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2.9. Check of the engine

PERFORMANCE ORDER
1. Clear all components of the engine.
2. Remove the remains of laying, sealant, dirt, oil, lubricant and other alien materials from the block of cylinders of the engine.

Check of a head of the block of cylinders

PERFORMANCE ORDER
1. Examine a head of the block of cylinders on absence of damage, cracks, leak of oil and cooling liquid. If necessary, replace a head of the block of cylinders.
2. A metal ruler and the probe in six directions check planeness of a head of the block of cylinders. If necessary, pereshlifuyta head of the block of cylinders.

Maximum regrinding: 0,1 mm

3. If not planeness exceeds admissible limits, replace or a pereshlifuyta a head of the block of cylinders.
Replace or repair a head of the block of cylinders with the following defects:
      – the burned-through saddles of valves;
      – damage of the interfaced surface for installation of inlet and final collectors;
      – damage of nests for installation of oil sealing rings of camshafts.
4. Measure height of a head of the block of cylinders from the lower surface of a head to the surface of installation of laying of a cover of a head of the block of cylinders.

5. If height of a head of the block of cylinders differs from nominal rates, replace a head of the block of cylinders.

Height:
TED: 133,9–134,1 mm
BFD: 133,8–134,0 mm

6. Measure by a metal ruler and the probe planeness of the interfaced surfaces of collectors in two directions.

Deviation from planeness: no more than 0,20 mm

7. If not planeness exceeds admissible limits, replace a head of the block of cylinders.
8. A metal ruler and the probe in six directions check planeness of the interfaced surface of the block of cylinders.

Deviation from planeness: no more than 0,20 mm

Check of valves

PERFORMANCE ORDER
1. Examine each valve on detection of the following defects:
      – damages or deformation of a core of the valve;
      – damages of a plate of the valve;
      – damages or uneven wear of an end face of a core of the valve.
2. If necessary, repair or replace the valve.

Height of an edge of the valve:
TED: 1,2 mm
BFD: 1,0 mm

3. Measure length of each valve.

Valve length:
Inlet valve:
TED: 10,2,92 mm
BFD: 105,29 mm
Final valve:
TED: 101,42 mm
BFD: 105,39 mm

4. A micrometer, in several places on height, measure diameter of a core of the valve.

Diameter of the valve:
Inlet valve: 5,970–5,985 mm
Final valve: 5,965–5,980

5. In several places, measure by Nutromer the internal diameter of the directing plugs of valves.

Internal diameter of the directing inlet and final valves: 6,01–6,03 mm

6. Calculate a gap between the directing plug and a core of the valve. For this purpose subtract the outer diameter of a core of the valve from the internal diameter of the corresponding guide of the plug of the valve.

Gap:
Inlet valve:
TED: 0,050–0,060 mm
BFD: 0,040–0,045 mm
Final valve:
TED: 0,030–0,065 mm
BFD: 0,045–0,050 mm
Maximum permissible value: 0,020 mm

7. If the gap exceeds maximum permissible value, replace the valve and / or the directing valve plug.
8. Measure height of a vystupaniye of each plug of the valve. If necessary, replace the directing valve plug.

Inlet valve A:
TED: 13,7–14,3 mm
BFD: 16,8–17,4 mm
Final valve:
TED: 16,7–17,3 mm
BFD: 18,1–18,7 mm


Prevention

The directing plugs of inlet and final valves are various.


Check of a saddle of the valve

PERFORMANCE ORDER
1. Check a working surface and facets of a saddle of the valve for lack of the following defects:
      – roughness;
      – burn-out;
      – pointed corrosion;
      – cracks.
2. The special cutting tool at an angle 45 ° restore a working edge of a saddle of the valve.
3. Apply special structure of blue color on a working facet of the valve and the valve and let's dry to structure.
4. Install the valve in a valve saddle, press and turn on 360 °. If the blue structure is not completely removed from a working facet of the valve, replace the valve. If the blue structure is not completely removed from a working facet of a saddle of the valve, repeatedly process a valve saddle.

5. Measure width of a working facet of the valve.

Width:
TED: 1,98–2,69 mm
BFD: 0,8–1,4 mm

6. Check depth of an arrangement of a working surface of a saddle of the valve, measuring it in the center of a facet of the valve. If the valve installed in a saddle of the valve is located too highly, process a valve saddle development with a corner 63 °, then development with a corner 45 °. If the valve installed in a saddle of the valve is located too low, process a valve saddle development with a corner 0 °, then development with a corner 45 °.
7. Using special abrasive powder, grind in the valve and a saddle of valves.
8. Clear the valve and a saddle of valves of the remains of abrasive powder.

