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Service connecting rod and piston assembly and the cylinder bores
 | To perform the procedures described below require the following special equipment: countersink to remove the stepped cylinder wear; micrometer and telescopic bore gauge (to check the condition of the cylinder); khon (to restore cylinder bores) and tools for the expansion and contraction of the piston rings (for mounting and installing connecting rod and piston assemblies). |
Removing the connecting rod and piston assembly | In principle, the removal of connecting rod and piston assembly can be done without removing the engine from the car, but when you take into account the difficulties involved in removing the sump and the work under the vehicle, such an approach does not seem appropriate. The drafters of the Guidelines recommend doing the work on the engine is removed from the car. |
Components connecting rod and piston assembly  | |
| - Remove the engine from the car.
- Mount the motor on the mounting stand or a sturdy workbench and remove the cylinder head, oil pan and oil pump maslozabornik.
- Make available identification labels on the bottom heads of rods and connecting rod bearing caps of the crankshaft. Try to remember how to install assemblies.
- With the probe blade type Check the axial clearance of rods. If you exceed the allowable backlash (see. Table sizes and adjustments in the end of this manual), replace worn rod.
- Citing the first cylinder to the bottom of its stroke, give the nuts cover the bottom head of a rod (rod bearing). Remove the cover.
- Clean the bearings in the cover and the open part of the crank pin shaft clean lint-free cloth, then lay along the cervical segment of the calibrated plastic wire measuring set Plastigage. Put the cap on the connecting rod and tighten nuts of its fastening with demanded effort.
- Remove the nut, remove the lid and measuring scale on the packaging of the set width of the flattened plastic thread, determine the amount of connecting rod bearing clearance. Compare result of measurement with the regulatory requirements (see. Table sizes and adjustments in the end of the Guidelines), in excess of the allowable limit, replace the bearing assembly.
- Repeat for the remaining rods. Note the value of each of the bearing clearance.
- Alternately, remove the covers of the bottom heads of rods and then push out the wooden handle of a hammer assembly of the cylinder through the top, and then immediately install the rods their covers with embedded inserts. If necessary, before embarking on a recovery connecting rod and piston assembly should be using the special countersink to remove the step wear at the top of the cylinder.
| To protect the crankshaft journals and the cylinder bores from damage during the extraction process connecting rod and piston assembly put on the bearing cap bolts lengths of plastic tubing. |
- Remove the pistons (over the top), piston rings and discard them.
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Checking the pistons | - Inspect the pistons for signs of response, scratching, scuffing and burnouts.
- Remove all traces of carbon deposits from the bottom of the piston and of the annular groove.
- Please rate the degree of deterioration of piston ring grooves. To this end, taking the new Measure, check the magnitude of backlash in the respective grooves of each of the pistons. Compare result of measurement with the regulatory requirements (see. Table sizes and adjustments in the end of this manual).
- Inspect the connecting rod bearing shells all pistons at identifying signs of wear. If you find elaboration outer edges of the inserts should check the appropriate rod to bend.
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| As for the straightening rods special equipment is required, the drafters of this Guide recommends this test and refurbishment of producing in the studio Car. |
Checking the status of the block and cylinder bores | - Check the mirror cylinders for cracks, burrs, scratches and operation.
- Using a special callipers complete with a micrometer, measure the diameter of the cylinder in order to assess their degree of wear and detection of roundness and taper. Measurements are made in both directions (up and down the block) and at three levels of height of the cylinder - at the upper end of the stroke, the middle and the bottom. The difference between the distances A and B, as measured by the upper and lower borders of the stroke determines the roundness of the cylinder, the difference between the measurements and the upper and lower planes of the working area of the cylinder determines the taper.
- From the results of the six dimensions of each of the cylinders, select the maximum and minimum readings. The difference between these readings can be considered as a criterion the degree of wear of the cylinder.
- If deterioration of any of the cylinders exceeds the limit (see. Table sizes and adjustments in the end of the Guidelines) should be pierced all cylinders to a standard repair size (in excess) and their subsequent honing.
| Selecting the size of the maintenance of specified standard is determined by the size of the most heavily worn cylinder. |
- Using the meter and probe the flatness of the blade type, check the flatness of the upper mating surface of the block (Proceed as for checking the flatness of the cylinder head). If the flatness unit exceeds the limit (see. Table sizes and adjustments in the end of the Guidelines), a groove block.
- Thoroughly flush the unit with a suitable solvent and dry it with compressed air, paying particular attention to flushing maslotokov and inaccessible cavities.
