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Build Engine
You will need: a torque wrench, hammer (preferably with a striker of soft metal or polyurethane), a device for the pistons in the cylinders, the same keys as for the dismantling of the engine, screwdriver, blade assembly. 1. Insert the piston into the connecting rod, piston pin lubricate engine oil and press-fit it into the rod on the same device on which a finger is extruded, or with a hammer, and a suitable mandrel is inserted into the inner hole of the finger. The piston must be pressed boss to the top head of a rod in the direction of pressing a finger, allowing him to take the correct position.
NOTE The finger is inserted into the upper head of a rod with an interference fit, so to facilitate assembly and maintain its landing heat the rods, placing them on the top head 15 minutes in a preheated 240 ?� C furnace. The temperature of the heating rod can be controlled using thermochromic pencil. For proper connection with a rod finger press in the finger as quickly as possible, because after cooling finger position can not be changed. |
| Fig. 5.12. The order of the piston rings on the piston: 1 - connecting rod; 2 - piston; 3 - the lower ring of the composite oil ring; 4 - expander oil ring; 5 - the top ring of the composite oil ring; 6 - lower compression ring; 7 - the top compression ring; 8 - label |
2. Place the piston ring in the reverse order, placing them as shown in Fig. 5.12.
A WARNING When you install the expandable ring is not more than necessary, so as not to deform or break them. |
NOTES Lower compression ring install recessed down (arrow) in the second groove. Marking ?�Y?� in the compression rings must be directed upwards. |
| Fig. 5.13. Location piston rings before installing the piston into the cylinder: 1 - expander oil ring and the top compression ring; 2 - the upper ring of the composite oil ring; 3 - lower compression ring; 4 - lower ring of the composite oil ring |
3. Align the ring, as shown in Fig. 5.13. Set the rings to the other pistons.
NOTE Locks the upper and lower rings of composite oil ring should be located at a distance of 25-30 mm, respectively, left and right of the lock extender. |
4. Lay in bed cylinder upper main bearing shells.
NOTES The average bed (third) main bearing lay the liner thickness increased with support ribs. Refills are set so that the installation mustache liner aligned with the notch on the bed. |
5. Grease liners engine oil. 6. Set the crankshaft in the engine block. 7. Place in the main bearing caps lower liners, aligning the antennae inserts with recesses on the lid.
NOTE The upper and lower main bearing shells may vary by location hole for supplying oil. Refills are set so that the holes align with channels for supplying fuel to the main bearing supports beds. After installing the liner in the socket of their ends protrude slightly, so for the proper orientation of the inserts in the final tightening bolt bearing caps, make sure that both ends of the protrusion was the same. |
8. Apply engine oil to the crankshaft main journals. 9. Apply engine oil loose leaves in covers of radical bearings of the crankshaft. 10. Install the crankshaft bearing caps according to serial numbers, oriented to the markings.
A WARNING To install the bearing caps of the crankshaft, use a hammer with soft brisk, made of brass, lead or polyurethane. Set cap tightening fasteners smoking, as in this case will be damaged sealing surfaces and the cylinder covers. |
11. Install the cap bolts evenly tighten the bolts to the full, without tightening completely, turn to one turn and tighten to 50 N ?� m (5.0 kgf ?� m) and tighten a further 40-60 ?�.
A WARNING Bolts main bearing caps be sure to replace with new ones. |
12. Check the assembly, having turned the crankshaft by hand a few turns. The shaft must rotate freely. 13. Install the inserts into the rod with antenna installation of the liner with a notch on the connecting rod. 14. Apply engine oil to the mirror, pistons, piston rings and connecting rod bearings. | | 15. Install the piston device for compression rings and, turning the screw, squeeze the ring. | 16. Rotate the crankshaft so that the crank pin, which is mounted on the connecting rod and piston group, established in TDC. Set the piston in the cylinder in accordance with the marking cylinder number on the connecting rod, press (for example, the hammer handle) on the piston and push it into the cylinder from the mandrel. Similarly, set the pistons in the other cylinders. |
NOTE When installing the pistons in the cylinders mark (triangle) on the piston must be towards the front of the engine. |
A WARNING Place the piston in the cylinder being careful not to damage the bottom head of a rod crank pin of the crankshaft. |
17. Install connecting rod bearings into the connecting rod cap, aligning the antenna installation of the liner with a notch on the cover. 18. Coat the connecting rod bearings with engine oil to covers of rods and crank pins. 19. Establish a cover of a rod, connecting rod to the crankshaft and align the mark on the connecting rod and cap. 20. Replace the connecting rod bolts, without tightening them completely. 21. Tighten the connecting rod bolts to the full, without tightening them completely; then unscrew them by one turn and tighten to 25 N ?� m (2.5 kgf ?� m) and tighten by 30 ?�, and then a further 15 ?�. 22. Check the ease of movement of the connecting rod along the crank pin. When scuffing unscrew the connecting rod bolts and re-tighten them to the specified torque. 23. Check the connecting rod side clearance, it should be 0,070-0,242 mm. The increased gap indicates excessive wear of the cheeks of cranks of the crankshaft. In this case, replace the crankshaft. 24. Similarly, secure the lid other rods. | | 25. Check the axial clearance of the crankshaft, it should be 0.07-0.1 mm. The increased gap indicates wear of crankshaft bearing flanges or bed medium main bearing. In this case, replace the crankshaft. If this does not lead to a reduction in the axial clearance need to replace the cylinder block. | |
30. Next, assemble the engine in reverse order. Installation of cylinder head is described in the section "Replacing the cylinder head gasket", the water pump - in the section "Replacing the water pump", the timing belt - in the "Replacement and adjustment of a tension the timing belt and replace it with the tension wheel."
HELPFUL ADVICE After assembling the engine it is recommended to run-in at the booth. As is specialized repair organizations make it possible, after the installation of the engine on his car run-simplified cycle in the following order. 1. Make sure to adjust the throttle, fill with oil and coolant, check the tightness of all connections. 2. Start the engine and let it run without load on the next cycle. Do not allow the engine to maximum capacity. 3. During operation, check the tightness of the engine and its systems, oil pressure, note the presence of background noise. 4. If there are any extraneous noise or other malfunction, stop the engine and remove the cause. 5. The start of operation of the vehicle, observe the modes provided for the break-in period of the new car. |
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