4.2.9. Recovery repair of the block of cylinders

General information

During recovery repair of the block of cylinders replacement of pistons with piston rings, radical and conrod bearings of a bent shaft, components of the GRM drive and the oil pump is usually made. On OHV engines also the camshaft and pushers of valves is subject to replacement.

The pro-point cylinders/replacement of sleeves is in case of need made. Mirrors of cylinders owe otkhoningovana without fail.

The bent shaft usually is also subject to a pro-point with the subsequent selection of repair inserts of bearings.

Removal of step wear in the top part of cylinders

 PERFORMANCE ORDER

1. In view of the fact that during the running cycle pistons do not reach the top cut of the cylinder, at the end of their course on a mirror of cylinders the step which existence prevents extraction of conrod and piston assemblies is formed and can be the reason of damage of new pistons at their installation in the engine.
2. Several types of the vertical drills applied to removal of step wear of cylinders are issued, all of them are among rather inexpensive tools.
3. Turn a bent shaft so that the piston of the corresponding cylinder fell to the lower situation.
4. Cover the piston bottom with a protective layer of rags
5. Prepare a vertical drill and, adhering to instructions of manufacturers of the tool, process the top part of the cylinder, having removed from it step wear.

Try not to be overzealous and not to damage a mirror of cylinders in its working part!

6. Take a vertical drill, rags and the sawdust formed as a result of processing.
7. Working in a similar manner, remove step wear from mirrors of all cylinders.


Dismantling and cleaning

 PERFORMANCE ORDER

1. Install the engine on the assembly stand or a strong workbench. Alternatively lay the unit on the garage floor on pair of wooden blocks (the surface interfaced to transmission down). Position of the engine has to provide free access to fixture of covers of the lower heads of rods and a possibility of a provorachivaniye of a bent shaft. All covers provided by a unit design have to be removed from the engine.
2. Remove components of the GRM drive and a head of cylinders from the engine. Remove the pallet of a case and maslozaborny knot. In case of need remove the drive of the oil pump, balancing and auxiliary shaft.
3. Remove traces of step wear in the top part of cylinders (see above).
4. Turn the engine so that direct access to a bent shaft opened. By means of a chertilka or a center punch mark rods according to accessory them the to cylinders. Similarly mark also covers of radical bearings.
5. Again turn the engine, - this time the first cylinders up. Turn a bent shaft so that the piston of the first cylinder appeared in the lower part of the course. Release fixture and uncover the lower head of a rod of the first cylinder (track that the insert of the conrod bearing remained in a cover).

6. Pull pieces of a fuel hose on fixing hairpins, having provided thereby protection of a neck of a shaft and mirror of cylinders against damage to process of extraction of conrod assembly.

7. The wooden handle of the hammer push a rod up approximately on 25 mm and take from a bed in its lower head the top insert of the bearing.

8. Continue to tap carefully assembly up to that time until from the cylinder piston rings are released.

In case of resistance immediately stop percussion of assembly and make sure of completeness of removal of traces of step wear in the top part of a mirror of the cylinder!


9. Manually finally take conrod and piston assembly from the block. Enclose bearing inserts in beds, establish into place a cover of the lower head of a rod, slightly having tightened fixture.
10. Working in a similar manner, take the remained conrod and piston assemblies from the block.

At service of V-shaped engines at first assemblies from cylinders of the same kind are taken, then the engine turns over the second row up and the remained assemblies are taken.

12. At this stage the bent shaft has to appear the only thing remaining in the block a component. In stages evenly weaken fixture and uncover radical bearings (with the inserts enclosed in them).
13. Carefully take from the beds in the block a bent shaft.
14. Make careful cleaning of all removed components. If you are not going to start immediately assembly of the engine, lay the block in a pure plastic bag.


Check of a condition of components

 PERFORMANCE ORDER

1. During check of a condition of components of the block of the engine some special tools will be required. Such tools are among:

· Two or three micrometers for measurement of diameters of pistons and necks of a bent shaft;
· Dial measuring instrument of plunger type;
· The machine for assessment of extent of deformation of rods.
2. In the absence of near at hand necessary tools performance of check of a condition of components should be charged to specialists of car service.
3. Attentively examine the block on existence in it of cracks and other mechanical damages. Ways of identification of the latent defects are described in the Section Recovery repair of a head of cylinders devoted to check of a condition of a head of cylinders. It will be most correct to charge performance of check of a condition of casting of the block to specialists of car service.


