2.1. Engine of fashion. 331

Possible malfunctions of the engine of fashion. 331, their reasons and ways of elimination

Features of a design
The engine is line, verkhneklapanny, four-cylinder, four-cycle, carburetor.

Fig. 2.1. Longitudinal section of the engine of fashion. 331: 1 – the asterisk conducted the camshaft; 2 – block head cover; 3 – laying of a cover of a head of the block; 4 – block head; 5 – sleeve of cylinders; 6 – coupling case; 7 – casing; 8 – connecting plate; 9 – coupling switching off bearing; 10 – press diaphragm spring; 11 – press disk; 12 – flywheel; 13 – the conducted clutch plate; 14 – insert of the radical bearing; 15 – bent shaft; 16 – cover of the radical bearing; 17 – insert of the conrod bearing; 18 – oil pump; 19 – oil filter; 20 – asterisk leading chain transfer; 21 – drive of the oil pump; 22 – ratchet; 23 – epiploon of a bent shaft; 24 – block of cylinders; 25 – rod; 26 – finger piston; 27 – piston; 28 – ignition distributor; 29 – laying of a head of the block of cylinders; 30 – camshaft drive chain


Fig. 2.2. Cross-section of the engine of fashion. 331: 1 – block of cylinders; 2 – knot of the right suspension bracket; 3 – final collector; 4 – saddle of the final valve; 5 – final valve; 6 – valve spring big; 7 – valve spring small; 8 – valve yoke; 9 – axis of yokes of final valves; 10 – camshaft; 11 – stopper of an oil-filling branch pipe; 12 – axis of yokes of inlet valves; 13 – head of cylinders; 14 – carburetor; 15 – inlet pipe; 16 – inlet valve; 17 – saddle of the inlet valve; 18 – piston; 19 – index of level of oil; 20 – starter; 21 – rod; 22 – knot of the left suspension bracket; 23 – bent shaft; 24 – oil case; 25 – maslozabornik


The block of cylinders 24 (fig. 2.1) is cast from aluminum alloy and has easily removable pig-iron sleeves. For decrease in height of the engine of an axis of cylinders are rejected on a corner 20 ° from a vertical. The shirt of cooling of the block is open in the top part towards a head. The head 4 blocks is cast from aluminum alloy with inlet and final channels. On the left side to a head on hairpins the inlet pipe, from right – a final collector fastens. In a head channels on which the liquid cooling combustion chambers in the lower part of a head circulates are cast. To the block of cylinders the head fastens through laying by hairpins. In the top part of a head the camshaft 10 (fig. 2.2) moving with the cams through yokes 8 inlet 16 and final 5th valves in the directing plugs is installed. The yokes established on axes 9 and 12 keep from shift by means of springs. For adjustment of thermal gaps in the valvate mechanism on the end of a long shoulder of yokes will screw press a bolt which is stopped by a lock-nut. The camshaft is put in action by a two-row vtulochny chain 30 (see fig. 2.1), located in a forward part of the engine and closed by covers. For compensation of stretching of links of a chain the tension mechanism is in use provided. The head of the block is closed by a cover in which are located a bulk mouth for oil and a tube for removal of crankcase gases. At the left on a head the gasoline pump with the drive by means of a rod from the clown of the camshaft is established.
The bent shaft 23 (see fig. 2.2) solid-forged, is established on five bearings of sliding. Covers of bearings from malleable cast iron fasten to the block two hairpins everyone. On the forward end of a bent shaft the leading asterisk of the camshaft, the leading gear wheel of the drive of the distributor of ignition and the oil pump, a pulley of the drive of the water pump and generator are established. On the back end of a bent shaft the flywheel is located.
Rods 25 (see fig. 2.1) steel shod, with covers on the lower heads. In the lower head of a rod the sliding bearing in the form of inserts from a steel-aluminum tape, in top – the bronze plug is installed.
Pistons are cast from aluminum alloy. On each piston three rings are established: two top – compression and lower – oil scraper.
The oil case cast aluminum, with the cast edges for cooling, closes the block of cylinders from below and serves as the tank for oil.
The lubrication system combined: under pressure and spraying. Under pressure support of a bent shaft, bearings of the lower heads of rods, the camshaft and yokes are greased. Other details are greased with oil spraying.
The lubrication system consists of an oil case 24 (see fig. 2.2), a maslozabornik 25 with a grid for rough purification of the oil, the gear oil pump 18 (see fig. 2.1) located in the lower cover of distributive asterisks and given to rotation from the ignition of the drive, general with the distributor, of the reducing valve, the full-line filter 19 of thin purification of oil with the perepuskny valve, the sensor of pressure of oil and oil channels.
The cooling system of the engine consists of the shirt of cooling located in space between sleeves and walls of the block of cylinders, the channel in a head of the block, channels in an inlet pipe, connecting hoses.
Circulation of liquid in system is provided by the centrifugal water pump. For adjustment of temperature condition of the engine install the thermostat which is disconnecting a big contour of system on not heated-up engine at a low temperature of cooling liquid in the cooling system.
The power supply system of the engine consists of the fuel pump having the mechanism for the manual drive, the carburetor and fuel hoses.
The system of ignition includes the distributor located on a cover of distributive gear wheels, the coil of high voltage, a candle and wire of high voltage.
Successful operation of all car depends on reliable and no-failure operation of the engine.
Timely elimination of the defects of the engine caused by wear of separate details will save from complex and expensive repair (for example, it is possible to avoid replacement of a bent shaft or its grinding, replacement of sleeves of cylinders, etc. if in time to replace inserts of bearings of a bent shaft, piston rings).
The list of malfunctions of the engine and ways of their elimination are provided below.

