4.22. Engine repair

It be required to you: keys «on 10», «on 13», «on 14», «on 17», «on 19», «on 21», «on 22», «on 36» (or a special key for a nut of fastening of a pulley of a cranked shaft, in the absence of such key it is possible to take advantage of an alligator wrench), face heads «on 12» and «on 13» (or a special key for bolts of fastening of a head of the block of cylinders), a screw-driver, a hammer, a stripper of the oil filter.

GOOD ADVICE If there is a possibility, work at the special rotary stand providing access to the engine from different directions as the engine is very heavy for fixing from moving at отворачивании the details of fastening tightened by the big moment.

1. Remove the engine from the car (Removal and engine installation »see«).

2. To similarly how it did on the engine established on the car (without operations on a detachment of wires, pipelines and hinged units), will perform following works: – Remove the oil filter (oil Replacement in the engine and the oil filter »see«); – Remove coupling (Removal and coupling installation »see«); – Remove a flywheel (Removal, installation and дефектовка a flywheel »see«); – Remove a head of the block of cylinders («Replacement of a lining of a head of the block of cylinders» see).

3. Turn away three bolts of fastening of the case of the pump of a cooling liquid to the block of cylinders and remove the pump in gathering with a pulley.

4. Ослабьте an inhaling of the gauge of an alarm lamp of insufficient pressure of oil, keeping an adapter from проворачивания, also turn out the gauge.

5. Remove a boot натяжителя chains of a drive of a camshaft (boot Replacement натяжителя chains of a drive of a camshaft »see«).

6. Shift a screw-driver an asterisk of a cranked shaft and remove it. Unbend edge of a lock washer, turn out a bolt of fastening of an asterisk of the platen of a drive of the oil pump and remove an asterisk.

7. Remove a chain of a drive of a camshaft.

8. Remove заглушку an assembly aperture in the block of cylinders («Replacement of a gear wheel of a drive of the oil pump» see).

9. Uncover сапуна ventilation systems crankcase (Clearing of system of ventilation crankcase »see«).

10. Turn out two bolts of fastening of a persistent flange of the platen of a drive of the oil pump, shift the platen forward and remove it.	11. Hook a screw-driver a gear wheel of a drive of the oil pump and remove it.

12. Turn on two nuts of fastening of a forward cover crankcase couplings and uncover.	13. Turn out two bolts of fastening oil crankcase to the holder of a back epiploon of a cranked shaft...

14.... Six bolts of fastening of the holder to the block of cylinders and, accurately having hooked a screw-driver, remove the holder of an epiploon.

THE PREVENTION Do not lose two bolts with square heads of fastening of a forward cover crankcase coupling. They are freely established in nests of the holder and easily drop out.

15. Turn out the remained bolts of fastening oil crankcase, remove washers and oil картер.

16. If the lining oil crankcase remained on the block of cylinders, remove it.

17. Turn out two bolts of fastening of the oil pump and remove it.

18. If the lining of the oil pump remained on the pump, separate and remove it.

19. Screw two nuts on a hairpin of fastening of an oil separator and mutually tighten them. Turn out a hairpin.	20. Turn out a bolt of fastening of an arm of a drain tube of an oil separator and remove an arm, having shifted it on a tube up to the end.

21. Remove an oil separator with a drain tube.

GOOD ADVICE Before dismantling krivoshipno-shatunnogo the mechanism and piston group mark pistons, rods, loose leaves radical and шатунных bearings that at assemblage to establish them on former places if they are efficient.

22. Turn on two nuts of fastening of a cover of a rod of any cylinder.	23. Shift a cover of a rod from a seat easy blows of a hammer and uncover with the loose leaf.

THE NOTE On a rod and шатунной to a cover cylinder numbers in which they are established are beaten out. Covers of rods невзаимозаменяемы (the rod is processed together with a cover). At figure assemblage (cylinder number) on a rod and a cover should be on the one hand.

24. Press wooden бруском (the hammer handle) bolts of a rod and...	25.... Take out the piston with a rod from the cylinder towards the top plane of the block of cylinders.

