| 1. All details should be checked well. If on details traces of furrows, dredging or wear are visible, they need to be replaced. It is necessary to make the following check of pistons: |
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2. Measure gaps of piston rings in flutes on height, establishing rings in turn in the corresponding flutes. The gap between a surface of a ring and a surface of a flute of the piston decides on the help of the flat probe. If the gap of a ring exceeds 0.12 mm, means rings or pistons are worn-out. Nominal size makes 0.02–0.07 mm. |
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3. Insert one after another all piston rings from the lower party of the block of cylinders into cylinders. By means of the turned piston of a ring it is necessary to press approximately on 15 mm down. At the same time both edges of a ring should be shifted to measure a gap in the ring lock. |
| 4. Nominal rates are specified in Specifications. The limit of wear is also various for various piston rings. |
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5. At too small gap (for example if a ring new), it is necessary to grind off edges of a ring, for this purpose it is necessary to clamp a file in a vice. At too big gap in the ring lock the corresponding ring should be replaced. |
| 6. Piston fingers and plugs of rods should be checked for wear and existence of the erased places. If at least one rod is unsuitable, it is necessary to replace all set. |
| 7. Nuts of conrod bearings have to be replaced. |
| 8. Rods should be checked for a bend and twisting in special adaptation. |
| 9. Check bolts of rods for existence of damages and if necessary replace. In this case rastyazhny bolts are applied, and they should be replaced same. |
| Assembly of conrod and piston group |
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10. If the oil nozzle for cooling of the piston was removed, it should be turned together with the safety valve (27 N of m). Nozzles are located in the lower part of cylinders. |
| 11. If pistons are replaced, it is necessary to check that all pistons were one type. |
| 12. Heat pistons to temperature of 60 °C (put in hot water). It is necessary to take care of existence of the suitable tool which can be put to inside of a piston finger. |
| 13. Press fingers by hand into heated pistons and into rods. |
14. At assembly of pistons and rods it is necessary to fulfill the following requirement:
– The arrow on the piston bottom (or drawn or beaten out on the new piston) has to be turned to the forward party of the engine.
– Cast ledges on a rod and a cover of the bearing have to be turned to a pulley.
– Designations of numbers of cylinders on rods and covers of bearings have to coincide. |
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15. Check that after assembly the piston could shake freely on a rod if to move it in the direction of an arrow. |
| 16. By means of flat-nose pliers for piston rings establish rings in flutes in turn. Both compression rings can be mixed and therefore it is necessary to check their section before installation. Besides, both compression rings are marked on the one hand with the word of "Torahs" or "Oben" and this designation after installation of a ring has to be read from above. |
| 17. Establish the oil scraper ring consisting of three parts, having distributed evenly locks. |
| Installation of conrod and piston group |
| 18. Well grease cylinders. |
| 19. Spread out all rods according to numbers of cylinders. Cast ledges on rods and covers of bearings have to be turned to a pulley of a bent shaft. |
| 20. Shooters on the bottom of pistons have to point to the forward party of the engine. |
| 21. Arrange locks of piston rings at identical distance on a piston circle, i.e. through 120 °. |
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22. Arrange a coupling tape for piston rings as it is represented on an illustration and press piston rings into flutes. Check that they were well pressed. |
| 23. Put on short pieces of rubber or plastic tubes rod hairpins not to scratch cylinders. |
| 24. Turn a bent shaft that two necks of a shaft were in the provision of NMT. |
| 25. Move a rod into the cylinder from above. The engine for this purpose needs to be put on one side that it was possible to bring rods to necks of bearings and not to scratch at the same time cylinders or conrod necks. The insert of the conrod bearing already has to be at the same time in a rod, a ledge in dredging. |
| 26. Move the piston until rings one behind another are moved into the cylinder, and the basis of a rod will sit down on a neck of a bent shaft. At the same time do not scratch a bearing neck. |
| 27. Lay an insert of the second bearing in a cover, well grease an insert, dress a cover on hairpins of a rod and slightly hammer. Pieces of rubber tubes it is necessary previously remove. Surely it is necessary to pay attention to that cast ledges on a rod and a cover of the conrod bearing coincided, otherwise at the last minute it is possible to make a mistake. |
| 28. Grease surfaces of a prileganiye of nuts on covers of conrod bearings with oil. |
| 29. Tighten nuts of covers of conrod bearings alternately the moment of 30 Nanometers and from this situation hold on for 90 °, i.e. on a quarter of a turn. |
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30. After tightening of conrod bearings it is necessary to examine each bearing once again. From experience it is known that defects of conrod bearings are sometimes shown after the end of repair when the cover of the bearing and a rod are not pulled together faultlessly. Figure 1 on an illustration designated both above-mentioned cast ledges, and figure 2 – designations of a cover of the conrod bearing and a rod, in this case for the second cylinder. The specified tags have to settle down on all rods the friend opposite to the friend. Such check should be made surely before closing of a case of the engine. |
| 31. After installation of rods the bent shaft needs to be turned several times to define whether there are no jammings. If is, it is necessary to double-check whether there are pistons in the correct situation, i.e. shooters on the bottoms have to be directed forward (towards a pulley). |
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32. By means of the measuring probe check a side gap of a rod to a cheek of a bent shaft. At the same time it is necessary to press the conrod bearing to the right to measure a gap by the measuring probe. It is an axial gap of the bearing of a rod, and it should not exceed 0.37 mm. Install the case pallet.