Engine block

Check of centering of beds of radical bearings

 PERFORMANCE ORDER

1. Check beds of radical bearings in the block and covers for existence of traces of an overheat, zadir and agnails and other mechanical damages. In case of need give the block to a pro-point, or make its replacement. Easy defects can be removed by means of a file with small tooth.
2. Check centering of beds of bearings in the block by means of the planeness measuring instrument, having laid the last along an axis of laying of a bent shaft, - in case of identification of a side play or gaps the block also should be pierced. Also covers of radical bearings have to be subjected to the corresponding boring to the repair size. After a pro-point the engine has to be completed with new inserts of the corresponding repair size.


Check of planeness of the interfaced surface of the block

 PERFORMANCE ORDER

1. The surface of the block interfaced to a head of cylinders called also by a sound board has to be smoothed carefully out with full removal from it all traces of material of old laying, coal and pitch deposits. Check is made by means of the measuring instrument of planeness and the probe of lezviyny type. At first not planeness degree along block DP, then, - along both of its diagonals is estimated.
2. If the size of not planeness exceeds 0.076 mm on length of 15.2 mm (or 0.152 mm at the full length of the interfaced surface), the block of cylinders is subject to a pro-point.


Cylinders

 PERFORMANCE ORDER

1. Usually working gap of landing of pistons in cylinders makes 0.0381 ÷ 0.0635 mm.

2. Estimate an external condition of mirrors of cylinders and make their measurement. Measurements are performed by means of a telescopic nutromer and a micrometer in three sections and two co-perpendicular planes. The analysis of results of measurements will allow to determine the volume of the forthcoming recovery work. Ovality and conicity of cylinders should not exceed the limit of admissible ranges. The taken measurements will allow to determine further the size of gaps of landing of pistons in cylinders.

3. The top part of cylinders is usually worn-out slightly stronger, than lower that leads to formation of conicity. If the size of conicity exceeds 0.305 mm, the cylinder is subject pro-points.
4. Besides, usually walls of cylinders wear out on the persistent surfaces of pistons usually stronger, i.e. in the plane, a perpendicular axis of a bent shaft. Such wear leads to formation of ovality of cylinders which also should not go beyond admissible limits (see Specifications).


Bent shaft

 PERFORMANCE ORDER

1. Wash out a bent shaft solvent, then carefully dry, having whenever possible used compressed air. Do not forget to clean a rigid brush oil openings. Then wash out them solvent.

When using compressed air put on goggles!

2. Check radical and conrod necks of a bent shaft for existence of zadir, cavities, cracks and signs of uneven wear. Examine all surface of a shaft on existence of cracks and other damages. For identification of the hidden cracks it is necessary to resort to magnetic powder defectoscopy, - give a shaft to a workshop of car service.
3. Carry out on necks by edge of a copper coin, - if on a surface there are copper traces, therefore, its roughness exceeds admissible and it is necessary to give a shaft to a pro-point.
4. Remove with a grinding stone, a file or a scraper agnails from edges of oil openings.
5. Check the remained shaft surfaces for existence of cracks and other mechanical damages. The razed cracks come to light in the course of conducting special check in the conditions of car repair shop.
6. Measure by a micrometer diameters of radical and conrod necks of a shaft. You perform measurement of diameter of each neck in several points on length and perimeter that will allow to estimate the size of its conicity and ovality which should not exceed the limit of admissible ranges (see Specifications). It is necessary to estimate also the size of a beating of a bent shaft, - pair of V-shaped blocks and the DTI measuring instrument will be required. In the absence of necessary stock ask for the help specialists of car service.
7. In case wear/conicity/ovality of necks exceeds admissible size, or mechanical damages of surfaces take place, the bent shaft should be given to a pro-point. After a pro-point of a shaft it is necessary to pick up new inserts of radical and/or conrod bearings of the corresponding repair size.
8. Check a condition of omental necks on both pins of a bent shaft. Existence of the developed flutes, agnails or zadir will lead to an exit of new epiploons out of operation in the near future. In certain cases pins can be restored by a pro-point and a napressovka on them special thin-walled plugs. If such recovery repair is not possible, replace a shaft.
9. Check a condition of inserts of radical and conrod bearings.


Conrod and piston assemblies

 PERFORMANCE ORDER

1. Previously conrod and piston assemblies have to be carefully cleared. Rings need to be removed from pistons.

 Piston rings are subject to replacement without fail.