Removal and installation of the engine (power unit)
Removal
1. Install the car over a viewing ditch or on the elevator so that the engine was under a waist or other load-lifting device, slow down the car the parking brake, establish an emphasis under wheels.
2. Remove a cowl.
3. Merge liquid from the cooling system and oil from cases of the engine and transmission.
4. Remove the rechargeable battery.
5. Remove a cooling system radiator assembled with a casing of the fan and the electric fan (see. "Cooling system").
6. Remove a floor tunnel casing, the lever of gear shifting and a sealing cover.
7. Disconnect wires from the backing light switch.
You carry out the subsequent works on removal of the engine serially from each party.
The works which are carried out on the left side
8. Disconnect a wire of "weight" from the block of cylinders of the engine, a wire from the generator, a starter, the sensor of temperature of cooling liquid, the microswitch of the EPHH system of the carburetor.
9. Disconnect a hose of ventilation of a case of the engine from a branch pipe of a bulk mouth.
10. Disconnect hoses from carburetor unions.
11. Disconnect hoses of the vacuum amplifier of brakes and the electromagnetic valve of the EPHH system from an inlet pipe of the engine.
12. Remove the air filter.
13. Install a technological cap on the carburetor or close his mouth a leaf of a cardboard.
14. Disconnect bringing and the taking-away heater hoses.
15. Disconnect the bringing hose from a gasoline pump.
16. Disconnect cables of drives of butterfly valves and the air gate from carburetor levers.
17. Disconnect a heater crane drive cable.
The works which are carried out on the right side
18. Disconnect a wire from the oil pressure sensor.
19. Disconnect from the coil of ignition of a wire, the ignitions going to the distributor.
The works which are carried out from below
20. Disconnect the driveshaft from the transmission.
21. Disconnect a flexible shaft of the drive of a speedometer from the transmission.
22. Disconnect a level of fastening of a reception pipe of the muffler from an arm on a transmission case.
23. Disconnect a reception pipe of the muffler from a flange of a final collector.
24. Remove the working cylinder of the drive of coupling from a coupling case.
25. Put a support under a back part of a case of coupling.
26. Turn off two bolts of fastening of a back support of the engine to a removable cross-piece.
27. Lower a back part of a case of coupling on a support.
28. Disconnect the transmission.
29. Turn off bolts of fastening of the left and right forward support of the engine to a cross-piece of a forward suspension bracket.
30. By means of the load-lifting mechanism remove the engine from the car.
Install the power unit on the car in the return sequence.

Dismantling and assembly
Before dismantling clear and wash out the engine. Disassemble the engine in the following order:
1. Remove arms of a forward engine mount from the block of cylinders and install the engine on the assembly stand.
2. Remove the carburetor, the distributor of ignition, wire of high voltage from the engine, turn out spark plugs and sensors of temperature of cooling liquid and pressure of oil.
3. Take off a belt of the drive of the generator and water pump.
4. Remove the generator.
Dismantling of the engine
1. Turn off two nuts of fastening of a starter and remove it from hairpins.
2. Turn off four nuts of fastening of a case of coupling to the block of cylinders and remove a coupling case.
3. Turn off six bolts of fastening of a casing of coupling to a flywheel and remove coupling from pins.
4. Turn off nuts of fastening of a cover of a head of the block of cylinders, uncover with laying.

Fig. 2.3. The provision of adjusting tags on a pulley of a bent shaft at the time of finding of the piston of the first cylinder in VMT: 1 – adjusting inflow on the lower cover of distributive asterisks; 2 – the tag corresponding to position of the first and fourth cylinders in VMT; 3 – a tag for installation of the initial moment of ignition


5. Turn a bent shaft clockwise to situation at which the piston of the first cylinder will reach position in compression step VMT, at the same time the tag of 2 (fig. 2.3) will coincide with an edge of adjusting inflow 1.
6. Turn off bolts of fastening of the top cover of distributive asterisks and uncover with laying.

Fig. 2.4. A detachment of bolts of fastening of the conducted camshaft drive asterisk


7. Turn off four bolts of fastening of the conducted asterisk of the drive of the camshaft and remove an asterisk from a shaft (fig. 2.4). If the engine is not required to be disassembled further, connect a chain with an asterisk a wire that it did not come off asterisk teeths.

       PREVENTION
It is impossible to turn a bent shaft at the disconnected chain drive and the head of the block of cylinders which is not removed still. It can lead to damage of valves because of their contact with the piston bottom.

8. Remove the water pump and the bringing branch pipe of the water pump with laying.
9. Turn off two nuts of fastening of the drive of the distributor of ignition and remove the drive.
10. Unbend a lock washer and turn off a ratchet of a bent shaft.

Fig. 2.5. Removal of a pulley of a bent shaft by means of a stripper


11. Remove a pulley of a bent shaft by means of a special stripper (fig. 2.5).
12. Remove an oil filter, having turned off three nuts of its fastening.
13. Remove an oil case with laying, having unscrewed eighteen screws and three nuts.
14. Turn off nuts of fastening of the lower cover of distributive asterisks and uncover with laying.
15. Take away an asterisk of the tension device from a chain and remove a chain.
16. Remove an uspokoitel of a chain from axes.
17. Remove from an axis a lock ring of the lever of the tension device and the lever with an asterisk.
18. Turn off ten nuts of fastening of a head of the block of cylinders and remove it together with an inlet pipe, a final collector, a nest of the thermostat and the fuel pump.
19. Remove sealing laying of a head of the block of cylinders from hairpins.


Fig. 2.6. Fixing of sleeves with levels: 1 – levels


       PREVENTIONS
If for further performance of repair work it is not necessary to remove sleeves of cylinders, then fix them in the block by the levels holders established on hairpins (fig. 2.6) that sleeves did not rise and their consolidation on end faces was not broken.

20. Turn off six bolts of fastening of a flywheel and remove a flywheel.
21. Turn off nuts of conrod bolts and uncover rods.
22. Push out from boring in the block of cylinders of a sleeve with pistons and rods. Mark each piston with serial number of the cylinder.

       PREVENTIONS
To take out from a sleeve the piston with rings and a rod assembled and to install it in a sleeve it is possible only from the lower aligning sleeve corbel. It is impossible to drag a rod through a sleeve – it can lead to damage of a mirror of the cylinder by sharp edges of a head of a rod.

23. Turn off six bolts of fastening of a back cover and uncover with a cuff assembled and laying.
24. Turn off bolts of fastening of covers of radical bearings and uncover together with the lower inserts.
25. Remove a bent shaft, the top inserts of radical bearings and persistent half rings.
The nominal sizes, admissions and landings of the main interfaced details of the engine and maximum permissible gaps, wear at operation and a deviation of a geometrical form are given in tab. 2.1.

Table 2.1 the Nominal sizes, admissions and landings of the interfaced details of the engine of fashion. 331i maximum permissible gaps, wear at operation and deviations of a geometrical form
Part 1
Part 2
Part 3
Part 4




Assembly of the engine
Before assembly oil engine inserts of bearings, persistent half rings, pistons, piston rings, fingers, cuffs. Collect the engine in the following order:
1. Establish inserts of radical bearings in nests of the block of cylinders and in the corresponding covers.
2. Lay in radical bearings a bent shaft with a gear wheel of the drive of the oil pump, the leading asterisk of the camshaft and the bearing of a main shaft of the transmission. Insert two persistent half rings into nests of an average cover of radical bearings.
3. Establish covers of radical bearings with the lower inserts according to tags, having previously evenly tightened nuts of hairpins of fastening of covers of radical bearings. Finally tighten nuts a dynamometer key the moment of 90-100 N · m (9–10 kgfs · м).

