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2.10. Assembly of the engine

PERFORMANCE ORDER
1. Before assembly clear all details of the engine.
2. Before assembly of details apply a thin film of pure engine oil on all surfaces of sliding.
3. Replace radical and connecting rods even if they have insignificant damages or wear. At installation it is necessary to use only new laying.
4. Establish a spring lock ring in a piston flute.
5. Install the piston in a rod and implant a piston finger via the piston and a rod before fixing by its already established lock ring. Check that relative position of the piston and a rod was same, as well as before dismantling.
6. Establish the second spring lock ring of a piston finger in a flute on the other side of the piston.
7. You hold the piston vertically and check freedom of movement of a rod.
8. Install three parts of an oil scraper ring on the piston:
      - oil pure engine a dilator of an oil scraper ring both top and lower speak rapidly rings;
      - install a dilator of an oil scraper ring on the piston so that the ends of a dilator were directed up;
      - install the lower part of an oil scraper ring on the piston. The ring can be established by any party up;
      - install the top part of an oil scraper ring on the piston. The ring can be established by any party up;
9. Check that the dilator of an oil scraper ring divides the top and lower parts of an oil scraper ring and is freely turned on the piston.
10. Install to Passatizhami for a release of piston rings on the piston the 2nd compression ring.
11. Install to Passatizhami for a release of piston rings on the piston the 1st compression ring.
12. Arrange locks of piston rings as shown in the drawing.
13. Clear radical and conrod necks of a bent shaft of lubricant, and blow lubricant openings compressed air.
14. Install inserts of radical bearings on the block of cylinders of the engine.
15. Establish persistent half rings of a bent shaft.
16. Install a bent shaft on inserts of radical bearings in the block of cylinders.
17. Establish the remained inserts of radical bearings in covers of radical bearings of a bent shaft.

18. Arrange pieces of a plastic measuring core of Plastigage on necks of radical bearings of a bent shaft.
19. According to marking establish covers of radical bearings.

20. In a certain sequence tighten bolts of fastening of covers of radical bearings of a bent shaft in the following order:
TED: and. tighten bolts the moment of an inhaling of 39,2 N • m;
b. in the sequence, the return to tightening, weaken bolts;
page tighten bolts the moment of an inhaling of 19,6 N • m;
d. tighten bolts on a corner 90 °;
e. tighten bolts on a corner 60 °;
BFD: tighten bolts the moment of an inhaling of 54-59 N • m.

Prevention

Do not turn a bent shaft of the engine at measurement of a gap of radical bearings of a bent shaft.


21. Turn out bolts and uncover radical bearings of a bent shaft. Measure by a measuring template width of the deformed plastic core of Plastigage and determine gap size.

22. If the gap exceeds maximum permissible value, a pereshlifuyta of a neck of a bent shaft and use repair inserts of the increased size.

Gap in radical bearings of a bent shaft:
TED: 0,024–0,042 mm
BFD: 0,018-0,036

23. Remove a bent shaft from the block of cylinders and remove the deformed plastic core of Plastigage from necks of a bent shaft and inserts of radical bearings.
24. Apply a thin film of engine oil on inserts of radical bearings in the block of cylinders and establish a bent shaft on inserts.
25. Apply a thin film of engine oil on radical necks of a bent shaft and inserts in covers of radical bearings.
26. According to marking establish covers of radical bearings of a bent shaft.
27. In a certain sequence tighten bolts of fastening of covers of radical bearings of a bent shaft in the following order:
TED: and. tighten bolts the moment of an inhaling of 39,2 N • m;
b. in the sequence, the return to tightening, weaken bolts;
page tighten bolts the moment of an inhaling of 19,6 N • m;
d. tighten bolts on a corner 90 °;
e. tighten bolts on a corner 60 °;
BFD: tighten bolts the moment of an inhaling of 54-59 N • m.
28. Turn a bent shaft and check that it rotates easily and smoothly.
29. Establish a measuring tip of the indicator of hour type on a forward end face of a bent shaft.
30. Move a bent shaft along an axis against the stop and establish a scale of the indicator of hour type on zero.
31. Move a bent shaft along an axis to other party against the stop and read values of an axial side play on an indicator scale.

Axial side play of a bent shaft: 0,080–0,282 mm.