2. By means of special adaptation remove rings from pistons, - try not to damage walls of the last incidentally.
3. Scratch out traces of coal deposits from the bottoms of pistons. After removal of the main layer of deposits smooth out a surface manually a wire brush or a piece of a fine-grained emery paper.

 Do not use for cleaning made of soft material and pistons easily subject to an erosion wire nozzles to the electric drill at all!

4. By means of special adaptation clean flutes under installation of rings on pistons. It is alternatively possible to use a fragment of an old piston ring for this purpose, however be careful, - do not scratch a bottom and walls of a flute and do not cut fingers.
5. Having removed the main deposits, wash out conrod assemblies by solvent and carefully dry them, whenever possible with use of compressed air.

 When using compressed air do not forget to put on goggles! Check passability of maslovozvratny openings in back walls of flutes under installation of piston rings, and also oil openings in the lower heads of rods.

6. If walls of pistons and a mirror of cylinders are not damaged and excessively are not worn-out, and the block of the engine was not pierced and not replaced, need for replacement of pistons also disappears. Normal wear of pistons is shown in the form of vertical traces of development on a persistent surface and a small weak point of landing of the top compression ring in the flute. Do not forget that replacement of piston rings is made without fail, regardless of their state.
7. Attentively examine each of pistons on existence of cracks in a skirt, around ledges under installation of piston fingers and around an arrangement of rings.
8. Check persistent surfaces of a skirt of the piston for existence of scratches, the bottom - on existence of through openings and progar on edge. Presence of scratches on a skirt can be regarded as a sign of long overheats of the engine, or too early ignition of air-fuel mix, - check serviceability of functioning of the cooling system. Progara at the edges of the bottom are the certificate of a detonation. Anyway, the cause of the revealed violation has to be removed in order to avoid a recurrence. Also leak of the soaked-up air, the wrong configuration of air-fuel mix, violation of installation of a corner of an advancing of ignition, the wrong functioning of systems of ignition and EGR can act as the possible reasons of education listed defects.
9. Pointed corrosion of pistons in the form of cavities speaks about hit in combustion chambers and/or a case of the engine of cooling liquid. Besides, take care that the cause of internal leaks was removed.

10. Estimate the size of a side gap of landing of piston rings in the flutes for what enclose a new ring outside in the flute on the piston and the probe of lezviyny type measure the remaining gap. Repeat measurement in two-three points on flute perimeter. You watch to mixing compression rings (top differs from the second). If the size of a gap exceeds admissible value (see Specifications), pistons are subject to replacement.

11. Define a landing gap of pistons in the cylinders, subtract from diameters of cylinders (see above) diameters of the corresponding pistons. Measurement of diameter of the piston is performed on a persistent surface at an angle 90 ° to an axis of a piston finger and on the set removal from the bottom. If the landing gap of the piston in the cylinder exceeds admissible value (see Specifications), the block should be given to a pro-point with a selection of new pistons and piston rings of repair diameter.

12. Having tried to rotate components in opposite directions, estimate density of landing of pistons on rods. Existence of a little noticeable side play speaks about excessive wear of a joint. For correction of a situation it is necessary to deliver conrod and piston assemblies in a workshop of car service where necessary recovery repair and replacement of fingers will be made.
13. Implementation of the procedure of removal of pistons from rods (in case of such need) has also to be entrusted to specialists of car service. In parallel, rods can be checked for existence of signs of a bend, twisting and other deformations with use of the special diagnostic equipment.

Needlessly it is not necessary to remove pistons from rods.

14. Check rods for existence of cracks and other mechanical damages. Temporarily uncover the lower heads, take inserts of old bearings, wipe beds in covers and heads and check them for existence of agnails, zadir and roughnesses. Having finished check, enclose inserts into place, establish covers on the lower heads of rods, and by hand tighten fixing bolts.

If the engine is under repair for the purpose of elimination of knock of fingers, replace conrod assemblies.


Bearings

Check of a state

 PERFORMANCE ORDER

1. In spite of the fact that bearings of a bent shaft in the course of capital repairs of the engine are subject to replacement without fail, old inserts should be kept for the purpose of attentive studying of their state which results can give a lot of useful information about the general condition of the engine. On an illustration examples of typical defects of inserts of bearings are given.

