Engine repair

Cylinder block

Dismantling

Remove toothed timing belt, cylinder head assemblies, drive plate, oil pan, the oil pump, pistons and crankshaft.

The cylinder block is shown in Fig. 2.81.

Check

Visually inspect the engine block for scratches and corrosion, as well as cracks and other defects. If necessary, replace or repair the engine block.

Special device to measure the diameter of the cylinder in three levels in mutually perpendicular directions A and B (Fig. 2.82):

- At the location of the compression ring during installation ?��1 piston at TDC;

- In the middle of the cylinder;

- At the bottom of the cylinder.

If the diameter of the cylinder exceed the required size or smaller than a cylinder walls are worn out or have a teaser, the cylinder block must be chiseled and othoningovat. You then need to install new pistons and rings oversized.

The cylinder diameter - 86.7 mm.

Maximum allowable ovality and taper of cylinder - 0.02 mm.

If the top of the cylinder formed collar, you must remove it or scan scraper without damaging the cylinder bore.

Pistons manufactured oversize with an increase of 0.25 and 0.5 mm in diameter.

When boring cylinders keep the specified clearance between the piston and the cylinder size of repair, as well as make sure that the pistons of the repair of the same size.

Measure the outside diameter of each piston at an angle of 90 ?� to the piston pin 12 mm from the piston skirt (see. Fig. 2.54).

The clearance between the piston and the cylinder - 0.01-0.03 mm.

Check the cylinders for damage or cracks.

Check metal ruler and probe in several directions the flatness of the upper surface of the cylinder. If the flatness exceeds the allowable size, pereshlifuyte or replace the cylinder block (Fig. 2.83).

Flatness - 0.03-0.05 mm.

Cylinder bore

Piston oversize should be determined based on the largest diameter of the cylinder bore.

Identification mark "0.25", "0.50" corresponds to an increase in the size of 0.25 and 0.50 mm.

Measure the outer diameter of the piston is used.

On the basis of this size determine the size of the bore.

The size of the bore diameter of the piston + = 0.01-0.03 mm (the clearance between the piston and the cylinder) -0.01 mm (honing field).

Ream each of the cylinders to the calculated size.

Honing cylinders until the required calculation diameter (outer diameter of the piston + gap).

Check the clearance between the piston and the cylinder. Nominal backlash is 0.01-0.03 mm.

Assembly

Set the items in the following order:

- crankshaft;

- The drive plate;

- piston;

- Cylinder head;

- toothed belt;

- The oil pump housing.

The pistons and connecting rods

Withdrawal

Removal and installation of pistons and rods is carried out after removing the cylinder head and sump.

Rotate the crankshaft and install the piston of the first cylinder in position BDC.

If the top of the cylinder formed shoulder, then it must be removed carefully scan or scraper, without damaging the cylinder bore.

Remove the connecting rod cap nuts of the first cylinder.

Remove the cover and remove the lower connecting rod bearing pad (Fig. 2.84). Mark the parts removed.

Hammer handle push the piston to the top of the cylinder and out of the cylinder. Remove the upper connecting rod bearing liner.

Repeat the operation, remove the connecting rods with the pistons of the other cylinders.

Before checking piston rods to remove the pistons, piston rings and thoroughly clean the pistons.

To remove the piston rings from pistons unclench a ring insert under it evenly around the circumference of two or three old blade and probe them slide ring piston. Be careful not to scratch the piston ring ends. Rings are very fragile and can crack if decompress them very much. Handle carefully with a sharp leading edge of the piston rings, so as not to cause injury. Keep each set of rings together with the piston to re-install them to their seats.

Remove all traces of soot from the top of the piston.

Remove the carbon deposits from the piston ring grooves for using an old piston ring.

For disassembly and assembly of the piston and connecting rod, use the special tool 09234-33001 (see. Fig. 2.57).

The piston pin is pressed into the top head of a rod, piston floats on his finger.

The tool consists of a fixing support with universal plug, the guide piston pin adapters, the installation of the rod and a stripper. The piston is retained fixing support during installation or removal of the piston pin. The guide piston pin helps to position the finger during removal or installation, while the connecting rod is held inserts.

To remove the piston pin from the piston, the piston is set in the fixing support so that the rod lying on the boxes (see. Fig. 2.58). Thread the puller through the top of the fixing support and use it to drive out of your finger.

Check

Check each piston for scratches, wear and cracks around the skirt and the piston pin hole. Check wear on the piston skirt, the openings in the piston head, and the presence of burnout in the upper part of the piston. If there are any defects, replace the piston.

Check each piston ring for breakage, damage and wear. If there are any defects, replace the piston rings. If you need to replace the piston, piston rings and replace.

Check the fit of the piston pin in the hole of the piston. Replace any piston and finger defects. The piston pin is necessary to gradually hand drive in the hole in the piston at room temperature.

Feeler gauge, measure the side clearance between the piston ring and the piston groove wall. If it exceeds the allowable, insert a new piston ring in the groove of the piston and re-measure the backlash. If the clearance still exceeds the limit, replace the piston with the piston rings. If the measured clearance less admissible, replace piston rings only.

The nominal gap between the compression ring ?��1 and the piston wall groove - 0.04-0.08 mm between the ring and the wall of the groove ?��2 - 0,03-0,07 mm

Maximum permissible backlash between the two compression ring grooves of the piston and the wall - 0.1 mm.

Check clearances piston ring. Insert the ring in the corresponding cylinder and push the piston crown at a shallow depth, to eliminate bias in the measurement of the ring, then remove the piston. Measure the clearance probe. If the clearance is excessive, replace the piston rings and repeat the procedure.

