2.22. Dismantling and assembly of the engine

We remove the engine from the car (see. "Removal of the engine") we also clear it of dirt and oil.

Cap key "on 13" we turn off two nuts, and a key "on 17" - one nut of fastening of the right arm of a forward support of the power unit and we remove it. On fixing hairpins of the right arm of a forward support we mount a plate of the dismantling stand and we fix the engine at the stand.

We take out the oil level probe index from the directing tube.

Cap key "on 10" we turn off a tube and we remove it.

Cap key "on 13" we turn off three nuts of hairpins of fastening of an arm of the left forward support of the power unit to the block of cylinders of the engine...

... also we remove an arm.

We remove the generator, a flywheel, a head of the block of cylinders, the pump of cooling liquid, the case pallet, the lower cover and a chain of the drive of the camshaft. Operations on dismantle of these knots are given in appropriate sections.

Key "on 13" we turn off two nuts of hairpins of fastening of a back arm of the generator to the block of cylinders...

... also we remove an arm.

Head "on "10" we turn off six bolts of fastening of a cover of a back epiploon of a bent shaft.

We uncover with an epiploon and sealing laying.

Key "on 10" we turn off two hairpins of fastening of an uspokoitel of a chain of the drive of the camshaft.

We remove from a sock of a bent shaft a maslootrazhatel.

We remove an oil receiver (see. "Removal of an oil receiver").

Head "on 15" we turn off two nuts of bolts of fastening of a cover of a rod (the piston at the same time has to be in NMT).

We uncover a rod with an insert.

We take out the lower insert of the conrod bearing from a cover.

Resting fingers of hands against bolts of fastening of a cover, we shift a rod up and we separate the lower head and a conrod neck of a bent shaft. Then, resting the wooden handle of the hammer against the socket of the lower head of a rod, we move a rod with the piston up a cylinder sleeve.

Pushing out the piston, do not damage a cylinder sleeve mirror conrod bolts and the lower head of a rod.

We take out the piston with a rod.

We take out the top insert of the conrod bearing from a rod head.

Similarly we take out pistons with rods from other cylinders of the engine.

We fix a rod in a vice with overlays of sponges from soft metal.

Carefully, without making big effort, unclenching fingers the lock of the top compression ring, we bring a ring out of a flute of the piston and we remove it.

In the same way we remove the second compression ring and disks of an oil scraper ring.

We remove a dilator of an oil scraper ring.

We hook a pricker and we take a lock ring of a piston finger from a ring flute in a piston lug.

In the same way we take out the second lock ring of a piston finger.

We heat the piston, having shipped it for 2-3 minutes in water with a temperature of 60-70 °C...

... and, holding a rod on weight, the hammer through a drift from soft metal we beat out a piston finger.

Two screw-drivers we hook a sleeve for the top fillet, leaning on the top privaloch-ny plane of the block of cylinders.

Not to damage strong pressing the privalochny plane of the block of cylinders, under screw-drivers it is possible to enclose wooden whetstones.

If the sleeve does not go out of the block of cylinders, it can be beaten out, striking blows with the hammer through a mandrel to its lower end face (it is more convenient to make it when the bent shaft is removed).

We take a sleeve from the block of cylinders.

Similarly we take out other sleeves.

If some details of tsilindro-piston group are not damaged and a little worn-out, then they can be used again. When dismantling these details should be marked to establish on former places. Before demontazhy a bent shaft we check its axial gap in the block of cylinders. For this purpose the assembly shovel moved a bent shaft in the axial direction to one party against the stop and measure the flat probe a gap between a cheek of a bent shaft and a persistent half ring. The maximum permissible size of a gap - 0,45 mm.

Head "on 19" we turn off two nuts of hairpins of fastening of a cover of the radical bearing of a bent shaft (on a photo fastening of a cover of the second bearing with an oil receiver arm is shown).

We remove an oil receiver arm...

... and a cover of the radical bearing with the lower insert.

We take out an insert from a cover.

Similarly we turn off nuts of hairpins of fastening and we uncover four more radical bearings.

