2.2. Engine of fashion. 2106

Features of a design
The engine is line, four-cylinder with a vertical arrangement of cylinders, four-cycle, carburetor. Combustion chambers wedge-shaped with a line arrangement of valves. The camshaft is installed in a head of the block of cylinders and is given to rotation by a two-row roller chain. The drive of the distributor of ignition, oil and fuel pumps is carried out from the intermediate roller installed in the block of cylinders.
The main basic details of the engine are the block of cylinders and a head of the block of cylinders to which details, knots and auxiliary units ensuring its functioning fasten.

Fig. 2.36. Device of the engine of fashion. 2106: 1 – a bent shaft, 2 – a cover of the radical bearing of a bent shaft; 3 – asterisk of a bent shaft; 4 – pulley of a bent shaft; 5 – spline of a pulley and asterisk of a bent shaft; 6 – ratchet (or bolt of fastening of a pulley); 7 – forward epiploon of a bent shaft; 8 – gas distribution mechanism drive cover; 9 – pulley of the water pump; 10 – belt of the drive of the generator and water pump; 11 – chain of the drive of the gas-distributing mechanism; 12 – head of the block of cylinders; 13 – camshaft asterisk; 14 – cover of a head of the block of cylinders; 15 – case of bearings of the camshaft; 16 – camshaft; 17 – inlet valve; 18 – final valve; 19 – block of cylinders; 20 – flywheel; 21 – back epiploon of a bent shaft; 22 – oil case; 23 – rod bolt; 24 – an opening stopper for oil discharge; 25 – rod cover; 26 – rod; 27 – piston finger; 28 – piston; 29 – final collector; 30 – inlet pipe; 31 – valve drive lever; 32 – internal spring of the valve; 33 – external spring of the valve; 34 – adjusting bolt; 35 – lock-nut of an adjusting bolt; 36 – carving plug of an adjusting bolt; 37 – spark plug; 38 – shaft of the drive of auxiliary units; 39 – gear wheel of the drive of the oil pump and distributor of ignition; 40 – oil filter; 41 – oil pump; 42 – reception branch pipe of the oil pump


The block of cylinders 19 (fig. 2.36) represents the uniform casting from special cast iron forming cylinders, a cooling shirt, the top part of a case and five support of a bent shaft executed in the form of partitions of a case and strengthened by stiffening ribs. On the block of cylinders there are special inflows, flanges, openings for fastening of details, knots and units, and also channels of the trunk oil main are executed.
The head of the block of cylinders 12 represents the uniform casting from aluminum alloy forming combustion chambers of maple type with inlet and final channels, a shirt of cooling, a lug, flanges and carving openings for fastening of the case of bearings of the camshaft, details of the gas-distributing mechanism, an inlet pipe with the carburetor and a final collector, details of the cooling system, a cover of a head, spark plugs and the sensor of temperature of cooling liquid. In a head of the block of cylinders the directing plugs of valves and a saddle of inlet and final valves are pressed.
Between a head and the block of cylinders the laying impregnated with graphite from the asbestos reinforced by a metal framework is established.
Pistons 28 are cast from high-strength aluminum alloy. Skirts of pistons have the irregular geometrical shape: on height conic, with the big basis in the bottom of a skirt, and in cross section oval, with the bigger axis located perpendicular to an axis of a piston finger. The external surface of pistons is covered with tin. Axes of openings under piston fingers are displaced from an axis of symmetry of pistons on 2 mm to the right side of the engine. On the cylindrical surface of pistons three ring flutes for piston rings are executed.
Piston rings produce by method of individual casting from the alloyed cast iron. On each piston establish three piston rings: two compression and one oil scraper.
Piston finger 27 steel, hollow. Its external surface is cemented and tempered by currents of high frequency.
Rod 26 steel shod. The opening for inserts of the conrod bearing is processed together with a cover 25. Inserts of the conrod bearing steel-aluminum, interchangeable.
The bent shaft 1 cast from high-strength cast iron has five radical necks and four counterbalances. On the forward end of a shaft 3 chains of the drive of the mechanism of gas distribution and a pulley 4 drives of the water pump and the generator establish an asterisk; on the back end of a shaft – a flange for fastening of a flywheel 20 and a nest for the bearing of a main shaft of the transmission. Radical and conrod necks are tempered by currents of high frequency on depth of 2-3 mm. Inserts of radical bearings thin-walled steel-aluminum.
The camshaft 16 pig-iron cast, has five support and eight cams. Working surfaces of cams are nitrated. The shaft is installed in the removable case 15 fixed on a block head by ten hairpins. On the forward end of a shaft the conducted asterisk of the 13th drive is established.
The camshaft is given to rotation by the two-row roller chain 11 having 116 links from the leading asterisk 3 established on cranked to a shaft. The same chain gives an asterisk of a shaft of the 38th drive of auxiliary units (oil and fuel pumps, and also the ignition distributor). Pull a chain a spring natyazhitel through a boot with a slip. Fluctuations of a chain are extinguished by an uspokoitel.
Final valves 18 welded of two parts: a core from hromonikelemolibdenovy steel, a plate from hromonikelemargantsevy steel from a naplavky working facet special heat-resistant alloy. Inlet valves 17 are manufactured of hromonikelemolibdenovy steel. Cores of all valves are nitrated, and end faces of cores are tempered by currents of high frequency. Valves move in the directing plugs under the influence of camshaft cams via the steel levers 31 leaning one shoulder on spherical heads of adjusting bolts 34, to others – to end faces of cores of valves. Adjusting bolts are screwed in plugs 36 and stopped by nuts 35.
The oil case 22 steel stamped, closes the block of cylinders from below and serves as the tank for oil.
The lubrication system combined: the most loaded details are greased under pressure, the others – spraying. Under pressure radical and conrod bearings of a bent shaft, support and cams of the camshaft, bearings of a shaft of the drive of auxiliary units, the plug of a cogwheel of the drive of the oil pump and the distributor of ignition are greased.
The system consists of an oil case 22, the gear oil pump 41 with the built-in reducing valve and an oil receiver 42 having the mesh filter of GRU -
fight of purification of oil, full-line filter 40 of thin purification of oil with perepuskny and antidrainage valves, sensor of a control lamp of insufficient pressure of oil and oil channels.
The cooling system of the engine consists of the shirt of cooling executed in casting and surrounding cylinders in the block, the combustion chamber and gas channels in a head of the block of cylinders and an inlet pipe.
Compulsory circulation of liquid in system is provided by the centrifugal water pump with the drive from a bent shaft by means of a maple belt 10. For maintenance of normal working temperature of cooling liquid install the thermostat blocking a big circle of system at not heated-up engine and low temperature of cooling liquid in the cooling system.
The power supply system of the engine consists of the diaphragm fuel pump with the mechanism of the manual drive, the carburetor, the filter of thin purification of fuel and fuel hoses.
The system of ignition consists of the distributor installed in special inflow of the block of cylinders, coils of high voltage, candles 37 and wires of high voltage.
Possible malfunctions of the engine of fashion. 2106, their reasons and ways of elimination practically do not differ from the fashion described for the engine. 331 (see. "Engine of fashion. 331"), except for some features: at the engine of fashion. 2106 does not happen malfunctions "Knock of piston fingers" owing to other way of their fastening; excessive noise of a chain of the drive of the camshaft can be caused by jamming of a rod of a natyazhitel of a chain; cooling liquid can get into an engine case only at damage of laying of a head of the block as this engine has no removable sleeves of cylinders; at the high consumption of oil on waste caused by wear of a mirror of cylinders, operability of the engine is restored only boring and a honingovaniye of cylinders for the same reason, as at the previous malfunction; the raised oil consumption at serviceable tsilindroporshnevy group can be caused by wear or damage of oil scraper caps on the directing plugs of valves, and also hardening of material of which they are made (at the engine of fashion. 331 other designs of consolidation of this knot); the engine can not be launched, work unstably or to stop idling and because of combustion of the resistor in an ignition distributor rotor (in the distributor of the engine of fashion. There are no 331 resistors).

Removal and installation
Remove and install the engine of fashion. 2106 almost in the same order, as fashion. 331. Distinction consists only in an arrangement of the disconnected knots and details and the number of fasteners.

Dismantling

Fig. 2.37. Pump of cooling liquid: 1 – final branch pipe of a shirt of cooling; 2 – a hose from a block head to the thermostat (байпас); 3 – pump; 4 – the coupling connecting the thermostat to the pump; 5 – thermostat


1. Remove the generator, the carburetor, the ignition distributor, the thermostat, the fuel pump, an oil filter, a generator drive belt, an arm of fastening of the generator, the water pump 3 (fig. 2.37), a final branch pipe of cooling liquid on a block head, a cover of a sapun of ventilation of a case and take out an oil separator of ventilation of a case.
2. Turn out spark plugs, the sensor of the index of temperature of cooling liquid, the sensor of a control lamp of insufficient pressure of oil.
3. Remove a case, the oil pump with an oil receiver, a clamp of a drain tube of an oil separator with a glass.

Fig. 2.38. Removal of a flywheel: 1 – key; 2 – flywheel; 3 – bolt of fastening of a flywheel; 4 – washer; 5 – a clamp for deduction of a flywheel from a provorachivaniye; 6 – forward cover of a case of coupling


4. Remove a pulley of a bent shaft, having fixed a flywheel of 2 (fig. 2.38) by a clamp 5 and having turned off a key a bolt of fastening of a pulley.
5. Uncover heads of the block of cylinders and a cover of the drive of the camshaft.
6. Turn off bolts of fastening of asterisks of the camshaft and roller of the drive of auxiliary units, previously having unbent edges of their lock washers.

