Features of the engine device Longitudinal and cross section of the engine Engine Mount 1 - support casing; 2 – a support of a forward suspension bracket of the engine; 3 – a flange of the block of cylinders;...
Removal and installation of the engine 1. Put the car on a lift or over a viewing ditch, set the stops under the front wheels and hang the rear axle on one or both sides. 2. Remove the hood, disconnect the wires from...
Engine disassembly Removing the flywheel 1 key; 2 - flywheel; 3 – a bolt of fastening of a flywheel; 4 - washer; 5 - retainer A.60330 / R to keep the flywheel from turning; 6 - front cover of the...
Engine Assembly Labels on the main bearing caps and conditional number of the cylinder block Supports are counted from the front of the engine. Cylinder Head Bolt Tightening Order Procedure for...
Bench tests of the engine The overhauled engine is bench tested (running-in) without load for the following cycle: 820–900 min -1 - 2 minutes; 1000 min -1 - 3 min; 1500 min -1 – 4 min; 2000 min -1 - 5...
Checking the engine on a car 1. Install the engine on the car, carefully check the installation. 2. Let the engine run for a while, then check: is there any leakage of coolant and fuel in the pipe...
Features of the cylinder block device The main dimensions of the cylinder block The cylinder block is cast from special low-alloy ductile iron. Cylinders are bored directly in the block and do not have insert sleeves....
General cleaning and inspection of the cylinder block 1. Wash the cylinder block thoroughly and inspect the oil passages. 2. Blow and dry the cylinder block with compressed air, especially the oil passages. 3. Inspect the cylinder...
Checking the tightness of the cylinder block 1. If there is a suspicion that coolant has entered the crankcase, then check the tightness of the cylinder block on a special stand. To do this, after plugging the holes in the...
Cylinders — Condition Check Measuring cylinders with a bore gauge 1 - caliper; 2 - setting the inside gauge to zero according to caliber A.96137 Cylinder measurement scheme A and B are the directions of...
The plane of the connector with the cylinder head Examination There may be deformations on the plane of the cylinder block connector with the head. Therefore, check the plane of the connector using a ruler and a set of probes....
Features of the device of pistons and connecting rods The main dimensions of the piston, connecting rod, piston pin and piston rings Piston The piston is made of aluminum alloy and coated with a layer of tin for improved run-in. The...
Pressing out the piston pin 1. It is necessary to remove the finger on the press, using the mandrel A.60308 and a support with a cylindrical recess into which the piston fits. Before pressing out the pin,...
Cleaning pistons and connecting rods 1. Remove carbon deposits from the piston crown and piston ring grooves, and remove any deposits from the piston and connecting rod oil passages. 2. Check carefully for damage on...
Piston to cylinder selection Estimated clearance between piston and cylinder (for new parts) is 0.05–0.07 mm. It is determined by measuring the cylinders and pistons and is ensured by installing pistons of...
Checking clearance between piston and pin The pin is pressed into the upper head of the connecting rod with an interference fit and rotates freely in the piston bosses. Attention! According to the outer diameter, the...
Checking clearances between piston grooves and rings Height clearance 1. Check the height gap between the grooves and the rings by inserting the ring into the corresponding groove (1 - piston ring, 2 - piston, 3 - set of probes). 2....
Piston mass control Scheme of removing metal from the piston to adjust its mass The arrows indicate the places where the metal can be removed. In terms of mass, the pistons of one engine should not...
Assembling the connecting rod and piston group 1. Since the pin is inserted into the upper head of the connecting rod with an interference fit, heat the connecting rod to 240°C to expand its head. To do this, place the...
Checking the pin fit Piston-pin-connecting rod assembly assembled on tool A.95615 for pin extrusion test 1 - indicator pin in contact with the end of the rod; 2 - the head of the rod in contact with...
Features of the device of the crankshaft and flywheel The main dimensions of the connecting rod and main journals of the crankshaft and their fillets Crankshaft The crankshaft is five-bearing, cast iron. The surfaces of the shaft...
Cleaning the channels of the lubrication system 1. To clean, remove the channel plugs. Then drive the sockets of the plugs with a countersink A.94016/10, put on the spindle A.94016, thoroughly rinse the channels with gasoline...