26. Similarly remove pistons and rods of other cylinders, turning a cranked shaft for access to nuts of covers of rods

GOOD ADVICE Turn a cranked shaft a key for лыску on the forward end.

27. Turn out two bolts of fastening of any cover of the radical bearing.	28. Separate a cover from a seat easy blows of a hammer and uncover with the bottom loose leaf.

THE NOTE Covers of radical bearings are intended only for one concrete block of cylinders (covers are processed together with the block). Among themselves covers невзаимозаменяемы. On covers the labels corresponding to an order of their installation are put, considering from a forward part of the engine.

29. Remove other covers of radical bearings and remove a cranked shaft.

30. Remove a back persistent half ring (ceramic-metal, yellow colour) a back support of a cranked shaft...	31.... A forward persistent half ring (steel-aluminium) a back support of a cranked shaft...

32.... All top loose leaves of radical bearings of a cranked shaft...

33.... Loose leaves from all covers of rods...

34.... The bottom loose leaves from all covers of radical bearings of a cranked shaft...

35.... Loose leaves from all rods.

THE NOTE If connecting rod bolts have no damages, they can to be taken out from rods.

36. Unclench top компрессионное a ring and remove it.

37. Similarly remove other rings.

38. Remove lock rings of a piston finger, having hooked their pointed tool.	39. Push out a finger from lugs of the piston and the top head of a rod.

GOOD ADVICE Mark details. If they are not damaged and worn a little out, they can be used, having established on former places.

40. Take out шпонку from a groove in the forward end of a cranked shaft.

It be required to you: a portable lamp, a set flat щупов, a ruler, a calliper, нутромер, a micrometer, шабер.

After dismantling carefully wash up details kerosene, blow and dry their compressed air (especially oil channels of details).

1. Examine the block, it is especially attentive – support of a cranked shaft. Cracks in any places of the block are not supposed.

GOOD ADVICE If there is a suspicion on presence of cracks in the block (the cooling liquid in картер has got or oil in cooling liquid), check up tightness of the block at the special stand. Check spend in the repair shops having the corresponding equipment.

2. Examine cylinders from both parties. Scratches, teases and cracks are not supposed.

GOOD ADVICE At survey of cylinders it is recommended to shine mirrors of cylinders with a portable lamp – thus defects are visible much better.

3. Define нутромером actual diameters of cylinders.

Fig. 4.10. The scheme of measurement of cylinders: And and In – measurement directions; 1, 2, 3, 4 – numbers of belts

THE NOTE Diameter of the cylinder measure in four belts (fig. 4.10), located on cylinder height on distance 5, 15, 50 and 90 mm from a plane of a socket with a block head. In each belt diameter measure in two mutually perpendicular directions (in longitudinal and cross-section). Block cylinders on diameter are subdivided into five classes: A = 82,00–82,01 mm; B = 82,01–82,02 mm; C = 82,02–82,03 mm; D = 82,03–82,04 mm; E = 82,04–82,05 mm.

The class of each cylinder of the block according to the manufacturer documentation is noted by a brand on the right party of the bottom plane (a plane of a socket with oil картером).

According to the manufacturer documentation on a left-hand side of the bottom plane of the block the brand with conditional number of the block of cylinders should be put. The same number should be on all covers of radical bearings for instructions of an accessory of covers to the given block.

In a zone of the first belt (on distance of 5 mm from a plane of a socket with a block head) cylinders practically do not wear out. On a difference of the sizes in the first and other belts it is possible to judge deterioration of cylinders. If the maximum value of deterioration is more 0,15 mm, chisel cylinders till next repair size of pistons (the increased on 0,4 or 0,8 mm), having left an allowance of 0,03 mm for the diameter under хонингование. Then отхонингуйте cylinders, maintaining such diameter that at installation of the chosen repair piston the settlement backlash between it and the cylinder was 0,05–0,07 mm. Дефектовку, расточку and хонингование the block spend in the workshops having the special equipment.

4. Check up a deviation from planeness of a surface of a socket of the block with a head of cylinders. Put a calliper (or a ruler) to a plane: in the middle of the block; in cross-section and longitudinal directions; on plane diagonals. In each position flat щупом define a backlash between a calliper and a plane. It also will be a deviation from planeness. If the deviation exceeds 0,1 mm, replace the block.