Fig. 2.39. Elements of fastening of a natyazhitel and uspokoitel of a chain: 1 – the cap-type nut of a natyazhitel; 2 – case of a natyazhitel; 3 – nut of fastening of a natyazhitel; 4 – boot of a natyazhitel; 5 – bolt of fastening of a boot; 6 – camshaft drive chain; 7 – bolt of fastening of an asterisk of the roller of the drive of the oil pump; 8 – bolt of fastening of an uspokoitel


7. Turn off the cap-type nut of 1 (fig. 2.39) of a natyazhitel of a chain, wring out an assembly shovel a rod of a natyazhitel and record it in this situation, having tightened the cap-type nut.
8. Turn off two nuts 3 fastenings of a natyazhitel of a chain to a head of the block of cylinders, remove a natyazhitel and, having turned off a bolt 5, take off a boot 4 natyazhitel of a chain.
9. Twist a restrictive finger of a chain from the lower part of the block of cylinders, remove asterisks of the drive of auxiliary units and the camshaft and take out a chain through the top window in a block head.

Fig. 2.40. Removal of a persistent flange of the camshaft: 1 – persistent flange; 2 – camshaft; 3 – case of bearings; 4 – nut of a hairpin of fastening of a persistent flange;
5 – nuts of fastening of the case of bearings


10. Having weakened nuts of 4 (fig. 2.40) of fastening of a persistent flange of 1 camshaft, turn off nuts of the 5th fastening of the case of bearings of the camshaft, remove the flat washers located under them from hairpins and remove the case with the camshaft.
11. Turn off nuts 4, remove spring washers and take out from a camshaft pro-point a persistent flange 1.
12. Carefully, not to damage sharp edges of cams a surface of support of the case of bearings, take out the camshaft from the case.
13. Turn off bolts of fastening of a head of the block of cylinders and remove it together with a final collector and an inlet pipe.

Fig. 2.41. Removal of the roller of the drive of the oil pump: 1 – persistent flange; 2 – bolt of fastening of a flange; 3 – roller of the drive of auxiliary units; 4 – key


14. Turn off two bolts of 2 (fig. 2.41) of fastening of a persistent flange of 1 roller 3 drives of auxiliary units, remove a persistent flange and take out the roller from the block of cylinders.
15. Remove a universal stripper a camshaft drive asterisk from a bent shaft.
16. Turn off nuts of conrod bolts, uncover rods and carefully take out pistons with rods via cylinders.

       NOTE
Taking out pistons, mark the piston and a cover of its rod that at assembly to install them in former cylinders.

17. Establish on a flywheel a clamp 5 (see fig. 2.38) if it was removed after an otvorachivaniye of a bolt of fastening of a pulley. Turn off bolts of fastening of a drive plate of coupling and remove it together with the conducted disk. Turn off bolts 3 fastenings of a flywheel, remove a washer 4 and a flywheel from a bent shaft.
18. Turn off two nuts of fastening of a forward cover of the 6th case of coupling, remove spring washers from mortgage hairpins and remove a forward cover.

Fig. 2.42. Vypressovka of the transmission shaft bearing from a bent shaft with on -
power of a pusher


19. A pusher to a vypressuyta the forward bearing of a main shaft of the transmission from a nest of a bent shaft (fig. 2.42).
20. Having turned off six nuts of fastening, remove the holder of a back epiploon of a bent shaft with an epiploon and laying.
21. Turn off bolts of covers of radical bearings, remove them together with the lower inserts, then remove a bent shaft, the top inserts and persistent half rings on a back support.
The nominal sizes, admissions and landings of the main interfaced details of the engine and maximum permissible gaps, wear at operation and deviations of a geometrical form are given in tab. 2.4.

Table 2.4 the Nominal sizes, admissions and landings of the main interfaced details of the engine of fashion. 2106 and maximum permissible gaps, wear at operation and deviations of a geometrical form
Assembly
1. Install the washed-up and cleared block of cylinders on the stand and wrap in it missing hairpins.
2. Lay in a nest of the average radical bearing of a bent shaft and in its cover the inserts without bore on an internal surface having in comparison with the others the increased width, and in other nests and the corresponding covers – inserts with bore. In nests of the block of cylinders of the 1, 2, 4 and 5 radical bearings it is possible to establish inserts also without bore. Establish inserts only by hands without use of any tool so that the unbent mustache on an edge of an insert entered a groove of a nest or a cover of the bearing.

       NOTE
Oil inserts of bearings and persistent half rings of a bent shaft, and also pistons and cuffs before installation engine.


Fig. 2.43. Installation of persistent half rings on a back support of the engine


3. Lay a bent shaft in radical bearings and insert two persistent half rings (fig. 2.43) which are picked up for thickness into nests of a back support.

Fig. 2.44. Tags on covers of radical bearings (count of support is kept from a forward part of the engine) and conditional number of the block of cylinders of the engine


4. Establish covers of radical bearings according to tags (fig. 2.44), and tighten bolts the moment of 70-86 N · m (7,0–8,6 kgfs · м).

       PREVENTIONS
1. Install covers of radical bearings in the former block without depersonalizing. For this purpose the block of cylinders and covers belonging to it are marked with identical conditional number (see fig. 2.44 and 2.56).
2. At installation of persistent half rings of dredging on their working surfaces have to be turned to persistent surfaces of a bent shaft, and from the forward party of a back support arrange a steel-aluminum half ring, and from the back party – ceramic-metal (yellow color).

Fig. 2.56. Marking of dimensional group of cylinders on the block of cylinders (red shooters) and conditional number of the block of cylinders (a black arrow)


5. Lay laying of the holder of an epiploon on a back flange of the block of cylinders.

Fig. 2.45. The holder of a back epiploon of a bent shaft (shooters specified ledges for centering of the holder concerning a flange of a bent shaft)


6. Put on the holder with an epiploon (fig. 2.45) a mandrel; having moved it from a mandrel on a flange of a bent shaft, center on three adjusting ledges and attach to the block of cylinders.
7. Install on two aligning plugs pressed in a back flange of the block, a forward cover of a case of coupling and fix it by nuts on the holder of a back epiploon.
8. Establish a flywheel on a flange of a bent shaft so that the tag (a cone-shaped hole) about a rim of a flywheel settled down opposite to an axis of a conrod neck of the 4th cylinder, block a clamp a flywheel and attach it bolts to a flange of a bent shaft the moment of 78-89 N · m (7,8–8,9 kgfs · м).

Fig. 2.46. Installation of the piston with piston rings in the engine cylinder by means of the plug from set


9. By means of the plug mandrel from set insert into cylinders pistons with rods (fig. 2.46). Set consists of three plugs: one – for pistons of the nominal size and two – for pistons of the repair size (increased by 0,4–0,7 mm). Choose the plug intended for the size of the installed piston.

Fig. 2.47. Installation of conrod and piston group in the engine cylinder: 1 – block of cylinders; 2 – device for compression of piston rings; 3 – piston


If there is no special set of plugs mandrels, it is possible to use the universal device for compression of piston rings (fig. 2.47).

       PREVENTION
The opening for a finger on the piston is displaced on 2 mm to the right side of the engine therefore at installation of pistons the tag "П" on the bottom of the piston or the shooter on a lug under a piston finger have to be turned into cylinders to a forward part of the engine.

10. Establish inserts in rods and covers of rods in the same way as it was done for radical bearings.
11. Connect rods to necks of a bent shaft, establish covers and tighten nuts of conrod bolts the moment of 44-55 N · m (4,4–5,5 kgfs · м).
12. Establish an asterisk on a bent shaft.

Fig. 2.48. Check of coincidence of an adjusting tag on an asterisk of a bent shaft with a tag on the block of cylinders of the engine


13. Turn a bent shaft so that the tag on an asterisk of a bent shaft coincided with a tag on the block of cylinders (fig. 2.48).
14. Install the roller of the drive of auxiliary units in the block of cylinders and fix it by a persistent flange.

Fig. 2.49. Order of an inhaling of bolts of fastening of a head of the block of cylinders


15. Establish on two aligning plugs on the block a head of the block of cylinders with laying, a final collector, an inlet pipe and a zabornik of hot air and tighten bolts of fastening of a head in a certain sequence (fig. 2.49) in two steps: previously moment of 34-42 N · m (3,4–4,2 kgfs · l) bolts 1–10; finally moment of 98-121 N · m (9,8–12,1 kgfs · l) bolts 1–10 and moment of 32-40 N · m (3,2–4,0 kgfs · l) bolt 11.

Fig. 2.50. Installation of the piston of the 4th cylinder in VMT at the end of a compression step: 1 – an adjusting tag on a camshaft asterisk; 2 – adjusting inflow on the case of bearings of the camshaft


16. Install an asterisk on the camshaft assembled with the case of bearings and turn a shaft so that the tag of 1 (fig. 2.50) in the form of a hole on an asterisk was against adjusting inflow 2 on the case of bearings.

