16.145
(0.6313)

shaft outside
diameter:
15.984-15.973
(0.6293-0.6289)

15.965
(0.6285)

arm to shaft
clearance:
0.016-0.045
(0.0006-0.0018)

0.070
(0.0028)

bore in crankcase
(diam):
12.000-12.018
(0.475-0.4731)

12.060
(0.4748)

diameter:
11.966-11.984
(.4711-0.4718)

11.945
(0.4703)

to crankcase bore
clearance:
0.016-0.052
(0.0006-0.0020)

0.100
(0.0039)

warm engine, idle


(min):
0.5 atm (7.3 psi)
warm engine at
2,500 RPM (min):

2.0 atm (29


psi)

3.0 atm (44 psi)


30. Oil Pump

Pump gears extend


beyond housing (no
gasket):
0.06-0.125 (0.00240.0049)
Thickness of
compressed gasket
(A):
0.16 (0.0063)
Gear end play, with 0.20
gasket and cover
(0.0079)
installed (B):
0.035-0.10 (0.00140.0039)
Gear backlash:
0.030-0.080
(0.0012-0.0031)

31. Spring for


pressure releif
valve in crankcase
and timing gear
cover

Free length:
66 mm (2.6 in)

Spring pressure
when compressed to
49 mm:
4.7 kp +/- 7% (10.4
lbs +/- 7%)

Spring wire cross


section (diam):
1.4 (0.55)
32. Oil Pressure
switch opens at
pressure of:

0.3-0.6 atm (4.4-8.8


psi)

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