Fig. 2.7. Installation of a cover of a back cuff
by means of a mandrel: 1 – mandrel; 2 – cover


4. Establish laying of a back cover, put on a cover with a cuff a mandrel of 1 (fig. 2.7); having moved a cover from a mandrel on a flange of a bent shaft, attach it bolts to the block of cylinders. Center a cover in relation to a flange of a bent shaft on three special ledges on a cover.
5. Establish a flywheel on a bent shaft and wrap bolts of its fastening, having enclosed under them three lock plates (on one under two bolts). Finally tighten bolts a dynamometer key the moment of 70-80 N · m (7–8 kgfs · м). Bend the ends of lock plates that bolts could not turn away.

Fig. 2.8. Check of a vystupaniye of an end face of a sleeve over the top surface of the block


6. Insert sleeves into the block of cylinders and check sleeve end face vystupaniye size over the surface of the block (fig. 2.8). The size of a vystupaniye has to be within 0,01–0,08 mm. Carry out check, previously having pressed a sleeve to the block by effort of 50-70 N (5–7 kgfs). After check take out sleeves from the block and install in them pistons assembled with rings and rods. Before final installation of sleeves grease with paint their landing surfaces.

Fig. 2.9. A relative positioning of locks of piston rings before installation of the piston in a sleeve


7. Establish piston rings in piston flutes so that their locks settled down at an angle 120 ° from each other (fig. 2.9).
Before installation squeeze rings special snap and track that the relative positioning of locks was not broken. At installation of a sleeve in the block of cylinders pay special attention to interposition of the piston and a rod. An arrow on a core of a rod and a groove on a cover of a rod have to be directed to the piston bottom, a ledge towards chain transfer of the drive of the camshaft.
8. Establish inserts in rods and covers of rods, previously having oiled them engine, and connect rods to necks of a bent shaft, having established covers and having evenly tightened nuts of conrod bolts. Finally tighten nuts a dynamometer key the moment of 55-65 N · m (5,5–6,5 kgfs · м).
9. Check ease of rotation of a bent shaft in bearings, previously having fixed sleeves by levels holders.
10. Establish on hairpins sealing laying, then a head of the block of cylinders with an inlet pipe, a final collector and the fuel pump, previously having removed levels holders from hairpins. Replace the damaged or strongly pressed out sealing laying new. For ensuring reliability of operation of the engine we recommend to replace laying at each dismantling.

Fig. 2.10. Sequence of an inhaling of nuts of hairpins of fastening of a head of the block of cylinders


11. Previously improve nuts of fastening of a head of the block of cylinders in the sequence specified fig. 2.10. Finally tighten nuts a dynamometer key the moment of 90-100 N · m (9–10 kgfs · м).
12. Establish an uspokoitel of a chain on the axes located at a forward end face of the block of cylinders.
13. Install the lever of the tension device with an asterisk assembled on the axis located at a forward end face of the block of cylinders and record a lock ring.
14. Turn a bent shaft so that the piston of the first cylinder appeared in VMT.

Fig. 2.11. Position of the camshaft on a head of the block of cylinders before its installation on the block: 1 – risk; 2 – inflow


15. Turn the camshaft so that risk on its flange coincided with the middle of inflow on a forward support of the camshaft (fig. 2.11).
16. Take aside an asterisk of the tension device and throw with a chain the leader and conducted camshaft drive asterisks, having installed the conducted gear wheel together with a chain on the camshaft so that the leading branch of a chain did not sag.
17. Draw in an asterisk of the tension device to a chain and achieve a full tension of the leading branch of a chain insignificant turn of the camshaft, without changing the provision of a bent shaft. At the same time risk on a flange of the camshaft should not go beyond inflow of a forward support.
18. Establish the lower cover of distributive asterisks with laying on hairpins and tighten nuts.
19. Establish an oil filter and tighten nuts of its fastening.
20. Collect the top cover of distributive asterisks with a plunger, a spring and a clamping level, drown a plunger in a cover opening and tighten a lock bolt of a natyazhitel. Vystupaniye of a plunger from an opening of a cover is not allowed.

Fig. 2.12. Sequence of an inhaling of bolts of fastening of the top cover of asterisks


21. Establish the top cover with laying on a forward end face of a head of the block of cylinders, supporting at the same time a chain in the tense state, and tighten bolts in the sequence specified fig. 2.12.
22. Turn off a lock bolt of a natyazhitel on 0,5–0,75 turns.

       PREVENTIONS
Do not turn off a lock bolt at a big size, than it is specified as its shaft can be separated with a clamping plate and the plunger of a natyazhitel will not be fixed. It can lead to serious damage of the engine because of jumping of a chain on asterisks.

23. Establish a pulley of a bent shaft and a lock washer of a ratchet, tighten a ratchet a dynamometer key the moment of 80-90 N · m (8–9 kgfs · м). Bend edge of a lock washer on a ratchet side.

Fig. 2.13. Inhaling of a lock bolt of the tension device of the chain drive of the mechanism of gas distribution: 1 – lock bolt


24. Turn clockwise on 2–3 turns a bent shaft with the released lock bolt of a natyazhitel for the choice of all gaps in the camshaft drive then tighten against the stop a lock bolt of 1 (fig. 2.13).
25. Turn a bent shaft clockwise to situation at which the piston of the first cylinder is in compression step VMT, both valves are closed, and the tag 2 (see fig. 2.3), the second for the direction of rotation, coincides with an edge of an adjusting pin.

Fig. 2.14. The provision of a groove on the ignition distributor drive roller before installation of the drive on the engine


26. Turn the ignition distributor drive roller so that the groove which the ignition distributor coupling enters was located at an angle about 16 ° to the straight line connecting the centers of openings for hairpins of fastening (fig. 2.14).

Fig. 2.15. The provision of a groove on the ignition distributor drive roller after installation of the drive on the engine


27. Accurately, trying not to turn the roller, install the ignition distributor drive in a nest of the lower cover of distributive asterisks. When the gear wheel of the drive enters gearing with the leading gear wheel fixed on the forward end of a bent shaft, the groove on the roller will reach the correct position (fig. 2.15), having a little turned counterclockwise. Then tighten nuts of fastening of the drive of the distributor.