Fig. 2.51. Order of an inhaling of nuts of fastening of the case of bearings of the camshaft


Then remove an asterisk; without changing the provision of a shaft, install the case of bearings on a head of the block of cylinders and fix it, tightening fastening nuts in a certain sequence (fig. 2.51) the moment of 19-23 N · m (1,9–2,3 kgfs · м).
17. Establish on a head of the block of cylinders an uspokoitel of a chain.
18. Put on a chain an asterisk of the camshaft and enter it into a drive cavity, establishing an asterisk on a camshaft flange so that the tag 1 (see fig. 2.50) on it coincided with inflow 2 on the case of bearings. Do not tighten a bolt of an asterisk against the stop.
19. Install an asterisk on the roller of the drive of auxiliary units, without tightening finally a fastening bolt.
20. Establish a boot of a natyazhitel of a chain and a natyazhitel, do not tighten the cap-type nut that the spring of a natyazhitel could press a boot.
21. Wrap a restrictive finger of a chain in the block of cylinders.
22. Turn a bent shaft on two turns in the direction of rotation to provide the necessary tension of a chain; check coincidence of tags on asterisks with tags on the block of cylinders (see fig. 2.48) and on the case of bearings (see fig. 2.50).
23. If tags coincide, block a flywheel a clamp (see fig. 2.38) and finally tighten bolts of fastening of asterisks the moment of 42-51 N · m (4,2–5,1 kgfs · l), the cap-type nut of a natyazhitel of a chain and then unbend edges of lock washers of bolts of asterisks on the verge of bolts. If tags do not coincide, then repeat operations 16-22 on installation of a chain.
24. Adjust gaps between cams of the camshaft and levers of the drive of valves.

Fig. 2.52. A camshaft drive cover (shooters showed ledges for centering of a cover concerning a nave of a pulley of a bent shaft)


25. Install a cover of the drive of the camshaft (fig. 2.52) with laying and an epiploon on the block of cylinders, without tightening finally bolts and nuts of fastening. Center a mandrel the provision of a cover concerning the end of a bent shaft on three adjusting ledges (are shown by shooters) and tighten finally nuts and bolts of its fastening.
26. Establish a pulley of a bent shaft and tighten a bolt of its fastening the moment of 104-128 N · m (10,4–12,8 kgfs · м).

Fig. 2.53. Adjusting tags on a pulley of a bent shaft and a cover of the drive of the mechanism of gas distribution: 1 – an ignition advancing tag on 10 °; 2 – an ignition advancing tag on 5 °; 3 – an ignition advancing tag on 0 °; 4 – VMT tag on a pulley


27. Finally check correctness of installation of the drive of the mechanism of gas distribution on tags of 4 (fig. 2.53) on a pulley of a bent shaft and 3 on a drive cover. These two tags have to coincide at the time of combination of a tag on a camshaft asterisk with inflow of its case (see fig. 2.50).
28. Establish an oil filter, having tightened it manually to the union on the block of cylinders and having oiled previously rubber sealing ring engine.
29. Establish an oil separator of ventilation of a case and a cover of a sapun. Fix a clamp of a drain tube of an oil separator.
30. Install the oil pump and an oil case with laying.

       NOTES
1. We recommend to establish at each dismantling of the engine new laying of the oil pump and an oil case as access to them on the engine mounted on the car is extremely complicated.
2. Tighten bolts of fastening of an oil case evenly cross-wise without excessive efforts.

31. Install the water pump, an arm of the generator and the generator. Put on a belt pulleys of the water pump, generator and a bent shaft and adjust its tension.
32. Establish on a head of the block of cylinders the bringing tube of a radiator of a heater and a final branch pipe 1 (see fig. 2.37) cooling shirts. Attach the taking-away heater radiator tube to the water pump and a final collector.
33. Install a bypass hose 2 from a block head to the thermostat and the rubber coupling 4 on the water pump. Install the thermostat on a hose and the coupling.
34. Install sensors of control devices on the places.
35. Establish a gear wheel of the drive of the oil pump and distributor of ignition in a nest of inflow of the block of cylinders, having greased its shaft and a gear wreath with engine oil.
36. Install the fuel pump (see. "Power supply system").
37. Check whether there is a piston of the 1st cylinder in VMT (if necessary establish it in this situation) and install the ignition distributor with paronitovy sealing laying on a flange in a nest of the block of cylinders. At the same time turn the distributor roller so that the external contact of a rotor was directed towards the hairpin of fastening of a cover of a head of the block second at the left, and deploy the case of the distributor so that the cover of the vacuum proofreader was directed towards the fuel pump.

       PREVENTION
The described way of installation of the distributor yields very approximate result and only provides the first launch of the engine after assembly. After installation of the engine on the car and its start-up surely adjust finally the ignition moment.

38. Screw spark plugs and tighten their moment 32–40 N · m (3,2–4,0 kgfs · м).
39. Establish a plait of wires of high voltage.
40. Install the carburetor with laying and attach to it and the fuel pump a fuel-supply line hose.
41. Establish a cover of a head of the block of cylinders with laying, having placed a fuel-supply line arm on the left forward hairpin of its fastening. Insert a fuel-supply line into an arm.
42. Establish forward support of the engine with pillows and adapters.
43. Establish the conducting and conducted clutch plates on a flywheel (see. "transmission. Coupling").

Repair of details and knots of the engine
Block of cylinders of the engine
Preparation of the block of cylinders for repair and assessment of its technical condition
Wash up the block of cylinders, having shipped it in a bathtub with the washing solution. Then wash out it a stream of the same solution under pressure to clear oil channels. Carefully blow and dry compressed air all block of cylinders, especially system of oil channels.
Examine the block of cylinders. If in support or other places of the block of cylinders there are cracks, replace the block of cylinders.
If there is a suspicion that cooling liquid gets to a case of the engine, check tightness of the block of cylinders at the special stand. For this purpose muffle all openings of a shirt of cooling and force in it water of room temperature under pressure of 0,3 MPas (3 kgfs/cm2), at the same time within 2 min. there should not be a leak of water from a shirt. If the shirt of cooling is untight, replace the block as this malfunction does not give in to elimination.
In the absence of the stand it is possible to check tightness of the block before removal and full dismantling of the engine, directly on the car. For this purpose merge liquid from the cooling system, remove a head of the block of cylinders, fill a shirt of cooling of the block with water and give compressed air to the vertical oil canal of the block. If in walls of oil channels there are cracks or sinks, in water vials of air will appear.

Fig. 2.54. Measurement of cylinders of the engine nutromer: 1 – nutromer; 2 – installation of a nutromer on zero on caliber


Fig. 2.55. Scheme of measurement of cylinders:
And yes In – the directions of measurement; 1, 2, 3, 4 – numbers of belts


Check whether exceeds a gap between the cylinder and the piston of admissible size (0,06–0,08 mm for the new engine and no more than 0,15 mm for working). The gap is determined by measurement of diameters of cylinders and pistons. Diameter of the cylinder is measured by a nutromer of 1 (fig. 2.54) in four belts in the longitudinal and cross direction (fig. 2.55).
In a belt zone 1 cylinders practically do not wear out. Therefore on a difference of measurements in the first and other belts it is possible to judge the size of wear of cylinders.
Diameter of the piston is measured in the plane, perpendicular to a piston finger, at distance of 52,4 mm from the piston bottom.

       NOTE
Block cylinders on diameter are broken through 0,01 mm into five classes: And, B, C, D, E. Klass of the cylinder is marked on the lower plane of the block (fig. 2.56). On the same plane, and also on covers of radical bearings the conditional number of the block of cylinders indicating accessory of covers of bearings to this block is branded.

Dimensional class
Diameter of the cylinder, mm
A
79,00-79,01
B
79,01-79,02
With
79,02-79,03
D
79,03-79,05
E
79,04-79,05


Fig. 2.57. Engine piston: 1, 2 and 3 – the planes of measurement of a profile of a skirt; 4 – the exaggerated skirt profile in longitudinal section (perpendicular to an axis of a piston finger)


For providing an optimum gap between a mirror of the cylinder and the piston the last divide on the largest diameter of a skirt in the plane of measurement of 2 (fig. 2.57) into five classes A, B, C, D, E. Alphabetic reference of a class is applied on the piston bottom.
Letters mean the following sizes of diameter of a skirt:

Dimensional class
Diameter of a skirt, mm
A
78,930-78,940
B
78,940-78,950
With
78,950-78,960
D
78,960-78,970
E
78,970-78,980

If the maximum size of a gap is more than 0,15 mm, chisel also to an otkhoninguyta cylinders under the repair diameter of pistons (increased on 0,4; 0,7 mm) taking into account an assembly gap of 0,06-0,08 mm between the piston and the cylinder.
Check whether there is no deformation of the plane of the socket of the block of cylinders with a block head. Carry out check by means of a metal line and a set of probes. Establish a ruler on an edge on diagonals of the plane and in the middle (in the longitudinal and cross directions) and enter the probe into a gap (if it is) between a ruler and the block. If not planeness exceeds 0,1 mm, replace the block of cylinders as it is impossible to grind or mill this surface.
Conrod and piston group
Selection of the piston to the cylinder
The piston and the cylinder corresponding to it have to belong to one class as the piston with a piston finger – to one category.

       NOTE
As it was stated above, on outer diameter pistons are broken into five classes (And, B, C, D, E), and on diameter of an opening under a piston finger – into three categories through 0,004 mm. A piston class (letter) and category of an opening under a piston finger (figure) are branded on the piston bottom.

For selection of the piston to any cylinder pistons and cylinders are broken into classes with some overlapping of the sizes. Therefore in spare parts deliver pistons only of classes A, C, E. These classes are enough for selection of pistons to any cylinder.
The main thing at selection of the piston – to provide a necessary assembly gap between the piston and the cylinder which is defined as a difference of the measured diameters of the cylinder and piston.
The difference of bigger and smaller diameters of a skirt of the piston in cross section makes 0,4 mm.
At selection of new pistons to the worn-out cylinder check a gap between a skirt of the piston and a mirror of a sleeve in the lower, less worn-out part of the cylinder. Reduction of a gap in this part of the cylinder to value less than 0,02 mm as there can be a jamming of the piston in the engine which is warmed up up to the working temperature is not allowed.
At maintenance, as a rule, install pistons which size (normal or repair) in partially worn-out cylinders same, as at working in this engine. However it is desirable to pick up a set of pistons with a big diameter of a skirt for reduction of a gap between the piston and a mirror of the cylinder.
Pistons change most often because of wear of a flute of the top piston ring less often because of wear of a skirt of the piston.
It is expedient to replace them in the same terms, as piston rings.
Except pistons of the nominal size, in spare parts deliver pistons of the repair sizes with the increased diameter of a skirt for installation in the chiseled and otkhoningovanny cylinders.