The moment of an inhaling of bolts of fastening for them various. |
| 33. From the forward party of the engine weaken bolts of a pulley of a bent shaft (a damper of tortional fluctuations), holding a flywheel. |
| 34. On cars with automatic transmission turn off a driving disk in the way described above. |
| 35. Remove a head of cylinders together with the inlet pipeline and a final collector. Some details are removed already at removal of the engine (depending on its type). |
| 36. Turn off a pulley from the pump of cooling liquid and the lower cover of a gear belt. |
| 37. Mark the direction of rotation of a gear belt with paint from outer side. |
| 38. After weakening of a nut of a tension of a belt take off a gear belt from gear wheels of the drive and a natyazhitel. The camshaft (shaft) cannot be turned after that. |
| 39. Unscrew the case pallet. |
| 40. Remove the oil pump. |
| 41. If it is necessary, remove only a bent shaft, it is possible to leave pistons and rods in the block of cylinders. Otherwise it is necessary remove pistons and rods. If pistons and rods remain in the block, it is necessary to mark in the order of a cover of conrod bearings, remove them and you store together with inserts of bearings. Not to forget that the damaged rastyazhny bolts should be replaced surely. |
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42. Install the arrow measuring instrument (indicator) on a support to the forward party of the block of cylinders or fix it by means of magnetic fastening on the block of cylinders, having put the measuring probe to a bent shaft. By means of the screw-driver press a bent shaft in one party, install the arrow measuring instrument on zero and press a shaft in other party. The arrow measuring instrument will show an axial gap of a bent shaft and this size should be written down. If it exceeds 0.25 mm, it has to be considered at assembly. Inserts of average bearings are supplied with the adjusting half rings defining an axial gap. |
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43. If the arrow measuring instrument is unavailable, the gap can be measured on the average bearing between a flange of the bearing and a surface of a bent shaft by means of the measuring probe of lezviyny type. For check by the measuring probe (thickness no more than 0.25 mm), it is necessary to wring out a shaft in one party. |
| 44. Turn off bolts of fastening of a sealing flange on the forward party of the engine and remove a flange with laying. |
| 45. Remove an intermediate plate of the engine, turn off bolts of a flange of an epiploon and remove a flange with an epiploon. The intermediate plate goes by means of the directing plugs. |
| 46. Weaken gradually cross-wise bolts of covers of bearings of a bent shaft and remove them one after another. Check that numbers of covers were well visible. The cover No. 1 is located from a pulley. |
| 47. Remove inserts of bearings and radical necks and you store them together with the corresponding covers of bearings. It must be kept in mind that one inserts are supplied with lubricant flutes, and others – are not present. |
| 48. To carefully take a bent shaft from an engine case. |
| 49. Take out the remained inserts from a case of the engine and you store them together with other inserts and covers of bearings. These inserts are supplied with lubricant channels and at assembly have to be established in an engine case again. |
| 50. Remove the lower half rings on the average bearing. They should be marked on lateral face. |