Fig. 2.16. Sequence of an inhaling of screws of fastening of an oil case


28. Establish an oil case with laying. If laying is damaged, replace it new. Tighten screws and nuts in the sequence specified fig. 2.16.
29. Install the water pump and the bringing branch pipe with laying, and also an adjusting level of the generator.
30. Establish a cover of a head of the block of cylinders with laying. If laying is torn, hardened or is pressed strongly out, replace it new. Before an inhaling of nuts of fastening of a cover establish on hairpins arms of fastening of wires of high voltage, a bracket of fastening of the bringing tube to the fuel pump and a bracket of fastening of a tube of the vacuum proofreader of the distributor of ignition. Put on flat washers then evenly tighten all seven nuts of fastening of a cover free hairpins, without making excessive efforts not to damage laying.
31. Install the carburetor, the generator, the distributor of ignition, spark plug, wire of high voltage, sensors of temperature of cooling liquid and pressure of oil on the engine.
32. Put on a belt pulleys of a bent shaft, the water pump and generator and adjust its tension, changing position of the generator.
33. Put on a vacuum hose one end the union of selection of depression from the carburetor, and to others – the union of the vacuum proofreader of the distributor of ignition, having passed it throughout an opening of the arm established on a hairpin of fastening of a cover of a head of the block.
34. Establish a fuel supply hose from a gasoline pump to the carburetor with the filter of thin purification of fuel.
35. Establish an oil filter, the oil probe, a starter, coupling on a flywheel, a coupling case, a coupling case guard, the transmission, forward support of the engine with pillows.

Repair of knots and details of the engine
Block of cylinders and sleeve
The main sizes of the block of cylinders and sleeves are specified in tab. 2.1.
Tightness of walls of a shirt of cooling and oil highways check at special stands. For check of tightness of a shirt of cooling muffle all exhaust outlets of a shirt in the block, lower the block in a bathtub with water and give to canals of a shirt compressed air under pressure of 150 kPa (1,5 kgfs/cm2) during 15 pages. The air leak determined by the leaving bubbles is not allowed.
For check of tightness of oil highways muffle all their exhaust outlets in the block and pump to canals of highways water with addition of chrompeak under pressure of 1500 kPa (15 kgfs/cm2) during 15 pages. Leak of water is not allowed.
If the block is untight, replace it.
When replacing the hairpins leaving in a cooling shirt cavity establish them and laying of a shirt on zinc whitewash.
Check the gap between the cylinder and the piston specified in tab. 2.1. The gap is defined as a difference between the measured diameters of the piston and cylinder.
Diameter of the cylinder is measured by a nutromer with the division price by no more than 0,01 mm in four belts as in the longitudinal, and cross direction at distance of 10, 50, 100 and 125 mm from its top end face.
Sleeves of cylinders are broken into five dimensional groups: And, B, In, D (through 0,01 mm). Dimensional groups are designated by a color strip (see tab. 2.1).
If the maximum value of a gap is more than value specified in the table, replace worn-out knot (the piston, a sleeve or a sleeve with the piston).
Conrod and piston group
The main sizes of conrod and piston group are specified in tab. 2.1.
Removal and installation of piston rings

Fig. 2.17. Stripper of piston rings: 1 – handle; 2 – ledges; 3 – emphasis; 4 – captures


Piston rings are removed from the piston and put on it by means of a special stripper (fig. 2.17).
Ledges 2 strippers enter a gap of the lock of a ring and when pressing handles 1 part a ring on a fixed value. The unclenched ring easily acts and established in a piston flute.

       PREVENTION
The piston ring is strictly forbidden to make a helpless gesture: at excessive deformation its form it is irreversible it is distorted.

Dismantling of the piston with a rod
Take out lock rings of a piston finger from flutes of lugs of the piston for what hook each of them the thin screw-driver or a pricker.
Heat the piston, immersing it for 2–3 min. in water with the temperature of 45-75 °C.
Vypressuyte a piston finger from the piston and the plug of a head of a rod blows of the hammer through a brass mandrel.
Selection of the piston to a cylinder sleeve
The piston and the sleeve corresponding to it have to concern to one dimensional group (their alphabetic indexes have to be identical). Alphabetic marking is applied on the piston bottom.
On outer diameter pistons are broken into five dimensional groups: And, B, In, D (through 0,01 mm).
Check a necessary assembly gap (0,05–0,07 mm) between the piston and a sleeve as a difference between the measured diameters of the cylinder and piston.
The mass of metal in the piston is distributed unevenly therefore his skirt in a cold condition of an irregular geometrical shape. In cross section it oval (the big axis of an oval is perpendicular axes of a piston finger) and conical (with the big basis below).
Diameter of the piston measure on a big axis of an oval of a skirt at distance 12,95 mm from an end face of the landing corbel with a diameter of 77,5+0,2 executed on an internal surface of a skirt.
Pistons select to sleeves not only for diameter, but also for weight for preservation of steadiness of the engine. Pistons of one engine should not differ on weight from each other more than on 3 g. At manufacturer pistons of the nominal size sort by weight on four groups which marking (1, 2, 3, 4) is applied on the piston bottom. All pistons installed on one engine have to be one group on weight.
Check of technical condition of piston rings
Need of check or replacement of piston rings arises at raised, more than 100 g on 100 km of a way, a consumption (waste) of oil.
For check of a condition of piston rings partially disassemble the engine and take out pistons with rings. Before check clear piston rings of a deposit and resinous deposits.
Check piston rings for compliance to technical requirements in the parameters specified in tab. 2.2.

Table 2.2 Key parameters of piston rings

Fig. 2.18. Check of a gap between piston rings and flutes: 1 – piston ring; 2 – piston; 3 – set of probes


Check a gap on height between a flute and a ring, inserting a ring into the corresponding flute (fig. 2.18).
Measure a gap in the lock of a ring, having placed a ring in that sleeve in which it worked, or if it new in which will work. For the correct installation advance a ring in a sleeve by means of a head of the piston used as a mandrel on distance of 20-30 mm from the lower end face of a sleeve. If check shows that a gap insufficient, file the butt surfaces of the lock a velvet file and if raised – replace a ring.
Measure elasticity of piston rings on special scales by means of the flexible tape covering a ring.
When checking a condition of piston rings it can turn out that replacement only of the top compression ring as it wears out much quicker than the others is necessary.
It is not recommended to establish at repair the new top compression rings with the chromeplated covering intended for installation in new sleeves, in the cylinders of the working engine having some wear. The chromeplated covering very firm therefore such rings will be slowly earned extra to a sleeve surface. For this reason repair kits of rings of the nominal size release with not chromeplated top rings.

Fig. 2.19. An arrangement of piston rings in piston flutes: 1 – piston; 2 – top compression ring; 3 – lower compression ring; 4 – oil scraper ring


The correct arrangement of piston rings in flutes of the piston is shown in fig. 2.19.
If wear of sleeves insignificant, then instead of old rings it is possible to use repair rings of the nominal size provided that the gap in the lock of the ring inserted into a sleeve does not exceed 0,75 mm. Otherwise replace a sleeve.
Check of a gap between inserts of conrod bearings and a bent shaft
The gap between an insert and a neck of a bent shaft is defined by a difference of the sizes received at measurement of diameters of openings in the lower heads of rods with the inserted inserts and shaft necks. Covers of rods have to be tightened by the full moment.
If value of a gap is in limits of the admission or does not exceed admissible at the wear specified in tab. 2.1 it is possible to use these inserts. At a bigger gap conrod necks of a bent shaft to the next repair size also establish to a proshlifuyta inserts of the repair size (tab. 2.3).