2. An exit of bearings out of operation can occur owing to a lack of lubricant, hit of particles of dirt, overloads of the engine and development of corrosion. Regardless of the nature of defects, the cause of damage of inserts has to be removed in the course of performance of capital repairs of the engine in order to avoid a recurrence.
3. For survey take inserts of bearings from the beds in the engine block / the lower heads of rods and radical/conrod covers and spread out them as installation on a pure working surface. Organization of placement of inserts will allow to tie the nature of the revealed defects to a condition of the corresponding necks of a shaft.
4. Dirt and foreign particles get to the engine in various ways. They can be left in the block in the course of assembly of the unit, or get via filters or system of ventilation of a case. All particles getting to motive oil, finally, sooner or later, appear in bearings. Often the metal sawdust which is formed in the course of normal operation of internal components of the engine takes root into soft material of inserts. The probability of presence at bearings of traces of an abrasive is high, in particular, when due attention was not paid to cleaning of the block after completion of recovery repair of the engine. Regardless of a way which foreign particles get to the engine as a result they with high degree of probability are introduced in a soft surface of inserts of bearings of a bent shaft and easily come to light at visual survey of the last. Large particles usually are not late in inserts, but leave on their surface and the surface of necks of a shaft noticeable traces in the form of scratches, cavities and zadir. The best guarantee from such troubles is the responsible attitude to cleaning of components after completion of capital repairs of the engine and care of respect for purity at assembly. Frequent regular change of motive oil also allows to prolong service life of bearings significantly.
5. Oil starvation can be a consequence of several various, but often interconnected phenomena. So, the overheat of the engine leads to fluidifying of engine oil and its replacement from working gaps of bearings. The lack of lubricant of bearings can speak the excessive size of working gaps, and also usual leaks (internal or external). Continuous excess of turns of the engine is often found reason of replacement of oil from gaps of bearings. The violation of passability of maslotok (which is usually connected with the wrong combination of openings at installation of components) also leads to reduction of supply of lubricant to bearings. Typical result of oil starvation is the full or local wipe / выщербливание a blanket of inserts from a metal substrate. At the same time working temperature can rise to such level that the substrate as a result of an overheat gets a bluish shade.
6. The driving manner also peculiar to the owner of the car has significant effect on service life of bearings. The movement with a small speed on an overgear leads to the considerable overloads of bearings which are followed by replacement of an oil film from their working gaps. Such overloads lead to increase in plasticity of inserts and emergence of cracks in a blanket (fatigue deformation). At the same time surface material begins to crumble and separate from a steel substrate. Operation of the car in a city cycle (frequent trips on short distances) leads to development of corrosion of bearings because the insufficient warming up of the engine involves loss of condensate and release of chemically aggressive gases. These products accumulate in motive oil, forming slags and acids. At hit of such oil in bearings aggressive substances promote development of corrosion of inserts.
7. The wrong installation of inserts in the course of assembly of the engine can also be the reason of their bystry destruction. Too hard landing does not provide the required size of a working gap of bearings that leads to their oil starvation. Under inserts (in the course of their installation) foreign particles formation of eminences from which blanket is quickly wiped is result of hit.
8. Balancing and auxiliary shaft can be equipped with ring bearings which performance of replacement should be charged to specialists of car service.


Honingovaniye of mirrors of cylinders

 PERFORMANCE ORDER

1. Before assembly of the engine the honingovaniye of mirrors of cylinders for the purpose of achievement of the correct landing to them of piston rings providing due tightness of combustion chambers is without fail carried out.

In the absence of near at hand necessary tools or unwillingness to independently carry out a honingovaniye, work for quite moderate payment can be charged to experts of a workshop of car service.

2. Before starting a honingovaniye, establish to the place of a cover of radical bearings / the connecting bridge (without inserts) and tighten fixing bolts with the required effort.
3. Two types of khans for processing of mirrors of cylinders are issued: хон like "the bottle brush" and, more traditional, superficial хон in the form of a nozzle with the sprung grinding stones. Both tools provide necessary quality of processing of mirrors of cylinders though use of the first is more preferable to the inexperienced mechanic. Also enough rags, special honingovochny or just liquid lubricating oil, and also the electric drill as the drive for honingovochny nozzles will be required. Act in the following order:
a) Clamp хон in an electric drill cartridge, reduce the sprung grinding stones / rods of the brush of a nozzle and fill the last in the cylinder.

Do not forget to put on goggles or a front guard!

b) Plentifully moisten a mirror of the processed cylinder with oil, include a drill and begin to make a nozzle back and forth motions in the cylinder. Speed of vertical movement of a hon has to provide drawing on a surface of a mirror of the cylinder of a mesh pattern with the angle of crossing of the parties of a cell about 60 °. Do not feel sorry for oil and try not to remove more material from a surface of walls of the cylinder, than it is really necessary for achievement of the required result.