- Inspect the unit for cracks and other mechanical damages.
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Honing of cylinder bores | Mirror cylinder suitable for use in a kit with the old pistons, but requiring replacement of piston rings to be honed. |
| - For removal of polishing cylinder bores use Hon surface with 280-grit grinding stones.
- Slide rotating nozzle hone up and down in the cylinder at a rate to achieve a mesh pattern cuts with an angle of intersection of 60 ?� scratches. Such processing ensures optimal conditions for the running of the piston rings.
 | It should not be removed from the cylinder bore more material than is necessary for the removal of polishing, since otherwise there will prohibitive cylinder diameter and hence the piston gap. |
- During the processing nozzle and lubricate the cylinder wall special honingovochnym oil.
| Using the transmission or motor oils as well as mineral spirits and kerosene for this purpose is unacceptable! |
- At the end of honing cylinders carefully wipe the mirror, completely removing all traces of them from the abrasive.
- After washing and drying the block once again wipe the mirror clean lint-free cloth cylinders, then lubricate motor oil to prevent the development of corrosion.
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Check piston clearance | - With high-quality bore gauge and micrometer to measure the diameters as described above all cylinders.
- Measure the diameter of the piston at a distance of 47 mm from the bottom of the piston.
- Deducted from the corresponding cylinder bore diameter of the piston, the piston define a gap. If the calculation results exceed the permissible values (see. Table sizes and adjustments in the end of this manual), at its discretion, replace or pierce the piston and cylinder othoninguyte.
- When the cylinder bore size to standard maintenance and honing, they must repeat the procedure for determining the piston clearance.
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| If the piston, piston pin and connecting rod must be replaced, it should be done in a workshop service centers, as for extraction / installation of the piston pin must be properly warmed up to a temperature of 70 ?� C, or need to use a hydraulic press. To remove the upper plugs of heads of rods requires a special tool holder. |
Replace piston rings | - Pick up a set of new piston rings corresponding to your standard size cylinders of the engine of your car (or standard or oversize).
- Alternately refuel each ring bottom inverted piston in the least worn part of the cylinder to measure the gaps in their castles. Using the piston rings for refilling the cylinder allows for perpendicular arrangement of the ring.
- After removing the piston measure a backlash in the ring lock using a probe-type blade.
| After measuring the gap in the lock ring must be used to complete this particular cylinder piston. |
- In accordance with the accompanying illustrations, which shows the cross section of piston rings, wear new rings to the corresponding pistons. Use a piston ring expander. Compression rings should be installed stamped marks a liter upwards (towards the bottom of the piston).
- Scraper rings are arranged so that the locks expander sections and not oppose each other.
- Expand the piston rings on the lock as shown in the figure, where: A = the upper compression ring, B = lower compression ring, C = expander oil ring, D = upper section of the oil scraper ring, E = the lower section of the oil scraper ring.
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Installing the connecting rod and piston assembly | - Lubricate the piston assembly and the cylinder wall of the first clean motor oil.
- Having turned the crankshaft, are the first crank pin of the crankshaft position BDC. Wipe the cervix with a clean cloth, then lubricate it with clean motor oil.
- Uncover the lower connecting rod bearing shells and wipe, or replace them as needed. Grease the mold is clean motor oil.
- Put on the cover bolts pieces of plastic tube to protect the walls of the cylinder and the shaft journal.
 | - Compress piston rings with special tool, then fill the crank assembly in the first cylinder, tapping the handle of a hammer in the bottom of the piston and at the same time directing the head of the connecting rod on a neck of the connecting rod bearing of the crankshaft.
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| The piston should be got into the cylinder front label at the bottom (see. Accompanying illustration - figures on the cylinders and characterize the dimensional parameters (standard or reconstruction)) forward on the engine, the mandrel tool to compress the piston rings must be tightly pressed against the unit around the perimeter at all times installing the crank assembly. |
- Remove the cover bolts to the bottom head of a rod protective plastic tube.
- Put on the head of the connecting rod bearing cap, watching combining inflicted during dismantling landing labels. Tighten fixing:
- In the first stage, tighten the nut with a force of 14 ÷ 16 Nm;
- Then tighten the nut with a force of 38 ÷ 44 Nm, or (preferably) on the protractor another (60 ?� ÷ 65 ?�).
- Operating in a similar manner, the connecting rod-piston assembly in the remaining (corresponding) cylinders.
- The further installation is made in the reverse order of removal.
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