5. Clear of a deposit the piston bottom шабером (it is possible to make of an old file).

6. Clear of a flute deposit under piston rings an old ring, rotating it.

7. Examine pistons, rods, covers: on them there should not be cracks.

8. Examine loose leaves. If on a working surface will find out risks, teases and отслоения an antifrictional layer, replace loose leaves new. All connecting rod loose leaves identical and interchangeable.

9. Measure diameter of pistons in a plane, a perpendicular axis of a piston finger, on distance of 52,4 mm from the piston bottom. By results of gaugings define a backlash between the piston and the cylinder and if necessary pick up new pistons to cylinders. The settlement backlash between the piston and the cylinder (for new details) makes 0,05–0,07 mm. It define a measurement of cylinders and pistons and provide with installation of pistons of the same class, as cylinders. As much as possible admissible backlash (at deterioration of details) 0,15 mm.

If at the engine which was in operation, the backlash exceeds 0,15 mm, it is necessary to pick up pistons to cylinders: the backlash should be as much as possible approached to the settlement.

10. Insert the finger greased with engine oil into an aperture of a lug of the piston. The finger freely rotates in lugs of the piston and in the top head of a rod. On external diameter fingers share on three categories through 0,004 mm. The category is underlined a paint at a finger end face:

1st (a dark blue label) – 21,982–21,986 mm;

2nd (a green label) – 21,986–21,990;

3rd (a red label) – 21,990–21,994.

The finger should densely, but without jamming to enter into apertures of a lug and a rod from effort of a thumb.

11. Turn the piston a finger axis vertically. The finger should not drop out of a lug. A finger dropping out of a lug replace with another, the following category. If in the piston a finger of the third category, replace the piston with a finger.	12. Check up flat щупом a backlash on height between flutes in the piston and rings, inserting a ring into a corresponding flute. The nominal (settlement) backlash makes:

– For top (first) компрессионного rings of 0,04-0,07 mm;

– For the second компрессионного rings of 0,03-0,06 mm;

– For маслосъемного rings of 0,02-0,05 mm.

Maximum permissible backlashes at deterioration – 0,15 mm.

13. Check up flat щупом a backlash in the lock of rings, having established a ring in the cylinder on depth about 50 mm.

   

GOOD ADVICE To establish a ring without a warp, advance a ring deep into the cylinder the piston.

Under the recommendation of manufacturer a backlash check at the rings inserted into special calibre, the having diameter of an aperture equal to nominal diameter of a ring with the admission ±0,003 mm.

The backlash should make 0,25–0,45 mm for all new rings. A maximum permissible backlash at deterioration – 1,0 mm.

In the absence of calibre is admissible to apply the shown way.

If a backlash insufficient, cut butt surfaces of a ring. If the backlash exceeds admissible, replace a ring.

14. At possibility check up weight of pistons: for one engine they should not differ from each other more than on ±2,5 It is possible to adjust them on weight metal removal in the shown place from both parties of the piston. Depth of removal of metal should not exceed 4,5 mm, considering from nominal height of the piston of 59,4 mm.	15. Measure нутромером internal diameter Dв a rod seat in gathering with a cover.

THE NOTE Before measurement tighten nuts шатунных bolts the nominal moment.

16. Measure a thickness Т шатунных loose leaves by a calliper.	17. Measure by a micrometer diameter Dн шатунных necks.

18. Calculate a backlash z between шатунными loose leaves and necks of a cranked shaft under the formula z=Dv-2T-Dn.

The nominal settlement backlash makes 0,02–0,07 mm. A limiting backlash of 0,1 mm.

If an actual settlement backlash less limiting, it is possible to use loose leaves which have been established again.

If a backlash more limiting, replace loose leaves on these necks new a nominal thickness (1,723–1,730 mm).

If necks of a cranked shaft are worn out and перешлифованы till the repair size, replace loose leaves repair (the increased thickness):

«0,25» = 1,848–1,855 mm;

«0,50» = 1,973–1,980 mm;

«0,75» = 2,098–2,105 mm;

«1,0» = 2,223–2,230 mm.

