Contents: Examination ↓ Cylinder repair ↓
Examination
Thoroughly wash the cylinder block and clean the oil passages. Blow and dry the cylinder block with compressed air, then inspect it. If there are cracks in the bearings or in other places of the cylinder block, it must be replaced.
If there is a suspicion of coolant getting into the crankcase, then check the tightness of the cylinder block on a special stand. To do this, having plugged the openings of the cooling jacket of the cylinder block, pump water at room temperature into it under a pressure of 3 kgf/cm². There should be no water leakage from the cylinder block within 2 minutes.
If oil is observed getting into the coolant, then without completely disassembling the engine, check for cracks in the cylinder block in the oil channel areas. To do this, drain the coolant, remove the cylinder head, fill the cooling jacket of the cylinder block with water and supply compressed air to the vertical oil channel of the cylinder block, which is located near the first bolt securing the cylinder head (see the bolt numbers on fig. 12). If air bubbles appear in the cooling jacket, replace the cylinder block.
Check the plane of the cylinder block joint with the head using a ruler and a set of feeler gauges. The ruler is installed along the diagonals of the plane and in the middle in the longitudinal direction and across. If the warping exceeds 0.1 mm, the cylinder block is replaced.
Cylinder repair
Check whether the cylinder wear exceeds the maximum permissible value of 0.15 mm. The cylinder diameter is measured with a bore gauge in four zones at a distance of 5, 15, 45 and 80 mm from the upper plane of the cylinder block in both the longitudinal and transverse directions of the engine. To set the bore gauge to zero, use a gauge type 67.8125.9501 for the 2105 engine or gauge A.96137 for the 2101 and 2103 engines. In the upper zone (at a distance of 5 mm from the upper plane) the cylinders are practically not worn out. Therefore, the difference in measurements in the upper and other belts can be used to judge the wear of the cylinders.
If the maximum wear of the cylinders exceeds 0.15 mm, then the cylinders are bored to the nearest repair size of the pistons (increased by 0.4 or 0.8 mm), leaving an allowance of 0.03 mm for honing. Then the cylinders are honed, maintaining a diameter such that when installing the selected repair piston, the gap between it and the cylinder is 0.06-0.08 mm for the 2105 engine or 0.05-0.07 mm for the 2101 and 2103 engines.
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