9. Install the valve in a head of the block of cylinders and measure a vystupaniye (size L) of a core of the valve in relation to an installation site of the lower part of a spring of the valve.

Check of a spring of the valve

PERFORMANCE ORDER
1. Examine each spring of the valve on lack of cracks and damages.
2. Measure spring length in a free state. Establish a spring on a flat horizontal surface and measure a deviation of the top part of a spring from the vertical plane.

Spring length in a free state:
TED: 46,7 mm
BFD: 45,6 mm
Maximum permissible deviation of a spring from the vertical plane:
TED: 1,63 mm
BFD: 1,59 mm

Check of the camshaft

1. Install the first and last necks of the camshaft on V-shaped blocks.
2. Establish a measuring head of the indicator of hour type on an average neck of the bearing of the camshaft and establish an indicator scale on 0.

3. Turn the camshaft and measure its beating.

Maximum permissible beating of the camshaft: 0,03 mm

4. Check the camshaft for lack of uneven wear, cracks or damages.
5. Measure height of each cam of the camshaft in two points.

Height of cams of the camshaft of inlet valves:
TED: 41,6949 mm
BFD: 40,888 mm
Height of cams of the camshaft of final valves:
TED: 42,2369mm
BFD: 40,688 mm

6. Measure diameter of each neck of the camshaft in two perpendicular directions.

Nominal diameter:
TED: 26,940–26,965 mm
BFD: 25,940–25,965 mm
Minimum admissible diameter:
TED: 26,910 mm
Maximum permissible ovality: 0,05 mm

7. If wear of necks of bearings of the camshaft exceeds maximum permissible value, replace the camshaft.

8. Measure a gap in bearings of camshafts with remote hydraulic compensators of valves.

9. Clear of lubricant of a neck of bearings of camshafts, a cover of bearings and bearings in a head of the block of cylinders.
10. Install camshafts on a head of the block of cylinders.
11. For measurement of a gap use the plastic calibrated round core of Plastigage. The core of Plastigage contracts between the bearing and a neck of the camshaft. After removal of a cover of the bearing of the camshaft, the deformed plastic core of Plastigage is measured by a special template which is available in a set. Cut off pieces of a plastic core and arrange them on camshaft necks
12. After installation of a plastic core do not turn the camshaft.
13. According to marking, establish covers of bearings of camshafts.

14. Establish bolts of fastening of covers of bearings and tighten them for 5–6 stages.

Inhaling moment: 11,3–14,2 N • m


15. In a certain sequence for 5–6 stages turn out bolts of fastening of covers of bearings of camshafts.
16. Uncover bearings of camshafts.

17. Measuring by a template width of the deformed plastic core, define gaps in camshaft bearings.

Nominal gap: 0,035–0,081 mm
Maximum permissible gap: 0,15 mm

18. If the gap exceeds maximum permissible value, replace a head of the block of cylinders.
19. Install camshafts in a head of the block of cylinders.
20. Establish a measuring tip of the indicator of hour type on a camshaft end face.
21. Move the camshaft along an axis against the stop to one party.
22. Establish an arrow of the indicator of hour type on 0.
23. Move the camshaft along an axis against the stop to other party.

24. Read indications on the indicator of hour type which shows the size of an axial side play of the camshaft.

Nominal axial side play: 0,08–0,10 mm
Maximum permissible gap: 0,20 mm

Check of hydraulic compensators of gaps of valves

PERFORMANCE ORDER
1. Check the face of hydraulic compensators of gaps of valves for lack of wear or damages and, if necessary, replace them.
2. Fill hydraulic compensators of gaps of valves with pure engine oil and squeeze them from two parties. If the hydraulic compensator of gaps of valves contracts, replace it. Never try to restore or repair the hydraulic compensator of gaps of valves.
3. In the opposite directions, measure diameters of cylinders for hydraulic compensators of gaps of valves.

Diameter: 30,000–30,025 mm

4. At two levels, measure diameters of hydraulic compensators of gaps of valves in the opposite directions.

Diameter: 29,959–29,975 mm

5. Calculate a gap between cylinders of the hydraulic compensator of gaps of valves and the hydraulic compensator. If the gap exceeds maximum permissible, replace the hydraulic compensator of gaps of valves and / or a head of the block of cylinders.