We remove an average radical cover with persistent half rings.

We remove persistent half rings.

We take out a bent shaft from beds.

We take the top inserts of radical bearings from beds of the block of cylinders.

By stripper it is pressed from a sock of a bent shaft a gear wheel of the drive of the distributor of ignition and the oil pump.

The hammer through a drift from soft metal we beat out the segment spline fixing a gear wheel from a groove of a bent shaft.

We remove a spline and the expansion plug.

By stripper it is pressed from a sock of a bent shaft a camshaft drive chain asterisk...

... and also we take the fixing spline.

Carefully we wash out engine details in kerosene, we clear of a deposit and resinous deposits and we will turn their technical condition. Ring flutes and skirts of pistons, piston rings and fingers, mirrors of sleeves of cylinders, radical and conrod necks of a bent shaft should not have cracks, zadir, deep рисок, chips and prizhog. The damaged details are subject to obligatory replacement. We determine wear of the details which do not have obvious defects by measurements. We measure the piston (the largest diameter of a skirt) by a micrometer with the price of division of 0,01 mm in the plane, a perpendicular axis of a piston finger.

We measure the internal diameter of a sleeve of the cylinder by a nutromer with the price of division of 0,01 mm. We take measurements in four belts (at distance of 10, 50, 100 and 125 mm from its top end face) in two mutually perpendicular directions.

The assembly gap between the piston and a sleeve of the cylinder (a difference between the measured diameters of the cylinder and piston) has to make 0,05-0,07 mm. If the maximum value of a gap is more than 0,17 mm (the extreme size of wear), then we replace the piston with a sleeve.

The gap on height between a piston flute and a piston ring is checked, having inserted a ring into the corresponding flute and entering the flat probe between an end face of a ring and a surface of a flute. The extreme size of a gap makes: for the top compression ring - 0,13 mm; for the lower compression ring - 0,12 mm; for an oil scraper ring - 0,11 mm.

We measure a gap in the lock of a piston ring by the flat probe, having established a ring in that sleeve in which it worked, at distance of 20-30 mm from the lower end face of a sleeve. The extreme size of a gap for each of rings makes 1,20 mm.

We measure radical and conrod necks of a bent shaft by a micrometer. If wear or ovality of necks exceeds 0,03 mm, necks should be proshlifovat to the next repair size. After grinding of necks of a bent shaft it is necessary to wash out oil channels in conrod necks of a shaft for removal of the remains of an abrasive. For this purpose...

... an impact driver we turn off caps of oil channels.

We clean channels a wire, carefully we wash out kerosene and we blow compressed air. We establish caps and we fuller everyone a center punch in three-four places. We wash out and clear oil channels of the block of cylinders of the engine of a deposit, we delete the remains of old laying, and also sealant from seats of sleeves of cylinders and we blow the block compressed air.

We assemble the engine in the return sequence.

We establish new inserts of radical bearings of the nominal or repair sizes in a bed of the block of cylinders and we oil engine working surfaces of inserts. We establish the leading asterisk of the drive of the camshaft, a gear wheel of the drive of the distributor of ignition on a sock of a bent shaft and we stack a bent shaft in a bed of the block of cylinders.

Covers of radical bearings are processed with the block of cylinders of the engine at the same time and marked...

... in figures 1-5, considering from the camshaft drive.

Marking is applied on triangular inflow in the middle of the cover back, at the same time the top of a triangle indicates forward (the camshaft drive).

We establish covers of radical bearings with the inserts oiled engine. At the same time locks of the top and lower inserts have to be from one (left) party of the block of cylinders (looking on the car course).

We establish a cover of the average radical bearing with persistent half rings so that surfaces of half rings with an antifrictional covering (on these surfaces flutes for a lubricant supply are executed) were turned to cheeks of a bent shaft. Previously we oil half rings engine.

