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4.5.7. Dismantling and assembly of the block of cylinders, service of components

Dismantle and installation of a bent shaft and conrod and piston assemblies can be made without removal of the engine from the car.

Dismantling

Design of the block of cylinders

1 — the Cover of the lower head of a rod
2 — Inserts of the conrod bearing
3 — the Rod with the piston
4 — Piston rings
5 — the Lock ring
6 — the Piston finger

7 — Covers of radical bearings
8 — the Bent shaft
9 — Inserts of radical bearings and persistent half rings
10 — the Directing bearing
11 — Masloraspylitel
12 — Casting of the block


 PERFORMANCE ORDER

  1. Remove the engine (see the Section Removal and installation of the engine).
  2. Remove a head of cylinders (see the Section Service of a Head of Cylinders and Components of the Gas-distributing Mechanism).
  3. Remove the oil pump (see the Section Removal and installation of the pallet of a case).
  4. Remove the pallet of a case and a flywheel / a driving disk (see the Sections Dismantling and assembly of the block of cylinders, service of components and Removal and installation of the oil cooler).
  5. Remove a back epiploon with a cover (see the Section Removal and installation of masloraspylitel).
  6. Turn out fixing bolts and uncover radical bearings with collecting with inserts.
  7. Turn out fixing bolts and uncover the lower head of the first rod assembled with an insert. Rest the handle of the hammer against a rod head and, pushing conrod and piston assembly up, take it from the cylinder.
  8. Working in a similar manner, take the remained assemblies.
  9. For the purpose of prevention of confusion when checking a condition of components at once establish on the former places covers of conrod and radical bearings of a bent shaft assembled with inserts and record them fixing bolts.
  1. By means of an inertial stripper dismantle the directing bearing installed in a back pin of a bent shaft.

Service

 PERFORMANCE ORDER

  1. Attentively study a condition of casting of the block. Check each cylinder for existence of cracks, zadir and other mechanical damages.
  1. Working in the manner similar described in the Section Service of a Head of Cylinders and Components of the Gas-distributing Mechanism, estimate extent of violation of planeness of the surface of the block interfaced to a head of cylinders. In case of need replace the block.

Restoration of planeness of the interfaced surface of the block by its machining is not admissible at all!

  1. Teases of mirrors cylinders can be pierced to the corresponding repair size in case such processing is not represented possible, replace the block.
  1. Measure diameter of each of cylinders at three levels and two directions that will allow to reveal such defects as conicity and ovality. Write down results. Minimum determine by way of subtraction from the maximum result degree of wear of the cylinder and if it exceeds extreme admissible value (see Specifications of the Head Dvigatel), cylinders should be chiseled to the next repair size. In conclusion of a mirror of cylinders there have to be otkhoningovana, - act according to the instructions attached to special honingovochny sets.
  1. Remove with a special vertical drill the step wear of cylinders left by the top compression ring at the end of the course of pistons.
  2. Remove lock rings, take piston fingers and make dismantle of pistons from rods.
  3. Study a condition of pistons, in case of identification of cracks, zadir and other mechanical damages prepare replacement.
  4. Measure diameter of each piston in the direction, perpendicular axes of a piston finger, and on removal in 19 mm from the lower cut of a skirt. By comparison of result of measurement with the size of diameter of the corresponding cylinder determine the size of a landing side play. If the side play exceeds extreme admissible value, replace the piston, having pierced the cylinder to the next repair size.
1 — the Control size

Along with the piston it is necessary to replace also piston rings (on corresponding the repair size, - see Specifications of the Head Dvigatel).

  1. Check piston rings for existence of signs of excessive wear, cracks, chips and other mechanical damages. In case of need make replacement.
  1. Serially filling piston rings in the cylinder and pushing them the piston bottom in the lower part of the last (the provision of NMT of the piston), measure sizes of gaps in locks of rings. Compare results of measurements to requirements of Specifications of the Head Dvigatel, in case of need chisel locks, or replace rings.
  1. Measure the size of a side play of landing of rings in flutes of pistons, in case of need replace the ring/piston.
1 — the Top compression ring
2 — the Second compression and oil scraper rings

Measurement should be performed in several points of perimeter of a flute. From this point rings have to remain "tied" to the pistons / cylinders.


  1. At the special stand believe rods on existence of signs of a bend and twisting. At excess by results of measurements of extreme admissible values replace defective components.
  1. By measurement of the corresponding diameters of piston fingers and plugs of the top heads of rods define side plays of landing of fingers in plugs. At excess by results of calculations of extreme admissible value make replacement of worn-out plugs.
  2. Squeezing of the plug is made by means of a mandrel with a diameter of 27 ÷ of 27.5 mm.
  3. Before a press fitting grease the new plug and a rod with pure motive oil. Track correctness of combination of lubricant openings. After a press fitting develop the plug development to nominal rate of internal diameter.
Zapressovyvaniye and development of the plug (2) of the top head of a rod, - track correctness of combination of oil openings (1).
  1. Attentively study a condition of a bent shaft. Check his root and conrod necks for existence of zadir, traces of an overheat and other mechanical damages. Make sure of lack of violations of passability of oil openings.
  1. Having laid a shaft in prisms, check it for existence of a bend by means of the DTI measuring instrument.
  1. Measure diameters of necks, estimate sizes of their conicity and ovality. If wear of necks exceeds extreme admissible value, pierce them under the next repair size (do not forget to pick up the corresponding size repair inserts), or replace a shaft.