Table 2.3 Nominal and repair sizes of necks of a bent shaft and inserts of bearings

Assembly of conrod and piston group
After selection of pistons to sleeves pick up piston fingers to pistons and plugs of small heads of rods.
Landing of a piston finger in lugs of the piston can be ranging from 0,0025 mm of a tightness to 0,0025 mm of a gap. The gap between a piston finger and an opening of the plug of a head of a rod has to be within 0,0045–0,0095 mm for this dimensional group of details.
For selection simplification piston fingers, pistons and plugs are injured into four dimensional groups differing on diameter on 0,0025 mm. Each group is marked by paint of a certain color (see tab. 2.1): on the piston – on the lower surface of one of lugs, on a piston finger – on an internal surface since one end, on a rod – at a small head.
Interface of a piston finger and the plug of a head of a rod check, implanting the finger oiled engine into a plug opening. At the correct interface the rod has to be turned on a finger under the influence of a body weight, and the finger should not drop out of the plug of the top head of a rod in vertical position. For observance of these requirements it is admissible to use fingers of adjacent group (towards reduction of a gap). In all cases select piston fingers at the air temperature of (20±3) °C.
If it is necessary to replace one of rods, it needs to be picked up for weight to other rods of a set. The difference of values of mass of the heaviest and easiest rod in the set installed on the engine should not exceed 8 g. The rods belonging to one group on weight are marked risky on inflows of their covers.
Before assembly heat the piston, having lowered it in a vessel with water with the temperature of 45-75 °C, and execute operations in the following sequence.
1. Implant the oiled finger into openings of lugs of the piston and plug of a rod.

       NOTE
At assembly of the piston with a rod orient them so that the arrow which is beaten out on the piston bottom was turned towards a ledge on a body of a rod and groove on a cover.

2. Insert lock rings of a piston finger into flutes of lugs of the piston.
3. Put on piston rings the piston, using a stripper (see fig. 2.17).
4. Arrange locks of piston rings at an angle 120 ° from each other (see fig. 2.9). The arrangement of rings in flutes of the piston has to correspond shown in fig. 2.19. Installation of the piston with a rod on the engine see in the subsection "Dismantling and Assembly of the Engine".

       PREVENTION
The rod is processed assembled with a cover therefore covers of rods are not interchanged and should not be depersonalized during the dismantling and assembly.

Head of the block of cylinders
Removal and installation of a head of the block of cylinders without removal of the engine from the car
The head of the block of cylinders is removed when it is required to eliminate malfunction only in it.
1. Merge cooling liquid.
2. Disconnect the bringing radiator hose from a thermostat nest cover.
3. Disconnect the hose going to the bringing branch pipe of the water pump from a thermostat nest square.
4. Disconnect hoses from carburetor unions.
5. Disconnect a cable of the drive of butterfly valves and draft of the drive of the air gate from the carburetor.
6. Disconnect wires from the carburetor EPHH microswitch.
7. Remove the air filter and a hose of ventilation of a case.
8. Remove the carburetor, having turned off nuts of its fastening.
9. Disconnect hoses from an inlet pipe of the engine.
10. Disconnect a wire from the sensor of temperature of cooling liquid.
11. Disconnect the bringing hose from a gasoline pump.
12. Disconnect a reception pipe of the muffler, having turned off three nuts of fastening.
13. Turn off seven nuts of fastening of a cover of a head of the block of cylinders and uncover.
14. Turn off bolts of fastening of the top cover of distributive asterisks and uncover.
15. Turn off bolts of fastening of the conducted asterisk of the drive of the camshaft and remove it from a shaft, without separating with a chain. That the chain did not come off asterisk teeths, connect it with an asterisk a wire.
16. Turn off nuts of fastening of a head of the block of cylinders and remove a head together with an inlet pipe, a final collector, the camshaft and valves.
Establish a head upside-down.
Dismantling and assembly of a head of the block of cylinders
1. Disconnect an inlet pipe and a final collector.
2. Remove the fuel pump.
3. Remove a thermostat nest.
4. Having fixed a head in a vice, unscrew screws of fastening of a persistent flange of the camshaft and remove a flange.
5. Having weakened lock-nuts, turn out adjusting screws of yokes so that their spherical ends were drowned in carving openings of yokes, and take out tips of adjusting bolts.
6. Mark in any way all yokes and expansion plugs in order that at assembly to establish them on the former place.
7. By means of a bronze or aluminum mandrel beat out axes of yokes from openings in a head and remove yokes, podzhimny springs and expansion plugs.
8. Take out the camshaft from beds in a block head.
9. Mark each valve with serial number of the cylinder.

Fig. 2.20. Stripper of springs of the valve: 1 – bracket; 2 – ring emphasis of a bracket; 3 – rod; 4 – level; 5 – the lever with a cam; I, II – provisions of the lever


10. A special stripper (fig. 2.20) squeeze springs of the valve which is subject to dismantling. For this purpose establish a stripper as it is shown in the drawing. When turning the lever 5 of situation I in situation II the cam presses a level 4 which moves a rod 3, squeezing valve springs.
11. Remove crackers from a valve core; weakening pressing, release springs.
12. Remove a stripper, springs, a plate, a protective cap and take out the valve from the directing plug.
13. Similarly remove all other valves.
Collect a head of the block of cylinders upside-down. At the same time check a state and wear of cores of valves and their guides of plugs, working facets of valves, saddles and valvate springs. At each assembly of a head of the block of cylinders with valves after repair or grinding in of valves surely replace sealing washers of plates of springs of valves new irrespective of their state.
At wear of cores of valves replace valves. At installation of valves surely grease their cores with graphitic lubricant.

Fig. 2.21. An arrangement of details of the drive of valves on a head of the block of cylinders: 1 – axis of yokes of inlet valves; 2 – axis of yokes of final valves


Before installation of axes of yokes check degree of wear of working surfaces of yokes and their axes and if necessary replace worn-out details. At installation of yokes on an axis grease with graphitic lubricant of a wall of openings in yokes. Establish yokes and expansion plugs according to the tags made during the dismantling, and an axis of yokes according to the tags of "VP" and "VYP" (fig. 2.21) which are beaten out on them.
Check and grinding of saddles of valves
Working facets of saddles of valves should be proshlifovat when replacing of the directing plugs of valves, and also at big wear and a beating of facets concerning openings in the directing plugs.