Number of the repair piston
Increase in diameter of a skirt, mm
21011-1004015-21
+0,4
21011-1004015-22
+0,8

On the bottom of repair pistons the largest diameter of a skirt of the piston rounded to 0,01 mm and its weight are beaten out.
Control of mass of pistons
Install pistons only of one group which on weight should not differ from each other more than on 5 g in the engine.

Fig. 2.58. The scheme of removal of metal from the piston for adjustment of mass of the piston (shooters specified places on which it is possible to delete metal)


If there is no set of pistons of one group, it is possible to remove a part of metal from the basis of lugs under a piston finger. Places of removal of metal are specified by shooters fig. 2.58. Metal can be removed on depth no more than 4,5 mm of nominal height of the piston (59,4 mm), and on width – to diameter no more than 70,5 mm.
Vypressovka of a piston finger
Vypressuyte a finger on the press by means of a mandrel and a support with cylindrical dredging in which stack the piston.

       NOTE
Before a vypressovka of a finger remove piston rings from the piston.

If the removed details are a little worn-out and are not damaged, they can be used again. Therefore when dismantling mark details further to establish details of conrod and piston group on former places.
Check of a gap between the piston and a finger
The finger is pressed in the top head of a rod with a tightness and freely rotates in piston lugs (with a gap of 0,016-0,08 mm).
Fingers and openings in lugs of the piston divide by the sizes into three groups through 0,004 mm and mark blue, green and red paint from smaller to bigger. In one cylinder of the engine the piston, a finger and a rod have to be one dimensional group.

Fig. 2.59. Check of correctness of selection of a piston finger


Fig. 2.60. Check of landing of a piston finger


Interface of a piston finger and the piston check, implanting the finger which is previously oiled engine into openings of lugs of the piston. The piston finger has to enter openings from effort of a thumb of a hand (fig. 2.59) and should not drop out of piston lugs in vertical position (fig. 2.60).
Replace the finger which is dropping out of lugs with another, the following group. If also the finger of the third group drops out, then replace the piston with a finger.
Selection of piston rings
Piston rings select for the size of gaps on height between rings and flutes in pistons, and also in the lock.

Fig. 2.61. Check of a gap between piston rings and flutes: 1 – piston ring; 2 – piston; 3 – set of probes


Check a gap on height between flutes and rings, as shown in fig. 2.61, inserting a ring into the corresponding flute.
Check a gap in the lock of piston rings a set of probes, inserting rings into caliber with a diameter of an opening equal to the nominal diameter of a ring with the admission of ±0,003 mm. In the absence of caliber insert a piston ring into that cylinder where it will work, and advance it the piston on depth of 20-30 mm from bottom edge of the cylinder.
For all rings the gap has to be 0,25–0,4 mm. If a gap insufficient, saw round butt surfaces a velvet file if increased – replace rings.
Height and face adjusting gaps of piston rings are specified in tab. 2.5.

Table 2.5  Adjusting data of rings

 Table 2.6 Diameter of Rings

Diameters of the fashion which is released for the engine. 2106 rings are given in tab. 2.6. In spare parts of a ring are delivered by a set on one engine.
Rings of the nominal size apply when replacing worn-out rings to cylinders of the nominal size. To reduce term extra earnings of new rings in cylinders of the working engine, the top compression rings in repair kits of the nominal size are not covered with chrome.
Pistons with rings of the increased diameter install in the cylinders chiseled to the repair size or use for replacement of worn-out rings in such cylinders.

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


Rings establish in flutes of pistons so that bore on an external surface of the second compression (scraper) ring was turned down, and facets on an external surface of an oil scraper ring were turned up (see fig. 2.19).

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


At non-compliance with this condition oil can get through rings into the cylinder that will lead to a nagaroobrazovaniye on combustion chamber walls, to a smoky exhaust and the increased oil consumption. Put on rings the piston and remove them only by means of special adaptation or the nippers (see fig. 2.17) providing the identical tension of a bend on a ring circle.
For qualitative extra earnings of piston rings after their replacement in the first 1000 km of a run the speed of the car should not exceed 60 km/h.
Assembly of conrod and piston group
The finger is implanted into the top head of a rod with a tightness therefore the rod needs to be heated to 240 °C for expansion of its head and, therefore, for increase in diameter of an opening under a finger.
1. Place rods in the furnace heated to 240 °C the top heads in the furnace for 15 min.

Fig. 2.62. Installation of a piston finger on the device for its press fitting in the piston and a head of a rod: 1 – adaptation roller; 2 – piston finger; 3 – guide; 4 – persistent screw


2. In advance prepare a finger for assembly: put on it the roller of 1 adaptation (fig. 2.62), establish on the end of this roller a guide 3 and fix it by the screw 4. Tighten the screw leaky that did not jam it at expansion of a finger from contact with a heated rod.
3. Take a rod from the furnace and quickly clamp it in a vice.
4. Putting on the piston a rod, track that the opening under a finger coincided with an opening of the top head of a rod.

Fig. 2.63. Press fitting of a piston finger
in the top head of a rod: 1 – adaptation; 2 – piston finger


5. Adaptation 1 (fig. 2.63) push the fixed piston finger in an opening of the piston and the top head of a rod so that the zaplechik of the roller of adaptation adjoined to the piston. Correctly to connect a finger to a rod, press a finger as soon as possible: after cooling of a rod it will already be impossible to change position of a finger.
During this operation the piston has to nestle a lug on the top head of a rod in the direction of a finger press fitting (it is shown by an arrow in fig. 2.63) that will provide the correct position of a finger.

       PREVENTIONS
1. Connect the piston to a rod so that the tag "П" on the piston was from an opening for an oil exit on the lower head of a rod. If on the piston there is a marking in the form of an arrow on one of lugs under a piston finger, its edge also has to be directed towards this opening.
2. After cooling of a rod oil a finger engine through openings in piston lugs.

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


3. At installation of piston rings their locks arrange through 120 ° (see fig. 2.9).
4. It is impossible to depersonalize covers of rods as rods process together with covers and they are not interchanged. Not to mix them at assembly, on a rod and the cover corresponding to it number of the cylinder in which they are established is branded. At assembly of figure on a rod and a cover have to be on the one hand.

Bent shaft
The main sizes of a bent shaft are given in tab. 2.7.

Table 2.7 Sets of inserts of bearings of the repair sizes and repair sizes of necks of a bent shaft of the engine of fashion. 2106

Cleaning of channels for lubricant
Remove caps of channels and the vertical drill which is put on a drill spindle, clean nests of caps, carefully wash out channels gasoline and blow compressed air.
Apply UG-6 sealant on surfaces of nests of caps.
Mandrel press new caps and for bigger reliability fuller a core each cap in three points.
Grinding of radical and conrod necks
Cracks on radical and conrod necks, and also cheeks of a bent shaft are not allowed. If they are found, replace a shaft.
Insignificant teases on necks it is possible to smooth out whetstone of a carborundum of small granularity. If risks very deep or wear and ovality of necks more than 0,03 mm, their proshlifuyta.
The sizes of radical and conrod necks when grinding reduce by 0,25 mm that depending on degree of wear to receive a certain repair size (see tab. 2.7).
After grinding and the subsequent operational development of necks carefully wash out a bent shaft for removal of the remains of an abrasive. Several times wash out channels for lubricant with remote caps gasoline under pressure. On the first cheek of a bent shaft specify the size of reduction of necks (0,25; 0,50 mm etc.).
Ovality and conicity of radical and conrod necks after grinding have to be no more than 0,007 mm.
Check of a beating and not coaxiality of necks

Fig. 2.64. Admissible beats of the main surfaces of a bent shaft


Establish a bent shaft on two prisms (fig. 2.64) and check the indicator the following.
1. Beating of radical necks (no more than 0,03 mm).
2. A beating of landing surfaces under an asterisk and the bearing of a main shaft of the transmission (no more than 0,04 mm).
3. Shift of axes of conrod necks from the plane passing through axes of conrod and radical necks (no more than ±0,35 mm).
4. Not perpendicularity of a face surface And flange of an axis of a bent shaft. Its beating should not exceed 0,025 mm.
Check of a gap between inserts of radical bearings and a bent shaft
On inserts it is forbidden to make any subracing operations. At teases, risks or peelings of an antifrictional layer replace inserts.
Check a gap between inserts and necks of a bent shaft with use of the special calibrated plastic wire.
1. Lay a piece of the calibrated wire on the checked neck along its axis.
2. Establish a cover with a radical insert and tighten bolts of fastening of a cover the full moment of 70-86 N · m (7–8,6 kgfs · м).