Manufacturers of piston rings can impose own requirements to the angle of crossing of the parties of a cell of a mesh pattern, - attentively study the instruction on packing of a remnabor.

c) Do not take хон from the cylinder to a full stop of a drill! Continue to make back and forth motions by a nozzle until it does not stop rotating. After a stop of a drill squeeze grinding stones and take хон from the cylinder. When using of the khan like "bottle brush" wait for a full stop of a drill, then take a nozzle, continuing to rotate manually a cartridge in the normal direction.
d) Wipe with rags a mirror of the cylinder and you pass to a following honingovaniye.

4. Upon completion of processing, use a file for removal of facets from the upper edges of cylinders, - this processing is made with the purpose there were no difficulties with gas station in cylinders of pistons with the rings which are put on them. Observe extreme care, - do not scratch a file a cylinder mirror.
5. In conclusion all block has to be washed carefully out by warm solution of soap water.

Cylinders can be considered washed out when after carrying out on a mirror the gray raid does not remain the white rags moistened with oil on it. Do not forget to clean a cylindrical brush all oil openings and channels, then wash out the block a water stream under a pressure.

6. After washing carefully dry the block and oil the pierced surfaces for protection them from corrosion. Prior to assembly of the engine wrap the block in a pure plastic bag.


Assembly

 PERFORMANCE ORDER

1. First of all it is necessary to prepare a workplace, having paid special attention to purity of surfaces and existence of sufficient free space. Take care of the equipment of the space for warehousing of the components which are subject to installation. All established details also have to be very carefully cleaned and dried up.
2. Fix the block of cylinders on the assembly block and once again carefully wash out it solution of soap water, paying special attention to a clearing of maslotok and water galleries. Dry the block, whenever possible with use of compressed air, then spray it anticorrosive solution of the WD-40® type. Wipe mirrors of cylinders pure неворсящейся with rags.
3. Establish into place release traffic jams and caps of oil galleries.
4. Clean a bent shaft not less carefully and start its installation on the engine (see below).


Engine assembly order

 PERFORMANCE ORDER

1. Before starting assembly of the engine, make sure available all necessary details, materials and tools to which number the following belongs:

a) Standard set of the metalwork tool;
b) A dynamometer key with the drive on 1/2 inches;
c) The tool for putting on of piston rings;
d) The tool for a staving of piston rings;
e) Short pieces of a fuel hose for putting on on hairpins of covers of conrod bearings;
f) Measuring Plastigage set;
g) Set of probes of lezviyny type;
h) A file with small tooth;
i) Fresh motive oil;
j) Assembly motive, or molibdensoderzhashchy lubricant;
k) Pro-masonry sealant;
l) Sealant for fixing of threaded connections.
2. For saving of time and minimization of volume of the arising problems you make assembly of the engine in the following order:

Four-cylinder engines

a) Piston rings;
b) Bent shaft and radical bearings;
c) Conrod and piston assemblies;
d) Back epiploon of a bent shaft;
e) Balancing assembly of the engine;
f) A head of cylinders with pushers of valves;
g) Camshafts;
h) Balancing shaft with asterisks;
i) Gas-distributing chain;
j) Oil pump;
k) Maslozabornik with the mesh filter;
l) Case pallet;
m) Inlet pipeline and final collector;
n) Cover of a head of cylinders;
o) Flywheel / driving disk.

V6 engines

a) Piston rings;
b) Bent shaft and radical bearings;
c) Conrod and piston assemblies;
d) A back epiploon of a bent shaft with the holder;
e) Oil pump;
f) Case pallet;
g) Heads of cylinders;
h) Camshafts and pushers of valves;
i) A gas-distributing belt with cogwheels;
j) GRM drive covers;
k) Covers of heads of cylinders;
l) Inlet pipeline and final collectors;
m) Flywheel / driving disk.


Installation of piston rings

 PERFORMANCE ORDER

1. Before installation of new piston rings it is necessary to check gaps in their locks. It is meant that side gaps of landing of rings in flutes of pistons are already checked and meet accepted standards (see above).
2. Spread out conrod and piston assemblies with sets of rings on a working surface of a workbench. From this point each set of rings will "be rigidly tied" to the piston. Now it is possible to start measurement of gaps in locks of rings.

3. Fill top (No. 1) a compression ring in the first cylinder of the engine and level it perpendicularly, having pushed the piston bottom down. The ring has to appear around the lower bound of the working course of rings in the cylinder.