Nominal gap: 0,025–0,066 mm
Maximum permissible gap: 0,180 mm

Check of blocks of cylinders

PERFORMANCE ORDER
1. Check the block of cylinders for lack of the following damages:
      – local damages or leaks;
      – cracks;
      – development of cylinders.
2. A metal ruler and the probe in six directions check planeness of the interfaced surface of the block of cylinders.

Deviation from planeness: 0,15 mm

3. If not planeness exceeds admissible limits, a pereshlifuyta the block of cylinders.

The most admissible regrinding: 0,20 mm.

4. If regrinding of the block of cylinders, at a big size is necessary, replace the block of cylinders.

Prevention

Before regrinding of the block of cylinders measure height of the block of cylinders from an axis of a bent shaft to the top interfaced surface.


5. Measure diameters of cylinders in the opposite directions, in three planes on height of cylinders.

Diameter of the cylinder:
Nominal:
TED: 81,006–81,019 mm
BFD: 78,006–78,019 mm
Repair +0,25 mm:
TED: 81,256–81,269 mm
BFD: 78,256–78,269 mm
Repair +0,50 mm:
TED: 81,506–81,519 mm

BFD: 78,506–78,519 mm

6. For definition of conicity of the cylinder, measure diameter of the cylinder in the top, average and lower parts.

Maximum permissible conicity:
TED: 0,019 mm
BFD: 0,15 mm
Ovality: 0,019 mm

Check of sprays for cooling of pistons

7. Giving compressed air to an opening And a spray, check that air comes out an opening of Century. If air does not pass, replace a spray.

Air pressure: 245,3–301,4 kPa

8. Check an oil spray tip for lack of pollution of internal canals. If necessary, replace a spray tip.

Check of pistons


Prevention

When replacing the piston, it is also necessary to replace piston rings.


PERFORMANCE ORDER
1. Check the external surface of the piston for absence of damage, developments or uneven wear. If necessary, replace the piston.
2. Measure the outer diameter of each piston a sort by a corner 90 ° to a piston finger, at distance of 21,5 mm in the TED engine and at distance of 17,6 mm in the BFD engine from bottom edge of an oil scraper ring.

Diameter of the TED piston
Nominal 80,9540–80,9720, mm
The 1st repair (+0,25) 81,204–81,222, mm
The 2nd repair (+0,50) 81,454–81,472, mm
BFD
Nominal 77,954–77,974, mm
The 1st repair (+0,25) 78,204–78,224, mm
The 2nd repair (+0,50) 78,454–78,474, mm
3. Calculate a gap between the piston and a wall of the cylinder, subtracting diameter of the piston from the largest diameter of the cylinder, in each cylinder.

Nominal gap:
TED: 0,040–0,053 mm
BFD: 0,032–0,065 mm
Maximum permissible gap: 0,15 mm

4. If the gap exceeds maximum permissible value, replace pistons with the bigger repair size and chisel cylinders.

Check of piston rings

PERFORMANCE ORDER
1. Insert a new piston ring into a flute of the piston and, the probe, measure a gap between a piston ring and a wall of a flute. A gap between a piston ring and a flute in the piston,

1st compression ring of TED: 0,04–0,08, BFD: 0,030–0,065
Maximum permissible gap – 0,15
2nd compression ring of TED: 0,03–0,070, BFD:030–0,065
2. If the gap exceeds maximum permissible value, replace the piston.
3. Check piston rings for absence of damage, wear or breakage.
4. If necessary, replace piston rings.
5. Measure a gap in the lock of piston rings, having manually inserted a piston ring into the engine cylinder.
6. The bottom of the piston push a piston ring in the lower part of the cylinder.

7. Measure by the probe a gap in the lock of a piston ring.

Gap in locks of piston rings:
First compression ring: 0,15–0,30 mm
Second compression ring: 0,30–0,45 mm
Oil scraper ring: 0,20–0,70 mm
Maximum permissible gap: 1,0 mm

8. If the gap exceeds maximum permissible value, replace piston rings.

Check of piston fingers

PERFORMANCE ORDER


1. Measure diameters of openings for a piston finger in the piston, in two opposite directions, four planes.

Diameter:
TED: 19,994–20,002 mm
BFD: 19,998–20,000 mm

2. Measure diameter of each piston finger, in two opposite directions, four planes.

Diameter:
TED: 19,987–19,993 mm
BFD: 19,974–19,980 mm

3. Define a gap of a piston finger in the piston, subtracting diameter of a piston finger from diameter of an opening for a piston finger.

