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2.8. Dismantling of the engine


Head of the block of cylinders


1 – forward cover of the camshaft;
2 – camshaft;
3 – hydraulic compensator of gaps of valves;
4 – bolt of fastening of a head of the block of cylinders;
5 – head of the block of cylinders;
6 – laying of a head of the block of cylinders;
7 – crackers;
8 – top nest of a spring;
9 – valve spring;
10 – lower nest of a spring;
11 – valve;
12 – maslootrazhatelny cap;
13 – the directing valve plug

Forward and back covers of the engine and oil pallet

1 – press clutch plate assembled;
2 – clutch plate;
3 – flywheel;
4 – plate;
5 – oil pallet;
6 - a maslopriyemny tube with the mesh filter;
7 – back cover of the block of cylinders;
8 – water pump;
9 – oil pump;
10 – oil spray

Bent shaft, pistons and rods

1 – rod cover;
2 – connecting rods;
3 – rod and piston;
4 – piston rings;
5 - cover of the radical bearing of a bent shaft;
6 – bent shaft;
7 – radical inserts;
8 – block of cylinders

Dismantling

PERFORMANCE ORDER
1. Remove a support No. 2 of the power unit.
2. Remove a support No. 3 of the power unit and an arm of a support.
3. Turn out three bolts and remove a starter.
4. Turn out eight bolts and separate the transmission from the engine.
5. Turn out bolts and remove a bypass pipe of cooling liquid and a final collector.
6. Fix the engine at the repair stand.
7. Merge engine oil from the engine.
8. Remove forward and back eyes for raising of the engine.
9. Weaken an adjusting bolt, turn out bolts and a hinged bolt and remove the generator.
10. Remove an arm of support of an inlet collector.

11. Turn out bolts and remove an inlet collector.
12. Remove hydraulic compensators of gaps of valves.
13. You store hydraulic compensators of gaps of valves in the turned view in a container with engine oil.
14. In a certain sequence, for 2-3 stages turn out bolts of fastening of a head of the block of cylinders. Remove a head of the block of cylinders and laying of a head of the block of cylinders.
15. Special OK993 120 001 adaptation with a head OK993 120 004 squeeze a spring of the valve and remove crackers from a valve core.
16. Slowly release adaptation squeezing a spring and remove a valve spring from a head of the block of cylinders.
17. Passatizhami OK993 120 006 remove a maslootrazhatelny cap.
18. Repeat these operations on all 16 valves.
19. For storage of valves prepare the numbered plastic bags or containers.
20. Mark the valve in order that at assembly they could be established on the initial places.
21. Take the valve from a head of the block of cylinders.
22. Take the lower nests of springs from a head of the block of cylinders.
23. Install special tools for centering of a clutch plate and blocking of a flywheel from a provorachivaniye.
24. Gradually, on diagonal, weaken bolts of fastening of a casing of a press clutch plate until it is terminated a diaphragm spring, then turn out bolts manually.
25. Remove a casing of a press clutch plate and a clutch plate.
26. Using OK401 111 012 adaptation, remove the needle bearing.
27. Turn out eight bolts and remove a flywheel (on the BFD engine – six bolts).
28. Turn out bolts of fastening of the oil pallet.
29. An edge of the flat screw-driver separate the oil pallet from the block of cylinders.

Prevention

Do not insert the screw-driver between the block of cylinders and the oil pallet as it can damage the interfaced surfaces.


30. Turn out two bolts and pick up the oil receiver phone with the mesh filter.

31. Remove a pulley of the drive of a gear belt from a bent shaft.

 

32. Turn out bolts and remove the oil pump.
33. An edge of the flat screw-driver remove an oil sealing ring from a cover of the oil pump.
34. Turn out bolts and remove a back cover of the block of cylinders.
35. An edge of the flat screw-driver remove an oil sealing ring from a back cover of the block of cylinders.
36. Turn out bolts and remove the water pump.
37. Turn out an oil filter and the sensor of pressure of oil.

38. Check lack of a step and deposit in the top part of each cylinder.


Prevention

If to make removal of pistons, without having removed a step the top part of the cylinder, it can lead to damage of piston rings and pistons.



39. Using the special tool, remove a step in the top part of cylinders.
40. Turn a bent shaft of the engine so that the piston of the first cylinder was installed in the top dead point.
41. Turn a bent shaft of the engine so that pistons of the first and fourth cylinders were installed in the lower dead point.
42. Mark covers of rods and rods according to number of the cylinder in which they are established.
43. Note rods and covers of rods so that at installation they reached the correct position and the direction. At the wrong installation of rods supply of lubricant in connecting rods will be broken that will lead to their bystry damage.
44. Turn a bent shaft of the engine so that pistons of the second and third cylinders were installed in the lower dead point and, similarly, mark rods and covers of rods.
45. Turn off nuts of fastening of a cover of a rod and, easy blows of the plastic hammer, bring down a cover.
46. For protection of necks of a bent shaft, dress pieces of a rubber or plastic tube on bolts of fastening of covers of rods.
47. Wooden whetstone or the handle of the hammer, push out the piston with a rod from the cylinder.
48. Repeat these operations on other cylinders.
49. Mark pistons according to numbers of cylinders in which they were established.
50. Special passatizha unclench piston rings and remove them from the piston.
51. Install the piston vertically and check smoothness of movement of a rod.
52. Moving a rod, check lack of a side play and jammings.
53. If the rod moves with jammings, check an opening for a piston finger in the piston and a rod for lack of deformation.
54. Remove lock rings from end faces of a piston finger.
55. Incline the piston and allow a piston finger to slip out the piston. If necessary, squeeze out a piston finger from the piston.
56. Take a rod from the piston. When dismantling you hold together the piston, a rod, a piston finger and lock rings of a piston finger.
57. Number covers of radical bearings and note their arrangement.
58. In a certain sequence, for 2–3 stages, weaken and turn out bolts of fastening of covers of radical bearings.
59. Uncover radical bearings.
60. Remove a bent shaft.
61. Remove inserts of radical bearings from the block of cylinders and covers of radical bearings.

Assembly

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 11/6 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.