4. Determine gap size in the ring lock by means of the probe of the lezviyny Probe Edge(s) type has to slip hardly in the lock. Compare result of measurement to requirements of Specifications. If the size of a gap exceeds the limit of admissible range in this or that party before taking any actions for correction of a situation (see below), once again make sure that did not mix a ring.

5. If the gap is too small, it can be expanded by boring with a file with small tooth (previously study instructions to a set, - not all rings are allowed to be processed a file) Clamp a rectangular file in a vice, then put on a ring the lock a file so that the end of the last appeared in a circle. Slowly pull a ring on yourself, removing excess of metal from its end faces in the lock. Having reached the end of a file, remove a ring, again check a gap, in case of need repeat the procedure.

Do not push a ring from yourself at all on a file as at the same time edges of the lock will meet, and the risk of destruction of metal is high.

6. The excessive size of a gap is not crime if does not exceed value of 0.51 mm. Once again make sure that the acquired sets of rings meet according to the characteristics requirements of the engine of your car.
7. Repeat the procedure for the remained rings (the second compression and oil scraper) the piston of the first cylinder, then for rings of all other pistons. Remember that now each set of rings "is unambiguously tied" to the piston on which has to be established.
8. Having checked and having modified properly gaps in locks of rings, it is possible to start their putting on on the pistons.
9. The first on the piston the oil scraper (lower) ring puts on. The oil scraper ring consists of three separate sections. At first fill a spring dilator in the lower flute of the piston. If the dilator is equipped with an antirotational uvula, track that the last got to reciprocal drilling in a piston flute. Now establish the lower working section of a ring in a flute. In order to avoid casual damage of working sections of an oil scraper ring do not use any tool for their installation, - just bring to a flute under/over a dilator at first one end of section, densely press it a finger and, moving on ring perimeter, fill the rest. In the last turn the top working section of a ring is established.

10. Having put all three components of an oil scraper ring in the lower flute of the piston, check freedom of rotation (sliding in a flute) the top and lower working sections.
11. The second (lower) compression ring is established by the following. The ring has to be established by marking up (to the piston bottom).

Strictly follow instructions of manufacturers of rings which are usually printed on packing of a set. Do not mix the second compression ring with first (top) - they have various cross section.


12. Having used a special dilator and having tracked that the ring was turned by marking up, put him in an average flute on the piston. Try not to part the ring lock more than it is really necessary for its free putting on on the piston.

13. Working in a similar manner, establish the first (top) compression ring (marking up). Try not to mix the top ring with the second.
14. Serially complete with rings all remained pistons.


Installation of a bent shaft

 PERFORMANCE ORDER

1. Installation of a bent shaft is the first step of the procedure actually of assembly of the engine. It is meant that at this stage the block of the engine and actually a shaft are already properly cleaned, checked and subjected to necessary recovery repair.
2. Turn the engine upside down.
3. Give fixing bolts, uncover radical bearings / assembly of covers. Spread out covers on a workbench as installation on the engine.
4. If did not do it yet, take from the beds in the block and covers old inserts of radical bearings. Wipe beds pure неворсящейся with rags - they have to be perfectly pure.


Check of working gaps of radical bearings

 PERFORMANCE ORDER

Try not to touch surfaces of new inserts barehanded in order to avoid undesirable contact of bearings with always with the traces of oil and chemically aggressive substances which are present at fingers.

1. Wipe backs of new inserts of radical bearings and enclose the halves equipped with an oil flute in the beds in the block. Enclose the remained halves of inserts in the corresponding covers of bearings. Track that uvulas of inserts entered reciprocal landing grooves in beds of the block and covers. Oil openings in the block have also to correctly are combined with openings in inserts.

You make by no means attempts to begin to knock an insert resistant to installation in the bed the hammer. Grease with nothing bearings at this stage!

2. Wipe the surfaces of bearings in the block and radical necks of a bent shaft pure неворсящейся with rags. Check passability of oil openings of a shaft, in case of need clean them. Any foreign particles which are contained in maslotoka, eventually, inevitably get to bearings.
3. Accurately lay carefully wiped bent shaft in radical bearings of the block.
4. Before finalizing a shaft, it is necessary to check sizes of working gaps in its radical bearings.

5. Cut the calibrated plastic wire from the measuring Plastigage set pieces, length width of inserts are slightly shorter, and lay on one piece of a wire along each of radical necks of a shaft, parallel to their axis.

