Cylinder block

Remove the cylinder head, timing belt, front cover, flywheel, pistons and crankshaft.

1. Inspect the engine block for rust, corrosion, cracks or any other defects.
2. Measure the diameter of the cylinders in opposite directions, in three elevations cylinders:

• Level 1 - The location of the compression ring ?��1 when installing the piston at top dead center;
• Level 2 - in the middle of the cylinder;
• Level 3 - at the bottom of the cylinder.

3. If the cylinder diameter exceeds the limit, have a round or tapered surface of the cylinder or damaged or production, it is necessary to bore the cylinder block and install new pistons and piston rings of the repair sizes. The nominal diameter of the cylinder: 85,00-85,03 mm The maximum allowable ovality and taper of cylinder: no more than 0.01 mm

4. If the top of the cylinder has a step, cut it with a special tool.
5. As the parts are supplied pistons increased four sizes: 0.25, 0.5, 0.75 and 1.00 mm.
6. When the cylinder bore to the nearest oversized soak clearance between the piston and the cylinder and make sure that the pistons are of the same size increased.

Measure the outer diameter of each piston at 90 ?� to the piston pin, at a distance of 2 mm from the piston skirt.

The clearance between the piston and the cylinder: 0.02-0.04 mm

7. Inspect the cylinder block for damage and cracks.

8. The metal ruler and probe in six directions check the flatness of the mating surface of the cylinder. Deviation from flatness of 0.05 mm The height of the new cylinder: 284 mm The maximum deviation from flatness: 0.1 mm The allowable reduction in the height of the cylinder: 0.2 mm The mating surface for the installation of the cylinder after the rounding is to reduce the height of the cylinder is not more than 0.2 mm.

1. Pistons of the increased size to be used should be determined based on the largest diameter of the cylinder bore.

The marking is stamped on the bottom of the piston.

2. Measure the outside diameter of the piston.

3. On the basis of the measured size determine the size of the bore. The size of the bore diameter of the piston + = 0.02-0.04 mm
4. Ream each of the cylinders to the calculated size.

To eliminate the resizing of the temperature during honing manipulate cylinders in the following order: ?��2, ?��4, ?��1 and ?��3.

5. Honing cylinders until the required calculation diameter (outer diameter of the piston + gap).
6. Check the clearance between the piston and the cylinder.

When boring, bore all the cylinders to a larger size. Do not bore only one cylinder to a larger size.

Set the items in the following order:

1. Crankshaft
2. Flywheel
3. Piston
4. Cylinder Head
5. Toothed belt
6. Front Cover