Nominal backlash in the lock of a piston ring, mm:

compression ring ?��1 ..... 0,20-0,35

compression ring ?��2 ..... 0,37-0,52

extender oil ring ..... 0.2-0.7

Maximum permissible backlash in the lock of a piston ring, mm:

compression ring ?��1 and ?��2 ..... 0,8

extender oil ring ..... 1.0

When replacing the piston ring without adjusting the internal diameter of the cylinder, check the clearance with the ring mounted in the bottom of the cylinder, which is less worn.

On the connecting rod and the connecting rod cap is marked with the number of the cylinder, which must be located on one side. When refitting make sure that the number of cylinders supported on a rod and a cover during disassembly, correspond to the number of the cylinder. If a new rod, make sure that the recesses for fixing the bearing located on one side (see. Fig. 2.59).

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Setting

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A stripper piston rings set compression ring ?��1.

Place the piston rings on the piston so that each piston ring castle located at a maximum distance from the castle of the neighboring ring (see. Fig. 2.64). Ensure that locks the rings are not in planes parallel to and perpendicular to the piston pin axis.

Before installing the piston into the cylinder, piston rings it is necessary to tighten the belt tensioning clamp.

Install the upper main bearing shells in the crankcase.

Install the lower main bearing shells in main bearing caps.

Establish persistent half rings on both sides of main bearing shells ?��3 lubrication grooves located outside (Fig. 2.85).

Install the piston with the piston rings over the first cylinder, making sure that the front mark of the piston and connecting rod identification mark directed toward the front of the engine.

After installing the connecting rod cap, make sure that the numbers are applied to the connecting rod and cap during disassembly, correspond to the number of the cylinder.

If a new rod, make sure that the recesses for the bearing are located on one side (see. Fig. 2.59).

Before screwing bolts of covers of rods of oil the thread and the base of the head.

Tighten bolts of covers of rods in two stages: 16-25 Nm + to tighten on a corner 90-94 ?�.

Probe check connecting rod side clearance.

Nominal backlash - 0.10-0.25 mm, the maximum allowable - 0.4 mm.

The crankshaft and flywheel

Withdrawal

Remove toothed timing belt, the front cover with oil pump, flywheel, cylinder head assembly and the sump. For more information, refer to the relevant subsections.

Remove the back plate and the crankshaft rear oil seal.

Remove the nuts connecting rod covers, remove the cover and remove the lower connecting rod bearing shells.

Remove the bolts, remove the crankshaft bearing caps and crankshaft (Fig. 2.86). Keep main bearing shells with covers removed.

Check

Check the crankshaft journals for damage and uneven wear and cracks. Also check the purity of the holes for lubrication. In the presence of defects replace the crankshaft.

Check roundness and taper of the crankshaft journals.

The diameter of the main journals of the crankshaft - 61,982-62,000 mm crankpins - 47,982- 48,000 mm.

Visually inspect all bearing shells for the presence of delaminations, melting, jamming and incomplete contact. Replace defective bearing shells.

Measure the oil clearance main and connecting rod bearings of the crankshaft. To determine the oil clearance measure diameters of the crankshaft journals and the inner diameters of the bearings. The gap is defined as the difference between the outer and inner diameters.

Nominal backlash of radical bearings - 0,004-0,022 mm, connecting rod bearings - 0,018-0,036 mm.

Maximum permissible backlash connecting rod bearings - 0.1 mm.

Most accurately measure bearing clearance using a plastic rod calibrated as follows:

- Remove oil and dirt from the bearings and crankshaft journals;

- Set the main bearing shells in the engine block;

- Cut the plastic strip calibrated rod, equal to the length of the crankshaft journals;

- Place the plastic strip calibrated rod in the neck along the axis of the crankshaft is oil hole (Fig. 2.87);

- Install the crankshaft main bearing shells in the cylinder block;

- Set the main bearing shells in main bearing caps of the crankshaft;

- Set the cover with the main bearing shells on the crankshaft and tighten bolts of their fastening torque without cranking the engine;

- Remove the bolts and remove the crankshaft bearing caps;

- A ruler printed on the package, measure the width of the deformed plastic core in the widest place (see. Fig. 2.66);

- If the gap exceeds the permissible, replace main bearing shells;

- If the nominal clearance is not correct, even after replacing the main bearing shells, pereshlifuyte crankshaft to the recommended size reduction and install bearings of the same size.

Check the front and rear crankshaft seals for damage or wear and tear of working edges, if necessary, replace them.

Setting

Install main bearing shells with grooves on the engine block.

Install main bearing shells without grooves from the bearing caps.

Grease the crankshaft journals with engine oil and install the crankshaft to the cylinder block.

Install the crankshaft bearing caps so that the arrow is pointing toward the front of the engine. Secure the cover bolts, having tightened their demanded moment:

- M 7 - 10-12 Nm;

- M 10 - 14-16 Nm.

Tighten the bolts to the required torque in 4-5 receptions.

Make sure that the crankshaft rotates smoothly and it corresponds to the nominal axial clearance.

Nominal axial clearance of the crankshaft - 0,07-0,25 mm, the maximum allowable - 0.4 mm.

The mandrel (09231-33000), set into the body of the crankshaft rear oil seal.

Apply sealant to the mating surface of the housing crankshaft rear oil seal at locations shown in Fig. 2.88.

Replace the back plate to cylinder block and tighten the bolts to 10-12 Nm.

On vehicles with automatic gearbox, attach the adapter plate to the cylinder block.

Install the drive plate and tighten bolts of its fastening torque 73-77 Nm.

On vehicles with a manual transmission, set the flywheel and tighten it to a torque 73-77 Nm.