Fig. 2.65. Definition of a gap between a radical neck and an insert on a packing scale: 1 – scale; 2 – the calibrated wire


3. Uncover and, comparing width of the flattened wire to a scale of packing (fig. 2.65), define a gap.
The gap can also be calculated, having measured diameters of radical necks, beds under inserts and thickness of inserts (see tab. 2.7).
Nominal assembly gap between inserts of radical bearings and necks of a bent shaft of 0,05-0,095 mm. If the gap exceeds the most admissible at wear (0,15 mm), inserts replace repair, перешлифовав necks.
Sign of correctness of assembly and interface of necks to inserts is free rotation of a bent shaft.
Check of a gap between inserts of conrod bearings and a bent shaft
The gap between connecting rods and necks of a bent shaft is checked in the same ways, as for radical bearings.
Nominal assembly gap between inserts and necks of 0,036-0,086 mm. If at wear of 0,1 mm the gap does not exceed maximum permissible, then it is possible to establish the same inserts, without changing diameter of conrod necks.
At a gap it is more maximum permissible to a proshlifuyta conrod necks also replace inserts repair (see tab. 2.7).
If a gap in admissible limits, but on a working surface of inserts deep risks or firm impregnations, replace inserts new.
Inserts of conrod bearings and piston rings are recommended to be replaced at the same time. It will allow to avoid repeated repair, and, above all, will improve operating conditions of conrod necks of a bent shaft and considerably will increase the term of their service. Inserts of radical bearings usually replace after the considerable run of the car which engine one or two times was exposed to maintenance earlier. Inserts establish without any subracing operations and only in pairs, replacement of one insert from couple is inadmissible. You watch that the fixing ledges on joints densely entered the corresponding grooves of beds of the block of cylinders, covers of radical bearings, rods and their covers. After replacement of inserts of conrod or radical bearings the first 1000 km of a run the speed of the car should not exceed 60 km/h.
Check of an axial gap of a bent shaft
Axial movement of a bent shaft is limited to two persistent half rings established on both sides of the back radical bearing. From the forward party of the bearing establish a steel-aluminum half ring, from the back party – ceramic-metal (yellow color). Half rings make normal (2,31–2,36 mm) and increased (2,437–2,487 mm) thickness.
For check of an axial gap between persistent half rings and persistent surfaces of a bent shaft to execute the following.

Fig. 2.66. Check of an axial gap of a bent shaft


1. Install the indicator on a magnetic support and insert the ends of two screw-drivers into gaps between cheeks of a bent shaft and covers of radical bearings, as shown in fig. 2.66.
2. Move a shaft with screw-drivers in the longitudinal direction against the stop to any party, bring an indicator rack to an end face of a flange of a bent shaft and install the indicator on zero.
3. Move a shaft against the stop in the opposite direction and determine an axial gap which at a new shaft has to be 0,055–0,265 mm by the indicator.
If the gap at the working shaft exceeds the most admissible (0,35 mm), replace persistent half rings with others, increased by 0,127 mm.

       NOTE
The axial gap of a bent shaft can be checked also on the engine installed on the car. At the same time axial movement of a bent shaft is caused pressing and an otpuskaniye of a pedal of coupling, and the axial gap is determined by the size of movement of the forward end of a bent shaft.

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. 2.67. Engine flywheel: 1 – the surface of fastening of a bent shaft to a flange; 2 – surface of fastening of coupling; 3 – a basic surface of the conducted clutch plate; And – the radius on which the beating of a surface 2 is checked; In – the radius on which the beating of a surface 3 is checked


If on a working surface of 3 (fig. 2.67) of a flywheel under the conducted clutch plate deep scratches and teases, pierce a surface, removing a layer of metal no more than 1 mm thick. Then pierce a surface 2, maintaining the size of (0,5±0,1) mm and providing parallelism of surfaces 2 and 3 concerning a surface 1.
The admissible not parallelism measured on extreme points of surfaces 2 (on radius And) and 3 (on radius In), no more than 0,1 mm.
Establish a flywheel on a mandrel, aligning it on a landing opening with the emphasis on a surface 1, and check the indicator a beating of surfaces 2 and 3. On radiuses And yes In it should not exceed 0,1 mm.

Head of the block of cylinders and valvate mechanism
Dismantling and assembly
1. Establish a head of the block of cylinders on a table or a workbench.
2. Disconnect a final collector (at the same time remove a zabornik of hot air) and an inlet pipe with the carburetor (if it was not removed when dismantling the engine).
3. Remove a final branch pipe of a shirt of cooling.
4. Disconnect a liquid supply tube in a heater radiator.

Fig. 2.68. Valvate mechanism: 1 – head of the block of cylinders; 2 – valve; 3 – the directing valve plug; 4 – a lock ring of the directing plug; 5 – maslootrazhatelny cap; 6 – small spring of the valve; 7 – big spring of the valve; 8 – plate of valvate springs; 9 – cracker; 10 – valve lever; 11 – case of bearings of the camshaft; 12 – camshaft; 13 – podzhimny spring of the lever of the valve; 14 – adjusting bolt; 15 – lock-nut; 16 – plug of an adjusting bolt; And – a thermal gap of the gas-distributing mechanism


5. Remove the case 11 (fig. 2.68) of bearings of the camshaft 12 together with shaft, having turned off nuts of its fastening.
6. Remove levers 10 of the drive of valves, taking out them from under springs of 13 levers. Remove springs of levers.
7. Weaken lock-nuts 15, turn out adjusting bolts 14 and in need of the plug of 16 adjusting bolts.

Fig. 2.69. Removal of springs of valves: 1 – adaptation; 2 – assembly board


8. Install the device for compression of springs of valves, as shown in fig. 2.69, squeeze springs and take out crackers 9 (see fig. 2.68) from plates of 8 springs.
9. Remove springs of valves with plates and basic washers. Turn a head of the block of cylinders and take out valves from its reverse side.
10. Pincers like "anaconda" or a special stripper remove maslootrazhatelny caps 5 from the directing plugs of valves.
Collect a head of the block of cylinders upside-down.
Cleaning of a head of the block of cylinders
Remove a deposit from combustion chambers and from the surfaces of final channels with the metal brush inserted into a cartridge of an electric drill.
Examine and if necessary clear inlet channels and the channel of a supply of oil to the camshaft.
Clear a privalochny surface to the block of cylinders of the remains of old laying.
Check and grinding of saddles of valves

Fig. 2.70. Profile of a saddle of the inlet valve: I – new saddle; II – a saddle after repair


Fig. 2.71. Profile of a saddle of the final valve: I – new saddle; II – a saddle after repair


For ensuring tightness of valves of a facet of saddles have to have the form shown in fig. 2.70 and 2.71.
On working facets of saddles in a zone of contact with valves there should not be dot sinks, corrosion and damages. Small damages can be eliminated with grinding of saddles. Try to remove as little as possible metal.
Grind saddles in the following order.
1. Establish a head on a support, insert the aligning core into the directing valve plug and put on it a spring.

       NOTE
Cores for the directing plugs of inlet and final valves of different diameter.


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


Fig. 2.72. Grinding of a working facet of a saddle of the valve


2. Establish on a grinder spindle (see fig. 2.22) a conic abrasive circle for saddles of final or inlet valves, put on a spindle the directing core and a proshlifuyta a saddle of the valve (fig. 2.72). At the time of contact of a circle with a saddle the machine has to be switched off, otherwise there will be a vibration and the facet will turn out irregular shape.

       NOTE
For an exception of a possibility of distortion of a form of a facet we recommend to a thicket to govern a circle a diamond pencil.

After grinding check a beating of a working facet concerning an axis of an opening of the directing plug – it should not exceed 0,05 mm.

Fig. 2.73. Narrowing of a facet of the inlet valve the vertical drill established on a spindle


For saddles of final valves bring width of working facets a vertical drill with a corner 20 ° to the sizes specified rice 2.71 previously having removed a peening a vertical drill for the internal diameter of a saddle. Vertical drills are put on the spindle disconnected from the grinder rotate manually and as well as when grinding, aligned a core (fig. 2.73).
Bring width of a working facet of saddles of inlet valves a vertical drill to the sizes specified fig. 2.70. At first process an internal facet before obtaining the size of 33 mm, and then a vertical drill with a corner 20 ° bring width of a working facet to 1,9–2,0 mm.
Valves
Remove a deposit from valves. Check whether the core is deformed and whether there are no cracks on a plate; in the presence of damages replace the valve.
Check whether it is not too worn-out and whether the working facet is damaged. When grinding a working facet of the valve on the grinder sustain a corner of a facet 45 °30 '±5' and track that the plate edge of the valve was not pointed, and thickness of a cylindrical corbel on it after grinding was not less than 0,5 mm.
The directing plugs of valves
Check gaps between the directing plugs and cores of valves, having measured diameters of cores of valves and openings of the directing plugs.
If the gap between the directing plug and the valve is more than 0,08 mm and he does not manage to be reduced to normal replacement of the valve, replace plugs of valves.
For replacement of two guides of plugs of inlet and final valves of the 1st and 4th cylinders turn out two extreme hairpins of fastening of the case of bearings of the camshaft as they prevent installation of a mandrel.

Fig. 2.74. Vypressovka of the directing plugs: 1 – mandrel


Vypressuyte of the plug from a block head from combustion chambers by means of a special mandrel (fig. 2.74) and the hammer or under a press.
Press new plugs with the put-on lock rings by means of the same mandrel in a block head in the direction of combustion chambers against the stop of rings in a head surface.
After an opening press fitting in the directing plugs develop to diameter of 8,022-8,040 mm for inlet valves and 8,029–8,047 mm – for final. Ovality and conicity of openings has to be no more than 0,01 mm.
Then a proshlifuyta a valve saddle also bring width of a working facet to the necessary sizes as it was described above.
Maslootrazhatelny caps
Replace Maslootrazhatelny caps when peeling rubber from fittings, its hardening, cracks and excessive wear of a working edge.
At repair of the engine maslootrazhatelny caps are always recommended to be replaced new.
The damaged maslootrazhatelny caps can be replaced, without removing a head of the block of cylinders from the engine. For this purpose turn out spark plugs, remove the case of bearings of the camshaft, levers of valves and their spring, install the piston of the corresponding cylinder in VMT and remove valve springs, as shown in fig. 2.69.