Nominal diameter шатунных necks of 47,83-47,85 mm. Necks grind, if on them is забоины and risks or deterioration (or ovality) makes more than 0,03 mm, reducing diameter with step of 0,25 mm so that to receive (depending on deterioration degree) following values:

«0,25» = 47,58–47,60 mm;

«0,50» = 47,33–47,35 mm;

«0,75» = 47,08–47,10 mm;

«1,0» = 46,83–46,85 mm.

THE NOTE Designations «0,25», etc. specify, diameter of necks of a cranked shaft after polishing how much decreases.

19. Examine the top and bottom loose leaves of radical bearings. The top loose leaves 1, 2, 4 and 5th radical bearings have a flute on an internal surface (at bottom it is not present). Loose leaves of central (3rd) radical bearing differ from the others большей in the width, except that, its top loose leaf has no flute. If on a working surface of loose leaves there are risks, teases, отслоения an antifrictional layer, replace loose leaves new.

THE PREVENTION It is forbidden to spend any подгоночные operations on loose leaves.

20. Examine a cranked shaft. Cracks are not supposed. On the surfaces interfaced to working edges of epiploons, there should not be scratches, забоин, рисок. At detection replace a shaft.

21. Measure by a micrometer external diameter Dн radical necks. An actual backlash between loose leaves of radical bearings and radical necks of a cranked shaft define by a technique stated for шатунных of loose leaves.

The nominal settlement backlash makes 0,026–0,073 mm. A limiting backlash – 0,15 mm.

If an actual settlement backlash less limiting, it is possible to use loose leaves which have been established again.

If a backlash more limiting, replace on these necks loose leaves new a nominal thickness (1,824–1,831 mm).

If necks of a cranked shaft are worn out and перешлифованы till the repair size, replace loose leaves repair (the increased thickness):

«0,25» = 1,949–1,956 mm;

«0,50» = 2,074–2,081 mm;

«0,75» = 2,199–2,206 mm;

«1,0» = 2,324–2,331 mm.

Nominal diameter of radical necks of 50,799-50,819 mm. Necks grind, if on them is забоины and risks or deterioration (or ovality) makes more than 0,03 mm, reducing diameter with step of 0,25 mm so that to receive (depending on deterioration degree) following values:

«0,25» = 50,549–50,569 mm;

«0,50» = 50,299–50,319 mm;

«0,75» = 50,049–50,069 mm;

«1,0» = 49,799–49,819 mm.

THE NOTE Designations «0,25», etc. specify, diameter of necks of a cranked shaft after polishing how much decreases. A corresponding brand put on the first cheek of a cranked shaft, for example To 0,75; Ш 0,50.

22. Establish a shaft extreme radical necks on prisms and check up the indicator:

– Axial palpation of other radical necks (no more than 0,03 mm);

– Axial palpation of landing surfaces under an asterisk and the bearing of a primary shaft of a transmission (no more than 0,04 mm);

– Displacement of axes шатунных necks from the nominal plane passing through axes шатунных and radical necks (no more ±0,35 mm);

– Face palpation of a flange at diameter of 68 mm (no more than 0,025 mm).

THE NOTE Palpation check in garage conditions is almost impracticable, therefore spend her in the workshops having the special equipment.

23. Examine заглушки channels of system of greasing. Check up reliability of their landing by a screw-driver, without applying considerable efforts. If заглушки are established unreliably, replace them. Заглушки establish on hermetic УГ-6 and зачеканьте in three places.

GOOD ADVICE It is not recommended to open independently заглушки for clearing of channels which, certainly, is useful. Address in the workshops having the special equipment, or wash out channels, without opening заглушки, for what...

... Fill in in radial channels (are shown by arrows) gasoline, preliminary having muffled them on the one hand wooden stoppers. Sustain not less than 20 mines and wash out channels gasoline, injecting its rubber pear. Wooden заглушки remove after washing of connecting channels (are shown by a dotted line). If necessary repeat washing to вытекания pure gasoline.