Do not cut off a rounding off of necks at all (see an illustration), - the minimum admissible radius of a rounding off makes 2.6 ÷ 3 mm.


  1. Study a condition of inserts of bearings. In case of detection of defects prepare a replaceable set. Spread out inserts as installation them to the engine.

Assembly

 PERFORMANCE ORDER

  1. Before assembly make sure of absoluteness of purity of all components.
  1. Warm the piston up to the temperature of 50 ÷ of 70 °C. Grease the conrod plug and openings in inflows of the piston with pure oil, then fill one of lock rings in the piston. Bring a rod to the piston and record it a piston finger and establish the second lock ring, - track correctness of an arrangement from each other of an oil opening on a rod and tags of "F" on the piston. Working in a similar manner, mount all conrod and piston assemblies.
  1. Put the picked-up earlier piston rings on pistons: at first in the lower flute of the piston the dilator of an oil scraper ring is established, then its working sections are got. Further, in the remained flutes the lower and top compression rings (do not mix a ring - they differ in a section form) refuel, - track correctness of placement of rings.
1 — the Identification tag
2 — the Piston ring
3 — Up
4 — the Top compression ring
5 — the Second compression ring
6 — Working section of an oil scraper ring

Rings should be established by the party marked with a letter of "Y" up.

  1. Develop the rings put on pistons locks in the specified directions.
1 — the Top ring and a spring dilator of an oil scraper ring
2 — the Second compression ring
3 — Working sections of an oil scraper ring
  1. Accurately fill conrod and piston assemblies in the cylinders: walls of pistons and a mirror of cylinders before installation should be oiled pure motive, to press out piston rings a special mandrel; it is the best of all to make pushing through of pistons in cylinders the hammer handle. Track that pistons were installed by tags in the form of letters of "F" on the engine forward.

At emergence of resistance it is necessary to stop immediately pushing through of the piston, to take assembly and to make sure of completeness of removal of step wear in the top part of the cylinder!

  1. Put in the block of cylinders masloraspylitel and tighten bolts of their fastening with the required effort
    (12 ÷ 18 Nanometers).
  2. Carefully wipe necks of a bent shaft, a back of inserts of radical bearings and their bed in the block, having completely removed from them oil traces. Enclose inserts and establish a shaft.
  3. Once again wipe radical necks of a shaft, lay along them the calibrated plastic wire from the Plastigage set for definition of working gaps in sliding bearings.

Watch that the wire did not keep within over oil openings of necks!

  1. Wipe backs of inserts of bearings and their bed in covers, then establish the last, having tracked correctness of placement and, working strictly in a certain order, tighten bolts of their fastening with the required effort.
Scheme of installation of covers of radical bearings.
Order of tightening of fixture of covers of radical bearings.
  1. Release fixture, uncover and, measuring width of the flattened-out wire on the scale applied on packing of the Plastigage set, determine sizes of gaps in radical bearings.

During check do not turn a bent shaft! If the result of measurement exceeds extreme admissible value, make selection of new inserts, in case of need pierce a shaft to the repair size and establish repair inserts.


  1. Having finished check, grease working surfaces of the picked-up inserts and radical necks of a shaft with pure motive oil, lay a shaft in the block. Enclose in assembly of the central radical bearing persistent half rings working surfaces to cheeks of cranks of a shaft.
  1. Establish covers of radical bearings, push a shaft forward against the stop, then return back it and tighten bolts of fastening of covers with the required effort.
  1. Check the size of an axial side play of a bent shaft and freedom of its provorachivaniye. Compare result of measurement to requirements of Specifications of the Head Dvigatel, in case of need pick up new persistent half rings.

Replacement of forward half rings should be made only in case selection back did not possible to correct a situation.


  1. By means of a suitable mandrel, put the directing bearing on a back pin of a shaft, - do not forget to oil previously the bearing and a pin motive. After installation fill the bearing jellied lubricant.
  1. Having put the lower heads of rods on conrod necks of a shaft, make measurement of working gaps in conrod bearings, - act in the manner similar described above for radical bearings. Remember that inserts of bearings when checking have to be established on dry, track correctness of an arrangement of covers.
1 — Back on the engine
2 — Landing tags
  1. By means of the probe of lezviyny type make measurement of sizes of axial side plays of rods. Compare results of measurements to requirements of Specifications of the Head Dvigatel, in case of need replace the corresponding rods.
  1. Finalize conrod covers (having oiled the working surfaces of bearings), - track correctness of combination of landing tags and tighten bolts of their fastening with the required effort.

Carving parts of bolts and nuts before tightening also should be oiled pure motive.

  1. You make further installation as it should be, the return to an order of dismantle of components.