| 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. |
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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. |
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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. |
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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; |
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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. |
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10. Install to Passatizhami for a release of piston rings on the piston the 2nd compression ring. |
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11. Install to Passatizhami for a release of piston rings on the piston the 1st compression ring. |
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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. |
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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. |
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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. |
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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.
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| 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. |
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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
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| 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. |
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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. |
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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.
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32. If the axial side play exceeds admissible values, it is necessary to replace persistent half rings of a bent shaft. |
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33. Establish a connecting rod in a rod. |
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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. |
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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.
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| 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. |
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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
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| 43. Turn out nuts and uncover a rod. |
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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
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| 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
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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
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| 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. |
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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
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55. Remove the sealant which is squeezed out at installation of a back cover on the interfaced surface of the oil pallet. |
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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. |
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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. |
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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
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| 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. |
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64. Install the water pump with new laying and fix by bolts. Inhaling moments: 19–26 N • m
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| 65. Screw the oil pressure sensor. Inhaling moments: 11,7–17,6 N • m
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| 66. Grease with a thin layer of fresh engine oil a sealing ring of a new oil filter. |
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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. |
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68. Establish a maslozabornik with the mesh filter and new laying and fix by bolts. Inhaling moments: 7,8–11,8 N • m
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| 69. Clear the interfaced surfaces of the oil pallet and the block of cylinders. |
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70. Apply a continuous layer of silicone sealant on the interfaced surface of the oil pallet |
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71. Install the oil pallet and fix by bolts. Inhaling moments: 7,8–10,8 N • m
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| 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
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| 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. |
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77. In a certain sequence, in two or three stages tighten bolts of fastening of a flywheel. Inhaling moments: 97–103 N • m
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| 78. Establish a clutch plate and a casing of coupling with a press disk. |
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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
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| 80. Remove the tool blocking a flywheel from a provorachivaniye and the mandrel aligning a clutch plate. |
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81. Install the valve and on a core of the valve establish a maslootrazhatelny cap. |
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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.
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| 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. |
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86. Establish a valve spring so that rounds with a small step (In) were directed to a head of the block of cylinders. |
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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. |
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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
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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
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| 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
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| 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
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| 102. Establish forward and back eyes for raising of the engine. |
| 103. The load-lifting mechanism remove the engine from the stand. |
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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
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| 105. Establish the engine a support No. 3 and an arm and fix them by bolts. Inhaling moments: 73,5–102,9 N • m
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| 106. Establish the engine a support No. 2 and fix by bolts. Inhaling moments: 37,2–51,9 N • m
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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
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108. Establish a starter and fix by bolts.
Inhaling moments: 37–52 N • m
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109. Fill in engine oil in the engine. |