It be required to you: динамометрический a key, a hammer, the adaptation for installation of pistons in cylinders, keys «on 10», «on 13», «on 14», «on 17», «on 19», «on 21», «on 22», «on 36» (or gas), face heads «on 12» and «on 13» (or a special key for bolts of fastening of a head of the block of cylinders), a screw-driver, an assembly shovel.

1. Put on the piston a rod, watching, that the aperture under a finger has coincided with an aperture in the top head of a rod. Effort of a hand push the finger greased with engine oil in piston and rod apertures. Insert in проточки piston lugs lock rings and in addition grease a finger with engine oil through apertures in piston lugs.	2. Establish piston rings in an order, the return to removal.

THE PREVENTION At installation do not unclench a ring more than it is necessary not to deform or to break them.

THE NOTE Bottom компрессионное a ring establish bore (it is shown by an arrow) downwards in the second flute. If on a ring the label "Top" or «TOP» a ring establish a label upwards (to the piston bottom) is put.

3. Сориентируйте rings. Establish rings on other pistons.

THE NOTE Rings сориентируйте as follows: the lock top компрессионного rings should settle down at an angle 30–45 ° to an axis of a piston finger; the lock bottom компрессионного rings – at an angle approximately 180 ° to an axis of the lock top компрессионного rings; the lock маслосъемного rings – 90 ° to an axis of the lock of the top piston ring.

4. Lay in bed of the block of cylinders the top loose leaves of radical bearings (with flutes).

      

THE NOTE Loose leaves establish so that the adjusting short moustache of the loose leaf was combined with dredging on bed. In bed and a cover of the average bearing lay loose leaves большей width (without a flute).

5. Grease loose leaves with engine oil.

6. Establish a cranked shaft in the block of cylinders.

7. Lay in covers of radical bearings bottom (without a flute) loose leaves.

8. Grease with engine oil radical necks of a cranked shaft.

9. Grease with engine oil loose leaves in covers of radical bearings of a cranked shaft.

10. Establish covers (except back) radical bearings and grease persistent half rings with engine oil.

THE NOTE Covers establish in the same block according to labels, focusing them in the same party as was before dismantling.

11. Establish back (ceramic-metal, yellow colour) and forward (steel-aluminium) persistent half rings of a back support of a cranked shaft.

THE NOTE Persistent half rings establish dredging...

... To basic surfaces of a cranked shaft.

12. Establish a cover of the back radical bearing and bolts of covers, tighten them динамометрическим a key the moment resulted in enc. 1.

13. Check up flat щупом an axial backlash of a cranked shaft, having moved an assembly shovel a cranked shaft against the stop. The axial backlash should be 0,06–0,26 mm. As much as possible admissible backlash – 0,35 mm. If a backlash more, replace persistent half rings with others, increased by 0,127 mm.

14. Check up correctness of assemblage, having turned a cranked shaft a hand on some turns. The shaft should rotate freely and smoothly.

15. Insert connecting rod bolts (if them took out) and loose leaves into rods, having combined an adjusting short moustache of the loose leaf with dredging on a rod.

16. Grease with engine oil of a mirror of cylinders, pistons, piston rings and connecting rod loose leaves

.

17. Establish on the piston the adaptation for compression of rings and, wrapping the screw, compress rings.	18. Establish the piston in the cylinder according to marks of number of the cylinder on a rod, press (for example, the hammer handle) the piston and shift it from send in the cylinder. Similarly establish pistons in other cylinders.

THE NOTE At installation of pistons into cylinders of the marksman on the piston should be turned to a forward part of the engine

19. Establish connecting rod loose leaves in covers of rods, having combined an adjusting short moustache of the loose leaf with dredging on a cover.

20. Grease with engine oil connecting rod loose leaves in covers of rods and connecting rod necks of a cranked shaft.

21. Establish a rod cover, having connected a rod to a neck of a cranked shaft and having combined labels on a rod and a cover.