Main and connecting rod journals Permissible runout of the main surfaces of the crankshaft Examination 1. Install the crankshaft on two prisms (see fig. Permissible runout of the main surfaces of the crankshaft)...
Main bearing shells Do not perform any adjustment operations on the inserts. If there are scuffs, risks or deviations, replace the liners. The gap between the crankshaft journals and the liners can...
Flywheel — checking condition Flywheel 1 - mounting surface to the crankshaft flange; 2 – a surface of fastening of coupling; 3 – a basic surface of a conducted disk of coupling 1. Check the condition of the...
Checking the axial clearance of the crankshaft Checking the axial clearance of the crankshaft The axial movement of the crankshaft is limited by two thrust half rings mounted on both sides of the rear main bearing. A...
Features of the cylinder head and valves The main dimensions of the cylinder head, valves and guide bushings Cylinder head - common to four cylinders, cast aluminum alloy. It is unified, i.e. same for engines 2101, 21011...
Removal and installation on the car of a head of cylinders The cylinder head is removed from the engine on the car if the engine itself does not need to be removed to fix the problem, or if it is only necessary to remove carbon deposits...
Dismantling and assembly of a head of cylinders Valve train parts 1 - valve; 2 - retaining ring; 3 - guide sleeve; 4 - oil deflector cap; 5 - support washer of the outer spring; 6 - support washer of the internal spring; 7 -...
Cleaning the cylinder head 1. Install the head on the stand A.60353. 2. Remove carbon deposits from the combustion chambers and from the surface of the exhaust channels with a metal brush driven by an...
Checking and grinding valve seats Intake valve seat profile I - new seat; II - seat after repair Exhaust valve seat profile I - new seat; II - seat after repair The shape of the chamfers of the valve seats is...
Valves — cleaning and checking 1. Remove carbon deposits from valves. Check if the rod is deformed and if there are cracks on the plate; replace valve if damaged. 2. Check whether the working bevel is too worn...
Valve guide bushings 1. Check the clearance between the valve guides and the valve stem by measuring the diameter of the valve and the valve guide bore. Mounting clearance for new bushings:...
Oil deflector caps for guide bushings At oil seals, delamination of rubber from fittings, cracks and excessive wear of the working edge are not allowed. When repairing the engine, it is recommended to always replace...
Valve levers — check 1. Check the condition of the working surfaces of the lever mating with the valve stem, with the camshaft cam and with the spherical end of the adjusting bolt. If nicks or marks...
Valve springs — check Basic data for checking the outer valve spring Basic data for checking the internal valve spring Lever Spring Test Diagram A - the size in the free state; B - dimension under load...
Cylinder head gasket — check The gasket surfaces must not be damaged. They should be smooth, without dents, cracks, swelling and kinks. Detachment of the lining material from the reinforcement is not allowed....
Checking the tightness of the cylinder head Checking the tightness of the cylinder head using tool A.60334 1, 2, 4 - plugs; 3 - fixture plate; 5 - flange with water supply fitting 1. For a hydraulic leak test of the...
Features of the camshaft device The main dimensions of the camshaft and bores in the camshaft bearing housing Cylinder head section by exhaust valve 1 – a head of cylinders; 2 - exhaust valve; 3 - oil deflector...
Adjusting the gap between the levers and camshaft cams 1. Adjust the gaps on a cold engine, after adjusting the chain tension. After adjustment, the gap should be 0.14–0.17 mm. 2. Turn the crankshaft clockwise until the mark on the...
Camshaft chain tension adjustment 1. Loosen cap nut 1 (see fig. Chain tensioner section ) tensioner. In this case, the rod 3 is released and the chain is tensioned by the shoe 7 (see fig. Diagram of the camshaft...
Checking the camshaft On the bearing journals of the camshaft, scuffing, nicks, scratches, aluminum enveloping from bearing housings are not allowed. On the working surfaces of the cams, wear of more...
Checking the camshaft bearing housing 1. Wash and clean the camshaft bearing housing and oil passages. 2. Check the diameter of the holes in the supports. If the clearance between the camshaft journals and bearings...
Camshaft chain tensioner — disassembly and assembly Basic data for checking the tensioner spring Disassembly and assembly 1. To disassemble the chain tensioner, remove the cap locking nut 1 (see fig. Chain tensioner section ),...