6. Wipe surfaces of inserts in covers and establish the last on the regular places. Try not to shift the pieces of the calibrated wire laid along shaft necks. Slightly oil a carving of fixing bolts and screw them, having recorded covers.
7. In stages evenly tighten bolts of fastening of covers with the required effort.

Do not allow a shaft provorachivaniye in the course of tightening of fixture!

8. Turn out bolts and carefully uncover radical bearings. Put uncovered as an arrangement them on the engine. Try not to damage the flattened-out calibrated wire and do not turn a shaft. If any of covers does not give in to removal, for release accurately tap it the hammer with soft brisk.

9. Determine the size of working gaps of bearings by width of the flattened-out threads measured on the scale applied on packing of the Plastigage set. Compare results of measurements to requirements of Specifications.

10. If the size of a gap goes beyond admissible limits, perhaps, inserts not of that standard size were established. Before looking for new inserts, make sure that under enclosed at this stage dirt or oil did not get. If the calibrated wire is flattened out since one end more than from another, it demonstrates existence of conicity of a neck.
11. Carefully remove the calibrated wire from necks, having scratched out all its traces some not too strong tool (for example, edge of an old credit card). As a last resort, it is possible to use own nail, - the main thing that on a surface of necks/inserts there is no scratch left and zadir.


Final installation of a bent shaft

 PERFORMANCE ORDER

1. Carefully take a bent shaft from the engine. Wipe the surfaces of bearings in the block and evenly grease them with a thin layer of molibdensoderzhashchy or assembly motive lubricant. Do not forget to grease persistent washers also.

Try not to allow hits of lubricant on backs of inserts!

2. Make sure of absoluteness of purity of necks of a bent shaft, then grease (the same lubricant or pure motive oil) the surfaces of pins contacting to epiploons.
3. Establish a back epiploon of a shaft.
4. Wipe and grease surfaces of inserts in the block, then lay a shaft on the regular place. Establish a cover of the back bearing, then all other, except persistent. Tighten fixture of covers with the required effort.
5. Establish a cover of the persistent bearing screw bolts of its fastening and tighten them manually.
6. Shift a shaft forward, having pressed it to a persistent surface of the top insert of the bearing. Holding a shaft not movably, wring out a cover of the persistent bearing for the purpose of combination of persistent surfaces of both inserts back.
7. Wringing out a shaft forward, tighten boats of fastening of a cover with the required effort.
8. For measurement of size of an axial side play of a bent shaft fix the dial measuring instrument on the block, having pressed its plunger to a face surface of a forward pin of a shaft.
9. Carefully wring out a shaft back against the stop and, holding it in the wrung-out situation, nullify the measuring instrument.
10. Shift a shaft forward until the end of its course and consider instrument reading.
11. If the result of measurements goes beyond admissible value (see Specifications), replace inserts of the persistent bearing and repeat check. In case of need give a shaft for check to a workshop of car service.


Installation of conrod and piston assemblies and check of size of working gaps in conrod bearings of a bent shaft

Preparation

 PERFORMANCE ORDER

1. Before installation of conrod and piston assemblies of a wall of cylinders have to be carefully wiped, from their upper edges traces of step wear are completely removed and it is chamfered. It is meant that the bent shaft is already installed on the regular place in the block.
2. Uncover the lower head of conrod assembly of the first cylinder (make sure available the factory or put in the course of dismantle tags). Take inserts of the old bearing from a head of a rod and its cover and carefully wipe their beds pure неворсящейся with rags.


Check of a working gap of the conrod bearing

 PERFORMANCE ORDER

Try not to touch surfaces of new inserts barehanded in order to avoid undesirable contact of bearings with always with the traces of oil and chemically aggressive substances which are present at fingers.


1. Wipe a back of a new top insert and put it to bed the bearing in a rod head. Track combination of oil openings and that the directing uvula of an insert got to a reciprocal flute in a rod. At all not to a zastukivayta an insert in a bed the hammer. Grease with nothing the bearing at this stage.

2. Wipe a back of the second insert and lay it in a cover of the lower head of a rod. Again track that the uvula got to a reciprocal groove. Do not apply any lubricant - extremely important that the interfaced surfaces of the bearing and a rod remained absolutely pure and dry.