Fig. 2.22. The car for grinding of a facet of a saddle of the valve: 1 – case; 2 – anchor shaft; 3 – switch; 4 – leading gear wheel; 5 – case cover; 6 – intermediate gear wheel; 7, 8 – worms; 9 – giving screw; 10 – spindle; 11 – worm gear wheel; 12 – spline; 13 – the conducted gear wheel; 14 – holder; 15 – pendulum; 16 – tip; 17 – abrasive circle


Use the special grinder with the electric drive (fig. 2.22) to grinding.
The car for grinding has to be supplied a set of abrasive circles with cones 60, 90, 120 °; a set of the special mandrels inserted into openings of guides of plugs; devices for editing of abrasive circles and check of a beating of a facet.
Before starting grinding of a facet, pick up the mandrel which is densely entering an opening of the directing plug. Do giving of the abrasive tool manually, and carry out grinding until the abrasive circle does not begin to remove saddle metal evenly on all circle of a facet.

Fig. 2.23. The device for check of a beating of a facet on a valve saddle: 1 – tip; 2 – opening; 3 – coupling; 4 – holder; 5 – mandrel; 6 – indicator


Check a facet beating in relation to an axis of an opening of the directing plug special adaptation (fig. 2.23) which is put on the same mandrel on which ground a facet.
Adaptation consists of the coupling 3 rotating on a mandrel 5, the holder 4 indicators 6 who is densely fixed on a mandrel. On the top conic surface of the coupling the indicator core leg slides, and on the lower conic surface of the coupling the special tip 1 leaning on a surface of a working facet of a saddle is inserted into an opening 2. At a provorachivaniye a coupling hand the tip moves on a surface of a facet and in the presence of a beating causes axial movement of the coupling which is transferred to an indicator scale.
The beating for facets of saddles of inlet and final valves should not exceed 0,05 mm.
For measurement of a beating of facets of saddles of inlet and final valves couplings with various arrangement of tips as diameters of heads of these valves and facets are various are required.

Fig. 2.24. The sizes of facets for grinding of a saddle of the valve


The sizes of facets of saddles of valves after grinding are shown in fig. 2.24.
Then check width and a location on a facet of a surface of contact of a head of the valve with a saddle in the following order:
1. Apply a paint coat on a valve saddle.
2. Insert the corresponding valve into the directing plug and turn it, pressing to a saddle.
It is considered that the valve well adjoins to a saddle if the corbel of paint 1,2-1,5 mm wide formed on a valve head (both for inlet, and for final valves) settles down in the middle of a facet.
If it not so, it is necessary to grind a valve saddle in addition. At the same time the abrasive circle has to have a cone 60 or 120 ° depending on where it is required to displace a working facet of a saddle of the valve.
Valves
For check of a condition of the valve remove from it a deposit. If on a working facet there are cracks or the head of the valve is jarred on, replace the valve. For elimination of wear, a progar, sinks and other damages the facet is ground on the special machine.
When grinding it is necessary to chamfer the minimum layer of metal only to remove blackness, sinks and a beating. Surely you watch that the edge of a facet was not pointed and on it there was always a cylindrical corbel not less than 0,5 mm wide.

Fig. 2.25. Device for check of a beating of a working facet and core of the valve: 1 – plate; 2 – prism; 3 – holder; 4 – ball; 5 – angular emphasis; 6, 7 – indicators


For check of a beating the valve is stacked on the prism of 2 (fig. 2.25) fixed on a plate 1 so that the end face of its core rested against a ball 4, zavaltsovanny against a body of an angular emphasis 5. Tips of the indicators 6 and 7 fixed in holders 3 bring to a core of the valve and its facet.
When turning the valve one indicator will show a beating of a working facet, another – a core beating. Admissible beating of a facet and core of the valve of 0,02 mm.
The directing valve plugs
The directing plugs replace at the wear of their openings exceeding the maximum permissible sizes (see tab. 2.1), in the following order:

Fig. 2.26. A mandrel for a vypressovka of the directing valve plug


1. Vypressuyte the worn-out plug from a cylinder block head by means of a mandrel (fig. 2.26).
2. Install a head on the boring machine with an adjustable tilt angle of a table. Having inclined a table on 26 ° ±5 ў, establish a head so that the axis of a spindle coincided with an axis of an opening of the directing plug.

Fig. 2.27. Position of the directing valve plugs after a press fitting in a head of the block of cylinders: 1 – the directing plug


3. Develop an opening from which a vypressovan the plug, to 15,120–15,142 mm in a head. Press in the developed head opening the repair plug with the outer diameter (15,172–15,184 mm) increased by 0,15 mm to the size specified fig. 2.27.

       NOTE
Impregnate the directing plugs manufactured of metal ceramics before a press fitting during 1,5 h in engine oil.

4. Develop an opening in the pressed plug to 8,008–8,026 mm. At the same time ovality and conicity should not exceed 0,006 mm. After expansion of an opening check straightforwardness of an opening of the plug a mandrel with a diameter of 7,995 mm which has to pass freely on all length of the plug.
Yokes of valves and their axis
Before check of degree of wear of yokes and axes wash out them in gasoline and wipe with a pure rag.
At a yoke check diameter of an opening and size of a step on a cylindrical surface of a basic heel. Wear on a surface of a basic heel should not exceed 0,05 mm (flute depth in a middle part).
At an axis of yokes check outer diameter.
Admissible values of wear of diameter of an opening of a yoke and outer diameter of an axis are given in tab. 2.1.
Yokes and their axes which wear is higher than admissible replace new.
Springs
Before check of springs be convinced of lack of cracks on their rounds. Elasticity of springs is checked under loading:
398–464 N (40,7–47,3 kgfs) for a big spring with a length of 27,5 mm and 160-185 N (16,3–18,9 kgfs) with a length of 36,5 mm;
242–280 N (24,6–28,6 kgfs) for a small spring with a length of 25,5 mm and 100-116 N (10,2–11,8 kgfs) with a length of 34,5 mm.
If the effort created by a spring is 10% less than effort new, replace a spring. Keep in mind that the effort of a spring decreases if facets of the valve and a saddle were proshlifovana, so, the working height of a spring increased. In this case at assembly of details of the valvate mechanism under basic plates of springs establish additional washers. Choose thickness of washers so that at the closed valve length of a big spring was 36,5 mm.
Sealing washers

Fig. 2.28. Consolidation of a core of the valve in a plate: 1 – valve; 2 – cracker; 3 – plate of a valve spring; 4 – sealing washer


At each dismantling of the valvate mechanism surely replace sealing washers of 4 (fig. 2.28) new. Finally check tightness of consolidations of plates after assembly of a head of the block of cylinders.
For this purpose establish a head so that axes of each number of valves were serially vertical and in gaps between crackers pour gasoline. If gasoline remains a long time in gaps between crackers, then washers provide consolidation. At valves where gasoline filters, replace sealing washers.
Check of tightness and grinding in of valves

Fig. 2.29. Device for check of tightness of valves: 1 – lever; 2 – adaptation; 3 – support; 4 – a stopper for openings of spark plugs


Tightness of valves can be checked on a rupture of a paint coat, applied on facets of saddles and heads of valves, on infiltration of the kerosene which is filled in in the combustion chamber and also by means of pneumatic adaptation of the low pressure (fig. 2.29).
For check of tightness by means of adaptation:
1. Install adaptation 2 so that its rubber sealant covered one of combustion chambers of a head of the block of cylinders.
2. Press adaptation the lever 1 and create a rubber pear pressure of air of 50 kPa (0,5 kgfs/cm2). It should not fall during 10 pages.
If valves are untight, because of leak of air of the shooter of the manometer will move to zero.
In this case it is necessary to grind in valves in the following order.
1. Put on a squeezing spring a core of the ground-in valve.
2. Apply a thin film of the pritirochny paste prepared in the form of mix of small emery powder with engine oil on a valve head facet.