       NOTE
That at removal of springs the valve did not fail in the cylinder, record it, having inserted the solder bar entered through a candle opening between its head and the bottom of the piston.

Then remove from the directing plug the damaged cap and a mandrel to a napressuyta new, having oiled its internal surface engine.
Levers of valves, adjusting bolts and their plugs
Check a condition of the working surfaces of the lever which are interfaced to a valve core, to a cam of the camshaft and to the spherical end of an adjusting bolt. If on these surfaces there were teases, risks or deep development, replace the lever.
If the carving on adjusting to a bolt and its plug is damaged, the spherical end of a bolt is strongly worn-out or these details are deformed, replace them.
Springs

Fig. 2.75. A specification for check of an external spring of the valve


Make sure that on rounds of springs of valves and levers there are no cracks and deformation and their elasticity did not decrease. For this purpose check the size of deformation of springs in the axial direction under a certain loading. For big and small valvate springs the measured parameters see on

Fig. 2.76. A specification for check of an internal spring of the valve

fig. 2.75 and 2.76.

Fig. 2.77. Scheme of check of a spring of the lever: And – the size in a free state; In – the size under load (5,5±0,6) kgfs


For springs of levers (fig. 2.77) the size A (a spring in a free state) has to be 35 mm, the size B under load (55±6) N [(5,5±0,6) kgfs] – 43 mm.
Laying of a head of the block of cylinders
The surfaces of laying have to be equal, without damages, dents, cracks, swellings and breaks. Peeling of obkladochny material from fittings is not allowed.
On a fringing of openings there should not be cracks, progar and peelings.
However, even if the laying removed from the engine conforms to these requirements, at assembly of the engine it is recommended to replace it new.
Check of tightness of valves
Check tightness of valves the same as it is described for the engine of fashion. 331 "Check of tightness and grinding in of valves".
Check of tightness of a head of the block of cylinders
You carry out hydraulic test for tightness of a shirt of cooling of a head of the block of cylinders in the following order:

Fig. 2.78. Check of tightness of a head of the block of cylinders on adaptation: 1, 2 and 4 – caps; 3 – adaptation plate; 5 – a flange with the liquid supply union


1. Establish on a head of the block of a detail, devices for check of tightness (fig. 2.78) which are included in the package.
2. Force the pump in a shirt of cooling of a head water with chrompeak additive under pressure of 5 kgfs/sq.m.
Within 2 min. there should not be a leak of water from a head. If are found cracks through which water filters, a head of the block of cylinders replace.
Camshaft and its drive
The main sizes of the camshaft and case of bearings of the camshaft are given in tab. 2.8.

Table 2.8 Main sizes of the camshaft and case of its bearings

Check of the camshaft
Surfaces of cams and basic necks of the camshaft have to be well polished also without damages. If there are jamming traces, deep risks or steps from wear on working surfaces of cams, a shaft replace.
Install the camshaft by extreme necks on two prisms located on a testing plate and measure the indicator a radial beating of average necks which should not exceed 0,02 mm.
From axial movements the camshaft holds the persistent flange entering ring bore of the forward end of a shaft and fixed by bolts (or as option, nuts) at an end face of the case of bearings. The gap between a persistent flange and shaft determined by a difference of thickness of a flange and width of ring bore provides free rotation of a shaft.
Check of the case of bearings of the camshaft
Wash out and clear the case of bearings of the camshaft and the channel for an oil supply.
Check diameter of openings of bearings in support (tab. 2.8). If the gap between necks of the camshaft and support exceeds 0,2 mm (extreme wear), replace the case of bearings.
The basic surfaces of bearings have to be smooth, without zadir; if they are damaged or on the case there are cracks, replace the case of bearings.
Natyazhitel of a chain
For dismantling of a natyazhitel execute the following.

Fig. 2.79. Section of a natyazhitel of a chain: 1 – the cap-type nut; 2 – case of a natyazhitel; 3 – core; 4 – spring ring; 5 – plunger spring; 6 – washer; 7 – plunger; 8 – spring; 9 – cracker; 10 – spring ring


1. Turn off the cap-type nut of 1 (fig. 2.79), take out from it a spring ring 10 and a cracker 9.
2. Drown a plunger 7 in the case 2 against the stop and take out from the case a ring 4. Then take out a plunger 7, a spring 8 and a core 3 together with a spring 5 and a washer 6.
3. Take out from a core opening a spring 5 and remove from it a washer 6.
Collect a natyazhitel upside-down.
When checking pay attention whether there are no zadir on a cracker 9 and a core 3, and on the surface of a plunger which is interfaced to a boot of a natyazhitel – deep рисок and wear. Replace the damaged details.

Fig. 2.80. A specification for check of a spring of a natyazhitel


Elasticity of a spring 8 natyazhitel has to be in the limits specified fig. 2.80; at smaller elasticity replace a spring.

Fig. 2.81. Scheme of the mechanism of the drive of the camshaft and auxiliary units: 1 – camshaft asterisk; 2 – chain; 3 – uspokoitel of a chain; 4 – asterisk of the roller of the drive of the oil pump; 5 – asterisk of a bent shaft; 6 – restrictive finger; 7 – boot of a natyazhitel; 8 – natyazhitel of a chain


Check whether there is no increased wear of rubber overlays of a boot 7 (fig. 2.81) and an uspokoitel 3. If on slips deep paths from a chain, replace a boot and an uspokoitel.
 Camshaft drive chain
Wash out a chain in kerosene, wipe dry and check a condition of links. On rollers and cheeks of links there should not be chips, cracks and other damages.
During the operation of the engine the chain is extended extended) due to wear of axes of rollers. It is considered efficient if the natyazhitel provides a tension i.e. if the chain was extended no more than on 4 mm.

Fig. 2.82. Scheme of check of wear (pulling) of a chain: 1 – rollers


The pulling of a chain is checked on adaptation having two rollers of 1 (fig. 2.82) which put on a chain. Stretch a chain by effort of 300 N (30 kgfs), then reduce effort to 150 N (15 kgfs), repeat both operations and measure distance of L between axes rollers.
For a new chain the distance of L has to make 495 +0,5–0,4 mm. If the chain was extended to 499,4 mm, replace it.
Adjustment of a tension of a chain
After assembly of the engine surely adjust a chain tension in the following order.
1. Weaken a nut 1 (see fig. 2.79). At the same time the core 3 is released, the spring 8 puts forward a plunger 7 which moves the boot 7 (see fig. 2.81) pulling a chain.
2. Turn a bent shaft on 1–1,5 turns in the direction of rotation. At the same time the spring of a natyazhitel influencing through a plunger a boot will automatically choose a chain weak point.
3. Tighten the cap-type nut 1 (see fig. 2.79). At the same time the core 3 is clamped by grips of a cracker 9, the spring 8 is disconnected and during the operation of the engine the plunger 7 is influenced only by a spring 5. It wrings out a plunger from a head of a core 3, and in the gap of 0,2-0,5 mm formed between them during the operation of the engine flows oil, together with a spring of the 5th shock-absorbing blows of a chain into a boot at its fluctuations.
Thanks to the guaranteed gap between a core 3 and a plunger 7 at strong blows of a chain also the spring 8 comes into effect.
Oil pump
Removal and installation of the pump on the car
1. Install the car on a viewing ditch or the elevator, disconnect wires from the rechargeable battery.
2. Turn out a stopper of a drain opening from a case of the engine and merge oil.
3. Turn off nuts of fastening of adapters with pillows of a forward engine mount to a cross-piece and slightly raise the engine a jack or a waist that between a cross-piece and a case the sufficient gap was formed.
4. Turn off bolts of fastening of an oil case and remove it together with laying.
5. Turn off two bolts of fastening of the oil pump to the block of cylinders and remove the oil pump together with an oil receiver and laying of the case of the oil pump.
Install the oil pump on the engine upside-down.
Dismantling and assembly
1. Fix the oil pump in a vice, clamping it it is careful not to damage the case.
2. Turn off three bolts and remove a reception branch pipe with laying.

Fig. 2.83. Dismantling of the oil pump: 1 – reducing valve; 2 – spring; 3 – cover; 4 – case; 5 – roller


3. Uncover 3 (fig. 2.83) together with the reducing valve 1 and its spring 2 and take out from the case 4 the pump roller 5 with the leading gear wheel and the conducted gear wheel.
Collect the pump upside-down.
After assembly of the pump at a provorachivaniye of the leading roller a hand of a gear wheel have to rotate smoothly, without jamming.
Check of technical condition of details of the pump 
After dismantling wash out all details of the pump kerosene or gasoline, blow a stream of compressed air, and then examine the case and a cover of the pump; in the presence of cracks of a detail replace.

Fig. 2.84. Check of a radial gap in the oil pump


Check a set of probes gaps between teeths of gear wheels, and also between outer diameters of gear wheels and walls of a pump housing (fig. 2.84). Gaps have to be respectively 0,15 mm (maximum permissible 0,25 mm) and 0,11–0,18 mm (maximum permissible 0,25 mm). If gaps exceed admissible values, replace gear wheels, and if necessary and a pump housing.