3. Arrange piston rings locks as it is shown on an illustration.

3. Put pieces of a fuel hose on bolts of fastening of a cover of the bearing.
4. Grease the piston and piston rings with pure motive oil. Put on the piston a tool mandrel for a staving of rings. Leave a skirt of the piston acting from a tool mandrel approximately on 6 mm for free gas station it in the cylinder. Rings have to be pressed out aflush with the forming surface of the piston.
5. Turn a bent shaft so that the neck of the first crank fell into NMT state. Oil motive a mirror of the first cylinder.
6. Having developed assembly by marking on the piston bottom on the engine forward, accurately fill a rod in the first cylinder of the block. Enter a piston skirt into the cylinder, having densely pressed to the surface of the block bottom edge of a mandrel of the tool for a staving of rings.
7. Tap the upper edge of a mandrel for a guarantee of density of pressing it to the block on all perimeter of bottom edge.

8. Accurately tapping on the bottom with the wooden handle of the hammer, enter fill the piston in the cylinder, at the same time directing the lower head of a rod to a neck of the corresponding crank of a bent shaft. Piston rings can unexpectedly jump out from under a tool mandrel therefore constantly you watch pressing density to its block. Act without hurrying, at emergence of the slightest resistance immediately stop a piston zastukivaniye. Find out the reason of jamming and eliminate it.

Do not make at all attempts to push the piston in the cylinder by force, - it can lead to its mechanical damage or destruction of piston rings!

9. After introduction of conrod and piston assembly to the engine, before final installation of a cover of the lower head of a rod, it is necessary to check a working gap of the conrod bearing of a bent shaft.

10. Cut off a piece of the calibrated plastic wire from the measuring Plastigage set, length width of an insert of the conrod bearing are slightly shorter, and lay it along the first conrod neck of a bent shaft, parallel to an axis of the last.

11. Wipe the surface of the bearing in a cover of the lower head of a rod and establish a cover on a rod. Track that the tag on a cover was turned in the same party, as a tag on a rod.
12. Slightly grease the lower end faces of heads of fixing bolts with pure motive oil, screw bolts and in three stages tighten them with the required effort.

In order to avoid jamming of a key, use a thin-walled face head. At emergence of signs of jamming of a key between a nut and a rod, slightly raise a head and continue tightening. Do not allow a provorachivaniye of a bent shaft in the course of implementation of all procedure.

13. Give fixture and carefully uncover a rod. Try not to damage the flattened-out piece of the calibrated wire.

14. Determine the size of a working gap in the bearing by width of the flattened-out wire measured on the scale printed on packing to the Plastigage set. Compare result of measurement to requirements of Specifications.

15. If the size of a gap exceeds the limit of admissible range before looking for inserts of other standard size, check whether got under backs enclosed in beds in a rod and a cover of inserts dirt/oil. Once again measure diameter of a neck of a shaft. The wire flattening since one end more than from another speaks about existence of conicity of a neck.
Final installation of conrod and piston assembly
16. Carefully scratch out a nail or edge of an old credit card all traces of the calibrated wire from the surface of a neck and/or the bearing.
17. Make sure of absoluteness of purity of both bearing surfaces, then evenly grease them with a thin layer of molibdensoderzhashchy or assembly motive lubricant. For ensuring access to a surface of the top insert it is necessary to push a little the piston in the cylinder, - do not forget to put on rod cover bolts protective hoses in order to avoid damage of a surface of a neck of a shaft. Try not to allow vyskakivaniye from the cylinder of piston rings.
18. Return a rod into place, having carefully put on it the lower head a neck of the crank, remove protective hoses from bolts, establish a cover, and in three stages tighten fixing nuts with the required effort.

Track correctness of combination of tags on a cover of a rod and its lower head.

19. Repeat all procedure for the remained conrod and piston assemblies.
20. Do not lose sight of the next important points:

a) You watch that on backs of inserts and their bed in rods and covers dirt did not get;
b) You watch that each assembly was established in the cylinder (even in case of installation of new components as gaps of piston rings were adjusted to concrete cylinders);
c) Pistons have to settle down marking on the bottom on the engine forward (towards the GRM drive);
d) Do not forget to oil before installation of assemblies motive mirrors of cylinders;
e) Do not forget to grease before final installation of covers bearings (after check of working gaps in the last).
21. Having finished installation of conrod and piston assemblies, check freedom of rotation of a bent shaft, having turned it several times manually.
22. In conclusion it is necessary to double-check an axial side play of a bent shaft (see above).
23. Compare results of measurement of an axial side play to requirements of Specifications. If the side play was normal before dismantling of the engine and old conrod and piston assemblies are used, no surprises should be. In case of a side play size exit out of admissible limits after replacement of rods, the last need to be removed from the engine and to give to a workshop of car service for the corresponding machining.