32. If the axial side play exceeds admissible values, it is necessary to replace persistent half rings of a bent shaft.
33. Establish a connecting rod in a rod.
34. For protection of a neck of a bent shaft against damage, dress pieces of a rubber or plastic tube on bolts of fastening of covers of rods.
35. Check correctness of an arrangement of locks of piston rings on the piston.
36. Install the piston with piston rings over the first cylinder, at the same time F tag on the piston has to be directed to a forward part of the block of cylinders.
37. Turn a bent shaft in such situation that the conrod neck of a bent shaft of the 1st cylinder was in the lower dead point.
38. Special adaptation squeeze piston rings on the piston.
39. The handle of the hammer press the piston into the cylinder so that the lower head of a rod was established on a neck of a bent shaft.
40. Establish a connecting rod in a rod cover.
41. Arrange pieces of a plastic measuring core of Plastigage on necks of conrod bearings of a bent shaft.
42. According to marking establish covers of rods and fix them by nuts.

Inhaling moments:
TED: 47–50 N • m
BFD: 64–69 N • m

43. Turn out nuts and uncover a rod.
44. Measure by a measuring template width of the deformed plastic core of Plastigage and determine gap size. Remove the deformed plastic core of Plastigage from necks of a bent shaft and inserts of conrod bearings.

Nominal gap in the conrod bearing:
TED: 0,20–0,05 mm
BFD: 0,028–0,068 mm
Maximum permissible gap: 0,10 mm

45. If the gap exceeds maximum permissible value, a pereshlifuyta of a neck of a bent shaft and use repair inserts of the increased size.
46. Apply a thin film of engine oil on a conrod neck of a bent shaft and a connecting rod in a rod cover.
47. Establish a cover of a rod and fix by nuts.

Inhaling moments:
TED: 47–50 N • m
BFD: 64–69 N • m

48. Measure by the probe inserted between a rod and a bent shaft a side gap of a rod.

Nominal side gap of a rod: 0,110–0,262 mm
Maximum permissible gap: 0,30 mm

49. If the side gap of a rod exceeds maximum permissible value, replace a rod and a cover of a rod.
50. Apply a thin film of pure engine oil on an external surface and a working edge of a back oil sealing ring of a bent shaft.
51. Manually establish a sealing ring in a back cover of the block of cylinders.
52. Special adaptation press a sealing ring into a back cover so that the end face of a ring was flush with a cover or acted from it no more than on 0,5 mm.
53. Apply a layer of silicone sealant 2 mm thick on the interfaced surface of a back cover.
54. Establish a back cover and fix by bolts.

Inhaling moments: 7,8–10,8 N • m

55. Remove the sealant which is squeezed out at installation of a back cover on the interfaced surface of the oil pallet.
56. Apply a thin film of pure engine oil on a working edge of a forward oil sealing ring of a bent shaft and a nest of the oil pump.
57. Manually establish a forward sealing ring of a bent shaft.
58. Special adaptation press a sealing ring into the case of the oil pump so that the end face of a ring acted on 0,5–1,0 mm from the case of the oil pump.
59. Establish a new sealing ring of round section.
60. Apply a layer of silicone sealant with a diameter of 1-2 mm on the interfaced surface of the case of the oil pump, as shown in the drawing.
61. Install the oil pump and fix by 6 bolts.

Inhaling moments: 19–26 N • m

62. Remove the sealant which is squeezed out at installation of the oil pump on the interfaced surface of the oil pallet.
63. Clear the interfaced surface of the water pump.

64. Install the water pump with new laying and fix by bolts.

Inhaling moments: 19–26 N • m

65. Screw the oil pressure sensor.

Inhaling moments: 11,7–17,6 N • m

66. Grease with a thin layer of fresh engine oil a sealing ring of a new oil filter.
67. Screw an oil filter before contact of a sealing ring of an oil filter with the block of cylinders, then tighten the filter on 1–1/6 turns.
68. Establish a maslozabornik with the mesh filter and new laying and fix by bolts.

Inhaling moments: 7,8–11,8 N • m

69. Clear the interfaced surfaces of the oil pallet and the block of cylinders.
70. Apply a continuous layer of silicone sealant on the interfaced surface of the oil pallet

71. Install the oil pallet and fix by bolts.

Inhaling moments: 7,8–10,8 N • m

72. Clear a carving of bolts of fastening of a flywheel and an opening under bolts of the remains of old sealant. If sealant cannot be removed from a carving of bolts, replace them.
73. Install a transitional plate on the block of cylinders and fix by bolts.