Fig. 2.85. Check of a vystupaniye of a gear wheel
for the plane of the case of the oil pump


The probe and ruler check a vystupaniye of gear wheels for the plane of a pump housing (fig. 2.85). It has to be 0,05–0,135 mm (minimum admissible 0,02 mm). If vystupany less than 0,02 mm, replace gear wheels or a pump housing depending on what detail is worn-out.
Having measured details, define a gap between the conducted gear wheel and its axis which has to be 0,017–0,057 mm (maximum permissible 0,1 mm), and also between the roller of the pump and an opening of the plug of the case which has to be 0,016–0,055 mm (maximum permissible 0,15 mm). If gaps exceed admissible values, replace worn-out details.
Check of the reducing valve
At repair of the oil pump surely check the reducing valve. Pay attention to the surfaces of the valve and case as possible pollution or deposits on the interfaced surfaces can lead to jamming. On the working surface of the valve there should not be забоин also agnails which can become the reason of reduction of pressure in system.

Fig. 2.86. A specification for check of a spring of the reducing valve


Check elasticity of a spring of the reducing valve, comparing the obtained data with provided on fig. 2.86.
Check of the roller and gear wheels of the drive of the oil pump
On the basic surfaces of the roller and face surfaces of gear wheels there should not be dents and рисок.
On teeths of gear wheels of the pump and a gear wheel of the drive vykrashivaniye are not allowed, at their existence replace the roller or gear wheels.
Check of plugs of the roller of the drive of the oil pump
Check the internal diameter of the plugs pressed in the block of cylinders which has to make: for the forward plug of 48,084-48,104 mm; for the back plug of 22,000-22,020 mm. Maximum permissible wear of 0,15 mm. Also check reliability of their press fitting in nests and coincidence of a lubricant opening in the forward plug with the channel in the block of cylinders (if they do not coincide, so the plug is turned in operating time of the engine). If wear or signs of a provorachivaniye of plugs is found, replace them.

Fig. 2.87. Removal and installation of the plug of the roller of the drive of the oil pump: 1 – mandrel


For removal and installation of plugs use a mandrel (fig. 2.87), observing the following requirements:
– plugs have to be densely pressed in nests, at the same time the opening for oil in the forward plug has to coincide with an opening of the channel in the block of cylinders;
– plugs after a press fitting have to be finally processed and finished on internal diameter. To provide full coaxiality of plugs of a shaft, apply step development which at the same time process both plugs to their operational development.
Check of the plug of a gear wheel of the drive of the oil pump

Fig. 2.88. Vypressovka of the plug of a gear wheel of the drive of the oil pump and distributor of ignition: 1 – mandrel


The internal surface of the plug has to be smooth and without zadir, the plug has to be reliably pressed in a block opening, otherwise replace the plug. For a vypressovka and a press fitting of the plug use a mandrel (fig. 2.88). After a press fitting develop a plug opening to 16,016–16,037 mm.
Water pump
Dismantling

Fig. 2.89. Device of the water pump: 1 – case; 2 – bearing; 3 – pulley; 4 – pulley nave; 5 – lock screw of the bearing; 6 – cover; 7 – roller; 8 – epiploon; 9 – krylchatka


1. Disconnect the case 1 (fig. 2.89) of the pump from a cover 6.

Fig. 2.90. Removal of a krylchatka of the pump: 1 – stripper of A.40026; 2 – krylchatka


2. Fix a cover in a vice through laying from soft metal and a stripper of 1 (fig. 2.90) remove a krylchatka 2 from the roller.

Fig. 2.91. Removal of a nave of a pulley: 1 – pump housing cover; 2 – pulley nave; 3 – stripper of A.40005/1/5


3. Remove a stripper of 3 (fig. 2.91) a nave 2 pulleys from the roller.
4. Turn out the lock screw 5 (see fig. 2.89) and a vypressuyta the bearing 2 with the pump roller 7. Put effort of a vypressovka to an external holder of the bearing.

       NOTE
If it is precisely known that the bearing is faulty and it will be replaced, for simplification of dismantling it is possible to press off it, putting effort to the roller.

5. Vypressuyte an epiploon 8 of a cover 6.
Check of technical condition of details of the pump
Surely check an axial gap in the bearing, especially if the increased noise of the pump was noted. The gap should not exceed 0,13 mm at load of 49 N (5 kgfs). At a bigger gap replace the bearing assembled with the roller.
Epiploon of the pump and laying between a cover of the pump and its case, and also between the pump and the block of cylinders at repair it is always recommended to replace new. For the best consolidation of laying before installation grease with a thin layer of silicone sealant.
Examine the case and a cover of the pump, deformations or cracks are not allowed.
Assembly
1. Press a mandrel an epiploon in a pump cover, without allowing a distortion.
2. Press the bearing with the roller in a cover so that the nest for the lock screw in an external holder of the bearing coincided with a carving opening in a cover. At a press fitting put effort to an external ring of the bearing.

       PREVENTION
It is impossible to press the bearing with the roller, putting effort to the roller. It will inevitably lead to damage of the bearing.

3. Tighten the lock screw of the bearing and fuller edges of a carving opening to exclude a screw samootvorachivaniye.

Fig. 2.92. Napressovka of a krylchatka on the pump roller A.60430 adaptation: 1 – support; 2 – pump roller; 3 – pump housing cover; 4 – glass; 5 – adjusting screw


4. Napressuyte adaptation shown on fig. 2.92, a pulley nave on the roller, having sustained the size between end faces of a nave and a cover (84,4±0,3) mm. If the nave is made of metal ceramics, it is impossible to install it on the roller as landing of a nave on the roller after the previous dismantling will be weakened repeatedly. In this case to a napressovyvayta only a new nave.
5. Napressuyte the same adaptation a krylchatka on the roller. At the same time provide a necessary gap of 0,9-1,3 mm between shovels of a krylchatka and a pump housing. Such gap turns out if at a napressovka to sustain the size of 48-0,2 mm between back edges of shovels of a krylchatka and a privalochny flange of a cover.
6. Connect a pump housing to a cover, having established between them laying then surely check through a case branch pipe opening a gap between the case and a krylchatka, and also lack of a zadevaniye of a krylchatka for the case, turning the pump roller a hand.

Cooling system
Features of a design

Fig. 2.93. The scheme of the cooling system with the TC103 thermostat (engines of fashion. 331 and 2106): 1 – the taking-away heater radiator hose; 2 – the bringing heater radiator hose; 3 – water pump; 4 – the taking-away radiator hose; 5 – bypass hose of a small circle of cooling; 6 – electric fan; 7 – radiator; 8 – the bringing radiator hose; 9 – thermostat; 10 – a steam discharge hose from a radiator to a broad tank; 11 – the taking-away hose of an inlet pipe; 12 – inlet pipe of the engine; 13 – broad tank; 14 – perepuskny a hose from the engine to a broad tank; 15 – engine; 16 – the taking-away branch pipe of a head of the block of cylinders


The cooling system is liquid, the closed type, with compulsory circulation, includes a radiator of 7 (fig. 2.93) with an aluminum core, a translucent plastic broad tank 13, the electric fan 6 which is switched on and off by the sensor on a radiator tank, the thermostat 9, the water pump 3 engines and connecting hoses and branch pipes. Except these elements the radiator of a heater of salon of a body also belongs to the cooling system. Cooling systems of the cars equipped with engines of fashion. 331 and 2106, are essentially identical and differ only with a design, quantity and a location of separate details and knots (the water pump, the thermostat and connecting hoses) that is explained by distinctions in configuration of these engines.
Check of level and density of cooling liquid
Level of cooling liquid in completely filled system on the cold engine at a temperature of 15-20 °C has to be not lower than the mark MIN in a wall of a broad tank. It is necessary to check the level of cooling liquid on the cold engine because when heating liquid volume considerably increases.
Periodically check densimetry density of cooling liquid which has to be 1,078–1,085 g/cm3 for Tosola-A40.
If liquid level in a tank is lower than norm, and density is higher, then add the distilled water if density normal – Tosol-A40. If density of liquid is lower than norm, and the car will be operated in cold season, replace cooling liquid as with decrease in density at it freezing temperature sharply increases.
Filling of the cooling system with liquid
Fill system with liquid at its change, and also after repair of knots of system or the engine in the following order.
1. Check that all traffic jams of drain openings on a radiator and the block of cylinders of the engine were established on the places and are densely tightened.
2. Remove a stopper from a broad tank and open the heater crane.
3. Gradually fill in liquid (10 l) in a broad tank till the moment when its level in a tank ceases to decrease and allocation of vials of air will stop; establish into place a stopper of a broad tank.

       NOTES
1. For the guaranteed filling of the cooling system with liquid without air traffic jams during this operation the car has to stand horizontally, without inclination in any party.
2. For simplification of an air outlet from the cooling system of the engine of fashion. 331 it is recommended to turn out the sensor of temperature of cooling liquid from a thermostat nest and to return it into place when liquid without vials of air begins to follow from an opening under the sensor.

4. Launch the engine and idling warm up it up to the working temperature. At the same time the main valve of the thermostat will open and all remained air traffic jams will be removed from system.
When the engine cools down, check the level of cooling liquid. If it is lower than norm, and in the cooling system there are no dribble traces, add liquid.
Adjustment of a tension of a belt of the drive of the water pump


Fig. 2.94. Scheme of check of a tension of a belt of the drive of the pump of the cooling system of the engine of fashion. 331


At the engine of fashion. 331 at a normal tension of a belt the deflection And (fig. 2.94) between pulleys of the generator and water pump under effort of 40 N (4 kgfs) has to be 7–9 mm.