22. Screw nuts шатунных bolts, without tightening definitively. Similarly establish covers of other rods.

23. Tighten nuts шатунных bolts динамометрическим a key the moment resulted in enc. 1.

24. Establish the holder of a back epiploon of a cranked shaft, having replaced a lining. Centre the holder concerning a flange of a shaft special оправкой (if it is not present, align the holder on a working edge of an epiploon) and tighten six bolts of fastening of the holder, having combined a plane of the holder with a plane of a socket of the block without warps.	25. Establish a flywheel (preliminary having established a forward cover crankcase couplings) so that the label (cone-shaped лунка) about a rim was against an axis шатунной necks of the fourth cylinder, and fix a flywheel, having tightened bolts of its fastening by the moment resulted in enc. 1.

26. Establish details and knots in the sequence corresponding to transfer: an asterisk on a cranked shaft, an oil separator, a gear wheel of a drive of the oil pump, the platen of a drive of the oil pump, the oil pump (having replaced a lining), oil картер (having replaced a lining and without tightening definitively bolts of its fastening), a block head (having replaced a lining). Tighten bolts of fastening of a head in four receptions in certain sequence («Replacement of a lining of a head of the block of cylinders» see).

27. Establish an asterisk on a camshaft collected with the case of bearings, and turn a shaft so that the label on an asterisk was opposite to a label on the case of bearings. Remove an asterisk and, without changing shaft position, establish the case of bearings on a head of cylinders. Fix the case, tightening nuts in certain sequence («camshaft Replacement» see) the moment resulted in enc. 1.

28. Establish a boot натяжителя chains. Turn a cranked shaft so that to combine a label on an asterisk of a cranked shaft with a label on the block of cylinders. Put on a chain an asterisk, without changing position of a cranked shaft.

29. Put on a chain an asterisk of the platen of a drive of the oil pump and, having pulled a leading branch, establish an asterisk on the platen, without tightening definitively a bolt of its fastening. Attach to a chain a wire and lift a chain in a drive cavity upwards (or hook from above a hook and lift).

30. Put on a chain a camshaft asterisk, pull a leading branch and establish an asterisk on a shaft, having provided label coincidence on an asterisk and inflow on the case of bearings and without tightening definitively a bolt of its fastening.

31. Establish натяжитель chains (if it removed at dismantling of a head of the block of cylinders). Turn a cranked shaft on two turns in a rotation direction to provide the necessary tension of a chain. Check up simultaneous coincidence of labels on asterisks with labels on the block of cylinders and on the case of bearings.

32. If labels do not coincide, repeat chain installation. If labels coincide, definitively tighten bolts of asterisks and unbend edges of lock washers of bolts of asterisks. Establish a cover of a head of the block, having replaced a lining.

33. Establish a cover of a chain of a drive of a camshaft with a forward epiploon of a cranked shaft, having replaced a lining. Centre the holder concerning a flange of a shaft special оправкой (if send is not present, align the holder on a working edge of an epiploon, temporarily having established on a shaft of a cranked shaft pulleys) and tighten bolts and nuts of fastening of a cover.

THE NOTE Bolts, simultaneously крепящие an arm of the pump of the hydraulic booster of a steering, tighten after pump installation.

34. Definitively tighten bolts of fastening oil crankcase. Establish pulleys of a cranked shaft.

35. Establish other details and knots in an order, the return to removal.

GOOD ADVICE After engine assemblage it is recommended to spend it обкатку at the stand. As out of the special repair organisations it is impossible to make it, after engine installation on the car обкатайте it on the simplified cycle: 1. Be convinced of correctness of adjustment of a drive throttle заслонок, fill in oil and cooling liquid, check up tightness of all connections. 2. Start up the engine and allow to it to work without loading on a following cycle.

Frequency of rotation of a cranked shaft, mines-1	Operating time, mines
820-900	2
1000	3
1500	4
2000	5

Do not lead up work of the engine to the maximum modes.

3. In an operating time check up tightness of the engine and its systems, pressure of oil, ignition installation, frequency of rotation idling, pay attention to presence of extraneous noise.

4. If extraneous noise or other malfunctions are found out, stop the engine and eliminate their reason.

5. Having begun car operation, observe the modes provided for the period break-in of the new car.