       NOTE
For better and bystry grinding in of valves we recommend to use the special diamond powder or paste which are available on sale instead of emery powder.

Fig. 2.30. Device for grinding in of the valve: 1 – clamping screw; 2 – neck; 3 – valve core


3. Grease a valve core with a thin layer of graphitic lubricant and insert it together with a squeezing spring into the directing block head plug. Then put on a core of 3 (fig. 2.30) of the valve a neck 2 devices for grinding in and fix the valve the clamping screw 1.
4. Rotate the valve by means of adaptation in both parties, periodically slightly pressing it to a saddle.
During grinding in do not remove too much metal as it reduces possible number of repairs and service life of details from working facets of valves and saddles.
By the end of grinding in reduce the content of emery powder in paste, having parted it with a large amount of oil, and since the moment when surfaces become absolutely smooth and will accept equal grayish color, conduct grinding in only on pure oil. An external sign of high-quality grinding in is monophonic opaque gray color (without black spots) working surfaces of facets of a head of the valve and its saddle.
Camshaft of the engine and its drive

Fig. 2.31. Scheme of the mechanism of the drive of the camshaft: 1 – camshaft asterisk; 2 – chain; 3 – uspokoitel of a chain; 4 – asterisk of a bent shaft; 5 – the lever of the press device with an asterisk; 6 – natyazhitel of a chain


The main sizes of the camshaft and its bearings are given in tab. 2.1. The scheme of the mechanism of the drive of the camshaft is shown in fig. 2.31.
Carefully washed out and dry examine the threadbare camshaft, measure diameters of necks and height of raising of cams. External survey check a shaft for lack of zadir on surfaces of cams, necks and the clown. In the presence of zadir on cams the shaft for further operation is unsuitable.
It is impossible to grind under the repair sizes worn-out necks of a shaft and cams as in this case it is necessary to use special plugs in beds of bearings. Besides, when grinding the thermoprocessed layer on a surface of cams will be inevitably removed that will make them disabled.
If gaps in bearings exceed admissible, replace a shaft.
Check and adjustment of thermal gaps in the drive of valves
Gaps between tips of adjusting screws of yokes and end faces of cores of inlet and final valves have to be 0,15 mm.
Check and regulate thermal gaps of valves only on the cold engine (at a temperature of cooling liquid of 15-25 °C) in the following order.
1. Install the piston of the first cylinder in compression step VMT, having turned a bent shaft so that the tag 2 (see fig. 2.3) on a rim of a pulley of a bent shaft was combined with the adjusting pin 1 pressed in the lower cover of asterisks of the drive of the camshaft. At such provision of a bent shaft valves of the first cylinder are completely closed and their yokes are released.

Fig. 2.32. Check of thermal gaps of valves


2. Check thermal gaps of valves of the first cylinder, having inserted the flat probe between tips of adjusting screws and end faces of cores of valves (fig. 2.32). The probe has to move in a gap with some effort.
3. If necessary adjust thermal gaps of valves of the first cylinder for what a wrench (S=14 mm) release lock-nuts of adjusting screws and rotate their heads a face key until easy jamming of the probe.
4. Holding adjusting screws from a provorachivaniye, tighten lock-nuts and again check gaps the probe.
5. Turn a bent shaft on a half of a turn (180 °) and adjust gaps of valves of the third cylinder. Turning a bent shaft exactly on a half of a turn, install pistons of the fourth, and then second cylinders in compression step VMT, check and adjust gaps for these cylinders.
6. Establish into place a cover of a head of the block of cylinders, having checked a condition of its laying. If necessary replace laying.
Adjustment of a tension of a chain
1. Turn off a lock bolt 1 (see fig. 2.13) a natyazhitel on 0,5–0,75 turns.
2. Turn a bent shaft clockwise on 2–3 turns for the choice of all gaps in the camshaft drive.
3. Wrap a lock bolt against the stop.
 Camshaft drive chain
Check a condition of a chain only when dismantling the mechanism of the drive of the camshaft in the following order.
1. Wash out carefully a chain in gasoline, wipe and dry.
2. Examine all rollers of a chain to reveal cracks and chips.

Fig. 2.33. Device for a vypressovka of axes of links of a chain of the camshaft


3. Having separated one link of a chain by means of a stripper (fig. 2.33), check length of the chain stretched by effort of 140 N (14 kgfs). If chain length from 50 links more than 480 mm and also if on its rollers there are cracks and chips, replace a chain.
Bent shaft and flywheel
The main sizes of a bent shaft are specified in tab. 2.1.
Cleaning of channels for lubricant
1. Turn out from a bent shaft of a cap of oil channels.
2. Carefully wash out channels gasoline and blow compressed air.
3. Turn and fix by a kerneniye of a cap of oil channels.
Radical and conrod necks
If on radical and conrod necks, and also in cheeks cracks are found, replace a shaft.
Insignificant risks can be smoothed out whetstone of small granularity. If risks very deep or ovality of necks more than 0,03 mm, their proshlifuyta.
Radical and conrod necks grind, reducing their sizes by 0,25 mm to receive the certain repair size specified in tab. 2.3 depending on wear degree.
After grinding and the subsequent operational development of necks wash out a bent shaft the concentrated soap solution for removal of the remains of an abrasive. On the first cheek of a bent shaft specify by a branding the size of reduction of necks (0,25; 0,50 mm etc.).
If the bent shaft was прошлифован under the maximum reduction and application of inserts of the repair sizes does not provide necessary gaps in bearings, establish a new bent shaft with inserts of the nominal size.
Inserts of radical and conrod bearings
On inserts it is impossible to perform any subracing operations. In the presence of zadir, рисок or peelings they are replaced. At a significant amount of impregnations of firm particles (products of wear of details, abrasive particles, etc.) it is also necessary to replace inserts.
Determine gap size between necks and inserts. If the gap exceeds the most admissible (0,15 mm), after grinding of necks establish repair inserts (see tab. 2.3).
At the correct assembly and optimum interface of necks to inserts the bent shaft has to rotate freely.
Flywheel
Check a condition of a gear wreath. In case of damage of teeths replace a flywheel.
The flywheel surfaces interfaced to a bent shaft and the conducted clutch plate have to be absolutely flat, without scratches and zadir.