Gap:
TED: 0,001–0,015 mm
BFD: 0,008–0,026 mm

4. If the gap exceeds nominal rate, replace the piston and a piston finger.

Check of rods

PERFORMANCE ORDER


1. Measure the internal diameter of a head of a rod.

Internal diameter of a head of a rod:
TED: 20,003–20,013 mm
BFD: 19,943–19,961 mm

2. Define a gap of a piston finger in a rod, subtracting diameter of a piston finger from diameter of an opening of a head of a rod.

Gap:
TED: 0,010–0,027 mm
BFD: 0,013–0,037 mm

3. If the gap exceeds nominal rate, replace the plug in the top head of a rod.

4. Check a bend of each rod.
5. If necessary, replace rods. You make replacement of a rod together with a rod cover.

Check of a bent shaft

PERFORMANCE ORDER
1. Check necks of radical and conrod bearings of a bent shaft for lack of wear and development.
2. Check lubricant openings of a bent shaft for lack of a contamination.
3. Install the first and last necks of radical bearings of a bent shaft on V-shaped blocks.

4. Establish a measuring head of the indicator of hour type on an average neck of the bearing of a bent shaft and establish an indicator scale on 0. Turn a bent shaft and measure its beating. If the beating exceeds a nominal beating, replace a bent shaft.

Beating: 0,04 mm

5. Measure by a micrometer diameters of necks of a bent shaft in two opposite directions.
6. In the presence of development or ovality, a pereshlifuyta a bent shaft.
7. You carry out regrinding of necks of a bent shaft only to the following repair size.
8. If a bent shaft перешлифован on the repair size of +0,50 mm, carry out heat treatment of a shaft for increase in its durability.

Diameters of necks of radical bearings of a bent shaft:
1st repair size (+0,25 mm):
TED: 54,688–54,706
BFD: 49,688–49,706
2nd repair size (+0,50 mm):
TED: 54,438–54,456
BFD: 49,438–49,456
3rd repair size: (+0,75 mm):
TED: 54,188–54,206
BFD: 49,188–49,206
Diameters of necks of conrod bearings of a bent shaft:
1st repair size (+0,25 mm):
TED: 44,690–44,708
BFD: 39,960–39,706
2nd repair size (+0,50 mm):
TED: 44,440–44,458
BFD: 39,440–39,456
3rd repair size (+0,75 mm):
TED: 44,190–44,208
BFD: 39,190–39,206

Check of connecting and radical rods
PERFORMANCE ORDER

Check connecting and radical rods for lack of local corrosion, development and other damages. If necessary, replace inserts.

Check of a gear belt


Prevention

Strongly do not bend a gear belt and do not change the direction of its rotation. Do not allow oil and lubricant to contact with a gear belt as it will lead to its destruction.


PERFORMANCE ORDER
1. Replace a gear belt if it is polluted by oil or lubricant.
2. Check a gear belt for absence of damage, wear, stratification, cracks on teeths and in the basis of teeths, and also for defects at end faces and a reverse side of a belt.
With defects, replace a gear belt.

The mechanism of a tension of a gear belt and the directing roller


Prevention

You do not purge a roller of the mechanism of a tension or the directing roller of a gear belt with use of the clearing liquids. Grinding of rollers is allowed by pure soft rags. Do not scratch working surfaces of rollers as it will result in premature wear of a gear belt.


PERFORMANCE ORDER
Check a roller of the mechanism of a tension and the directing roller for smoothness of rotation and lack of noise at rotation. If necessary, replace a roller of the mechanism of a tension or the directing roller.

Tension mechanism spring

PERFORMANCE ORDER
Measure tension mechanism spring length in a free state. If length of a spring differs from nominal rate, replace it.

Spring length in a free state
TED: 35.6 mm
BFD: 59,5 mm

Shkifa of camshafts


Prevention

You do not purge pulleys with use of the clearing liquids. If necessary, use pure soft rags for their cleaning. Do not scratch working surfaces of pulleys as it will result in premature wear of a gear belt.


PERFORMANCE ORDER
Check teeths of pulleys for lack of wear and damages. If necessary, replace pulleys.