Inhaling moments:
TED: 18,6–30,4 N • m
BFD: 7,8–11,0 N • m

74. Establish a flywheel or a plate of the drive on a bent shaft.
75. Apply a thin film of sealant on a carving of repeatedly used bolts.
76. The special tool block a flywheel from a provorachivaniye.
77. In a certain sequence, in two or three stages tighten bolts of fastening of a flywheel.

Inhaling moments: 97–103 N • m

78. Establish a clutch plate and a casing of coupling with a press disk.
79. Establish the mandrel aligning a clutch plate and, in several stages, in a certain sequence tighten bolts of fastening of a casing of coupling with a press disk.

Inhaling moments:
TED: 22–32 N • m
BFD: 18–26 N • m

80. Remove the tool blocking a flywheel from a provorachivaniye and the mandrel aligning a clutch plate.

81. Install the valve and on a core of the valve establish a maslootrazhatelny cap.
82. Special adaptation press a maslootrazhatelny cap into place.

Prevention

Maslootrazhatelny caps of inlet and final valves are various. Maslootrazhatelny caps of final valves have 4 teeth.


83. Remove the device for a press fitting of a maslootrazhatelny cap.
84. Establish the lower nest of a spring on a head of the block of cylinders.
85. In the presence, establish protection of the hydraulic compensator of a gap of valves.
86. Establish a valve spring so that rounds with a small step (In) were directed to a head of the block of cylinders.
87. Establish the top nest of a spring and special adaptation, squeeze a spring.
88. Establish crackers and remove the special device for compression of a spring.
89. Several times strike with the plastic hammer a valve core end face in order that crackers were established on the places.
90. In the presence, remove protection of the hydraulic compensator of a gap of valves.
91. Similarly establish the others of the valve.
92. Install laying and a head of the block of cylinders on the block of cylinders.
93. Establish bolts of fastening of a head of the block of cylinders.
94. In a certain sequence tighten bolts of fastening of a head of the block of cylinders in the following order:
TED: and. tighten bolts the moment of an inhaling of 49 N • m;
b. in the sequence, the return to tightening, weaken bolts;
page tighten bolts the moment of an inhaling 39,2H • m;
d. tighten bolts on a corner 90 °;
e. tighten bolts on a corner 90 °;
BFD: tighten bolts the moment of an inhaling of 76-81 N • m.
95. Install hydraulic compensators of a gap of valves.
96. Establish new laying of an inlet collector.
97. Establish an inlet collector and fix by bolts.

Inhaling moments: 17,6–25,5 N • m

98. Establish an arm of an inlet collector and fix by bolts.

Inhaling moments:
TED: (A) 15,7–22,5 N • m
(C) 36,3–53,9 N • m
BFD: 31,4–46,1 N • m

99. Install the generator and fix it by assembly bolts and an adjusting bolt.
100. Establish a belt of the drive of the generator and adjust its tension.

Generator drive belt deflection:
New belt: 8–9 mm
The belt which was in the use: 9–10 mm

101. Tighten all bolts of fastening of the generator the required moments.

Inhaling moments:
Assembly bolts: 37–52 N • m
Adjusting bolt: 19-26 N of m

102. Establish forward and back eyes for raising of the engine.
103. The load-lifting mechanism remove the engine from the stand.

104. Establish a final collector and a bypass pipe of cooling liquid and fix them by bolts.

Inhaling moments: (A) 38,2-46,1 N of m

105. Establish the engine a support No. 3 and an arm and fix them by bolts.

Inhaling moments: 73,5–102,9 N • m

106. Establish the engine a support No. 2 and fix by bolts.

Inhaling moments: 37,2–51,9 N • m

107. Install the transmission and fix by 8 bolts.

Inhaling moments:
4 top bolts (1, 2, 3, 4) 89–116 N • m
4 lower bolts (5, 6, 7, 8) 37–52 N • m

108. Establish a starter and fix by bolts.

Inhaling moments: 37–52 N • m

109. Fill in engine oil in the engine.