Fig. 2.34. Flywheel: 1 – the surface of fastening of a bent shaft to a flange; 2 – surface of fastening of coupling; And – the radius on which the beating of a surface 2 is checked


If on a working surface of 2 (fig. 2.34) of a flywheel under the conducted clutch plate there are scratches, pierce a surface, removing a layer of metal no more than 1 mm thick.
Not parallelism of surfaces of 2 and 1 no more than 0,1 mm measured on extreme points of a surface 2 is allowed (on radius And).
Establish a flywheel on a mandrel, aligning it on a landing opening with the emphasis on a surface 1, and check a beating of a surface 2. On radius And the beating should not exceed 0,3 mm.
Cuffs
On the surfaces of a bent shaft interfaced to working edges of sealing cuffs there should not be scratches, забоин or рисок.
At repair of the engine it is recommended to replace surely both sealing cuffs of a bent shaft.
Oil pump
The main sizes of the pump and its drive are given in tab. 2.1.
Removal and installation
The oil pump has no special case. Gear wheels of the pump work directly in a cavity of the lower cover of asterisks of the drive of the camshaft.
For removal of the pump execute the following.
1. Turn off five bolts of fastening of the lower cover of asterisks of the drive of the camshaft and uncover with laying.
2. Take out from a cover cavity the pump roller with the leading gear wheel and the conducted gear wheel.
3. Turn out from a cover a stopper of the reducing valve with laying and a spring with the valve.
Install the pump upside-down.
Check of details
After dismantling wash out all details and a cavity of a cover (boring) kerosene or gasoline.
Check a set of probes a gap between the cylindrical surface of a cavity in a cover and gear wheels which should not exceed 0,1–0,2 mm (maximum permissible 0,25 mm). Then check a gap on height of gear wheels which has to make 0,1–0,19 mm. It can be adjusted selection of laying.
After installation of gear wheels in a cover of asterisks check ease of their rotation. Gear wheels have to rotate by hand freely, without jammings.
Examine the reducing valve. On the surface of the valve and case there should not be pollution and resinous deposits which can become the reason of jamming of the valve.
On the interfaced surfaces there should not be забоин also agnails which can lead to pressure decrease in system.
Check of a condition of details of the drive
1. Wear of teeths of the conducted drive gear wheel by a profile is determined, measuring their thickness a zubomer. At wear of teeths on thickness from initial more than replace a gear wheel with 0,15 mm.
2. The admissible gap between a basic washer and an end face of the case at which further operation is possible has to be no more than 0,25 mm.
3. The assembly radial gap between the case and the roller of the drive has to be 0,016–0,052 mm, the most admissible gap at wear – 0,1 mm.
Water pump
Removal and installation of the pump
1. Merge cooling liquid from the engine cooling system.
2. Weaken nuts of bolts of fastening of the generator to an arm.
3. Turn off a bolt of fastening of the generator to an adjusting level.
4. Move up the generator to the block of cylinders and take off a belt.
5. Turn out bolts of fastening of a pulley and remove a pulley.
6. Turn off four nuts of bolts of fastening of the pump to the lower cover of asterisks of the drive of the camshaft and remove the pump.
Install the pump upside-down. At the same time check a condition of paper laying between an end face of a flange of a pump housing and the plane of the basic platform on a cover of asterisks. Replace the damaged laying new. After installation of the pump and a pulley adjust a belt tension.
Dismantling, check and assembly of the pump
Disassemble the pump in case of wear of bearings and failure of an epiploon.

Fig. 2.35. Water pump: 1 – pump housing; 2 – krylchatka assembled; 3 – washer; 4 – spring washer; 5 – bolt; 6 – plug; 7 – bearings; 8 – nut; 9 – lock screw; 10 – expansion plug; 11 – roller assembled; 12 – nave


1. Turn off a bolt of 5 (fig. 2.35) of fastening of a krylchatka 2.
2. Press a stripper a krylchatka since the end of the roller 11.
3. Weaken a lock-nut of the 8th lock screw 9 of the bearing and turn out the screw.
4. Oboprite a forward end face of the case of 1 water pump on a support from soft metal or a tree and through a mandrel blow of the hammer to the end of the roller beat out it from the case assembled with bearings 7. This operation if there is an opportunity, it is better to execute on a manual press.
5. Press bearings from the roller (only in case of their replacement).
6. Wash out in gasoline all details of the pump, except a cuff and a sealing washer of an epiploon.
7. Check a condition of a surface of an end face of the plug 6 of a pump housing. The surface has to be smooth, without забоин and damages (purity of a surface of 0,63 microns). If necessary to a proshlifuyta end face.
8. Examine roller epiploon details. If the pump was disassembled because of an epiploon leak, replace epiploon details new.
9. Examine bearings and their consolidations. Bearings have to rotate easily without jamming and noise from rolling of bodies of swing. Sealing rings should not have damages and traces of the thrown-out lubricant. At detection of any defects replace bearings.
Collect the pump upside-down. At a napressovka of the external bearing on the roller its internal ring has to rest against a nave of the 12th pump. In the assembled pump the roller has to rotate by hand smoothly, without jammings.

Bench tests of the engine
The repaired engine is tested (roll) at the stand without loading on the following cycle:
(1100±200) min.-1 – 5 min.;
(1900±200) min.-1 – 5 min.;
(2600±200) min.-1 – 10 min.
During a running in of the repaired engine you do not bring its work to the maximum mode.
At tests at the stand check the following: whether there is no leak of water or fuel from connections and through laying; oil pressure; rotation frequency idling; whether there are no deviations in operation of the engine.
If malfunctions are found, stop the engine and eliminate them, then continue test.
At dribble of oil through laying tighten fastening bolts the recommended inhaling moments. If leak does not stop, check an integrity and correctness of installation of laying. Replace the damaged laying.

Check of the engine on the car
After installation of the engine carefully check correctness of installation for the car.
Launch the engine, let's it work some time, and then check the following:
– whether there is no dribble of cooling liquid and fuel in connections of pipelines. If necessary tighten connections;
– whether there is no oil dribble;
– whether provide cables of drives throttle and air carburetor gates their full opening and closing. If necessary adjust the drive;
– whether the generator belt is rather tense. If necessary adjust its tension;
– reliability of contacts of wires of electric equipment and operation of devices and lamps on the dashboard.
During an initial stage of operation of the engine strictly observe the running in modes ordered for the new car.