We tighten nuts of fastening of covers of radical bearings the ordered moment (see. "Appendix"). Sleeves of cylinders and pistons are issued five dimensional groups (respectively on internal and outer diameter); And, B, In, and D through 0,01 mm. On sleeves of cylinders the dimensional group is designated by a color strip: group A - green color, B - yellow, 8 - red, - blue and D - black. The dimensional group of the piston is specified beaten out) on its bottom. We select pistons to sleeves of cylinders so that each couple corresponded to one dimensional group. Pistons sort by weight on four groups which marking (1, 2, 3 and 4) is applied on the piston bottom. All pistons installed on the engine have to be one weight group.

We install sleeves of cylinders in the block, carefully we tap their top end faces the hammer through a wooden pro-rate for more dense landing. We check the size of a vystupaniye of the top end faces of sleeves over the surface of the block of cylinders. For this purpose we establish a lekalny ruler in turn on the top end face of each sleeve and the flat probe we check a gap between a ruler and the privalochny plane of the block of cylinders. The gap size (a sleeve vystupaniye) has to be in limits of 0,01-0,08 mm. After check we mark an arrangement of sleeves in the block and we take out sleeves from the block of cylinders.

Piston fingers, pistons and rods (under a piston finger) are sorted by the sizes of their openings on four dimensional groups differing on diameter on 0,0025 mm. Each group is marked in color: red, white, green or yellow. Color marking is applied on one of piston lugs, the internal surface of a piston finger and on a rod body near the top head. For installation on the engine we select details of one dimensional group. Correctly picked up piston finger oiled engine in vertical position should not drop out of the top head of a rod, and the rod has to turn freely concerning a finger.

Before assembly of a rod with the piston we heat the piston in water with a temperature of 60-70 °C. We focus the piston so that...

... the arrow which is beaten out on the piston bottom...

... and a ledge on a rod were turned into one party.

We implant the piston finger oiled engine into openings of lugs of the piston and the top head of a rod and we establish lock rings in pro-points of lugs of the piston.

We install piston rings on the piston. At the same time...

... the pro-point ("scraper") of the lower compression ring has to be turned down...

... and the facet on an internal surface of the top compression ring has to settle down from above.

We have piston rings on the piston so that locks of rings were at an angle 120 ° on a circle relatively each other.

We establish new top inserts of conrod bearings of the nominal or repair sizes in the lower heads of rods and we oil inserts engine. We grease also mirrors of sleeves of cylinders, pistons and piston rings. We apply sealant on seats of sleeves of cylinders and we install sleeves in the block of cylinders - everyone on the place. We press out piston rings on the piston an adjustable mandrel and it is careful not to scratch a cylinder mirror, we enter the lower head of a rod and a skirt of the piston into a sleeve. The piston in a sleeve we have so that the arrow was directed to its bottom forward (towards the camshaft drive). Resting the hammer handle against the piston bottom, we push the piston through a mandrel in depth of a sleeve of the cylinder until the lower head of a rod (with an insert of the conrod bearing) is established on the corresponding conrod neck of a bent shaft. At the same time the conrod neck of a shaft has to be in NMT.

It is also possible to insert pistons with rods into sleeves of cylinders before installation of sleeves in the block of cylinders. At the same time the piston with rings is entered into a sleeve from its lower adjusting corbel. Then the sleeve with the piston and a rod is established in the block of cylinders.

We insert into covers of rods and we oil engine the lower inserts of conrod bearings. We establish covers with inserts on bolts of the corresponding rods.

On side surfaces of a rod and a cover tags which have to coincide and settle down on the one hand are put.

We tighten nuts of fastening of a cover of each rod evenly ordered moment (see. "Appendix").

After installation of a sleeve with the piston in the block of cylinders at turn of a bent shaft the sleeve can leave the seat due to friction of piston rings about a sleeve mirror. That it did not occur, it is necessary to fix sleeves by levels holders, having established them on hairpins of fastening of a head of the block of cylinders, as shown in fig. 4.

We carry out further assembly of the engine in the sequence, the return dismantling, replacing new sealing laying and epiploons.

Fig. 4. Fixing of sleeves in the block of cylinders of the engine the fixing levels