Fig. 2.95. Scheme of check of a tension of a belt of the drive of the pump of the engine of fashion. 2106


At the engine of fashion. 2106 the tension of a belt is checked in deflection size between pulleys of the generator and water pump or between pulleys of the pump and a bent shaft. At a normal tension of a belt the deflection And (fig. 2.95) under effort of 98 N (10 kgfs) has to be 10–15 mm, a deflection In – 12–17 mm under the same effort.
For adjustment of a tension of a belt of the engine of fashion. 331 weaken nuts of two lower bolts of fastening of the generator and a bolt of fastening to an adjusting level, move the generator from the engine (for increase in a tension) or to the engine (for reduction of a tension) and tighten nuts and a bolt of fastening. Turn a bent shaft on two turns clockwise and check a belt tension. For the engine of fashion. 2106 the tension of a belt is regulated similarly, having weakened nuts of the lower bolt and a hairpin of fastening of the generator to an adjusting level.
Do not allow an excessive tension of a belt not to cause increase in loads of bearings of the generator and the water pump.
Radiator and broad tank
Removal and installation
Remove a radiator on the cold engine in the following order:

Fig. 2.96. Arrangement of a drain opening of a radiator of the cooling system: 1 – electric fan; 2 – drain stopper


Fig. 2.97. Arrangement of a drain opening of the cooling system of the engine of fashion. 331: 1 – stopper of a drain opening


Fig. 2.98. Arrangement of a drain opening of the cooling system of the engine of fashion. 2106: 1 – stopper of a drain opening


1. Merge cooling liquid from system, having turned off traffic jams of drain openings on a radiator (fig. 2.96) and the block of cylinders of the engine (fig. 2.97 and fig. 2.98), having removed a stopper of a broad tank and having opened the heater crane.

Fig. 2.99. A radiator with the electric fan and a broad tank: 1, 8, 15 – collars; 2 – sleeve; 3 – radiator; 4, 25 – nuts; 5, 6, 11, 12, 17, 18, 24 – washers; 7 – the arm is top; 9 – tank stopper; 10, 19 – bolts; 13 – peak; 14 – tank; 16 – bracket; 20 – casing; 21 – plug; 22 – the plug is intermediate; 23 – washer; 26 – electric fan; 27 – sleeve; 28 – collar; 29 – union; 30 – support; 31 – the arm is lower; 32 – thermal sensor; 33 – laying


2. In a radiator 2126-1301012 with the VAZ-2106 engine the drain stopper is absent. For discharge of cooling liquid from a radiator and a broad tank it is necessary to weaken a collar of 28 (fig. 2.99) and to remove from the union a sleeve 27.
3. Disconnect electric wires from the electric fan and the sensor of its inclusion.
4. Disconnect hoses from a radiator.
5. Remove a peak 13, having turned off two bolts 10.
6. Disconnect a bracket of the 16th fastening of a radiator and remove a radiator assembled with the electric fan, having pulled it up to release from support 30.
7. If necessary disconnect from a radiator a casing with the electric fan, having turned off three bolts of the 19th fastening of a casing to a radiator.
Before removal of a broad tank disconnect from it hoses and remove a tank from an arm.
Establish a radiator and a broad tank in the return sequence.
Check of tightness of a radiator
For check of tightness muffle radiator branch pipes wooden or plastic traffic jams, give to it air under pressure of 0,1 MPas (1 kgf/cm2) and lower in a bathtub with water not less than on 30 pages. At the same time from a core and tanks vials of air should not appear. If the radiator is untight, replace it as the aluminum core cannot be soldered – the special technology is required. As a last resort muffle in any way defective tubes (surely on both sides), but no more than 1,5% of total of tubes of a radiator.
Thermostat

Fig. 2.100. TC103 thermostat: 1 – an entrance branch pipe (from the engine); 2 – perepuskny valve; 3 – spring of the perepuskny valve; 4 – glass; 5 – rubber insert; 6 – output branch pipe; 7 – spring of the main valve; 8 – saddle of the main valve; 9 – main valve; 10 – holder; 11 – adjusting nut; 12 – piston; 13 – an entrance branch pipe (from a radiator); 14 – filler; 15 – holder; Д – a liquid input from the engine; Р – a liquid input from a radiator; N – a liquid exit to the pump


At the thermostat check temperature of the beginning of opening and the course of the main valve. For this purpose install the thermostat removed from the engine on the stand, having lowered in a tank with water or cooling liquid. For check of the thermostat bring an indicator leg arm from below to the main valve 9 (fig. 2.100).
Reference temperature of liquid in a tank has to be 73–75 °C. Gradually increase liquid temperature every minute by 1 °C and constantly mix that it was identical on all volume of liquid.
Take that at which the course of the main valve will make 0,1 mm for temperature of the beginning of opening of the valve.
Replace the thermostat if temperature of the beginning of opening of the main valve is not in limits of 78-82 °C or a thermostat valve stroke less than 6 mm.
It is possible to check serviceability of the thermostat in the elementary way – to the touch directly on the car. After launch of the cold engine with the serviceable thermostat the lower (taking-away) hose of a radiator begins to heat up when the arrow of the index of temperature of cooling liquid is approximately in the middle of a white zone of a scale that corresponds to 80-85 °C.

Power supply system
Fuel pump
Fuel pumps of engines of fashion. 2106 and fashion. 331 have the identical principle of work, but differ on a design: on the engine of fashion. 2106 the pump 2101-1106010 of production of the Saratov plant of the fuel equipment, the engine of fashion is installed. 331 it is equipped with the pump 412-1106010-02 (B7A) of the Buynaksk plant of the fuel equipment or 412-1106010-03 (2105-1106010-30 or 700-1106010) JSC Pekar (St. Petersburg).
Check of the pump
The float-operated camera of the carburetor can be filled insufficiently with gasoline not only because of malfunction of the fuel pump, but also at a contamination or damage of fuel-supply lines. Therefore before check of the pump estimate their technical condition.

Fig. 2.101. Fuel pump B7A: 1 – lever spring; 2 – diaphragm lever axis; 3 – diaphragm lever; 4 – screw of fastening of a head; 5 – pump head; 6 – a pump cover with the bringing union; 7 – screw of fastening of a cover; 8 – fuel supply union; 9 – the forcing union; 10 – pump diaphragm assembled; 11 – sealant of draft of a diaphragm; 12 – pump housing; 13 – lever of manual pumping


Fig. 2.102. Fuel pump 2101-1106010: 1 – delivery union; 2 – mesh filter;
3 – pump head; 4 – the soaking-up union; 5 – head cover; 6 – the soaking-up valve; 7 – diaphragm rod; 8 – lever of manual pumping; 9 – spring of the lever of manual pumping; 10 – clown; 11 – balance weight; 12 – diaphragm drive lever; 13 – pump housing; 14 – internal remote laying of a diaphragm; 15 – external remote laying of a diaphragm; 16 – plate of a diaphragm; 17 – delivery valve


Previously estimate operability of the pump directly on the car for what disconnect a hose from a delivery branch pipe of 9 (fig. 2.101) or 1 (fig. 2.102) and by means of the lever 13 (see fig. 2.101) or 8 (see fig. 2.102) manual pumping of fuel check whether fuel moves. If there is no fuel, then disconnect a hose from the soaking-up branch pipe 8 (see fig. 2.101) or 4 (see fig. 2.102) and check whether depression on an entrance of this branch pipe is created. If depression is, then fuel-supply lines are damaged if is not present – the fuel pump is faulty.
For check of serviceability of the fuel pump B7A of the engine of fashion. 331 connect to the reception union 8 (see fig. 2.101) a tube with an internal diameter of 4 mm, the second end of which ship in a vessel with gasoline. Then, pressing the lever 13 of manual pumping, put a diaphragm in action. At such test supply of gasoline on height of 850 mm has to begin not later than twenty full swings of the lever 13.
It is possible to check operation of the pump and at the special stand imitating operation of the pump on the engine. At the same time supply of gasoline on a tube with an internal diameter of 4 mm on height of 850 mm with a frequency of rotation of the roller with the clown of 120 min.-1 has to begin not later 10 with later launch of the pump.
At test the pump has to create pressure of 22,5-27,5 kPa (2,25–2,75 m of water column) and depression not less than 40 kPa (4,0 m of water column).
With a frequency of rotation of the roller of the mines-1 drive 1800 giving has to be not less than 50 l/h.
Similarly check also the pump 2101-1106010 of the engine of fashion. 2106. Forcing pressure at zero giving of this pump has to be 22–30 kPa (2,2–3,0 m of water column), and giving – not less than 54 l/h with a frequency of rotation of the roller (2000±40) of mines-1 and the air temperature of (20±5) °C.
After termination of work of pumps pressure and depression checked on control devices have to remain during 10 pages.
If pumps do not meet the requirements given above, sort them and check details.
Dismantling, check and assembly of the pump
Disassemble the pump B7A in the following order.
1. Unscrew two screws 7 (see fig. 2.101) fastenings of a cover 6 to a head 5 and uncover.
2. Turn out six screws 4 and remove a pump head. Before removal of a head from the case mark their relative positioning that at the subsequent assembly to keep position, former in relation to the engine, of the bringing and taking away unions.
3. Press a plate diaphragms 10 in the direction of an arrow A, and then incline it towards a flange In and bring the lower end of a rod of a diaphragm out of gearing with the lever 3, having at the same time taken out a diaphragm with a spring and a sealant of the 11th rod from the case 12.
4. Vypressuyte a mandrel an axis 2 levers 3 drives of a diaphragm also take out the lever, expansion washers and a spring of 1 lever from the case 12.

Fig. 2.103. A press fitting of valves in a pump B7A head: 1 – valve spring; 2 – valve plate; 3 – pump valve; 4 – valve holder


5. Vypressuyte from a head 5 by means of a mandrel two holders of 4 (fig. 2.103) of valves 3 of the fuel pump also remove valves together with springs 1.
After dismantling wash out all details and blow compressed air.
Examine a diaphragm. If its petals are torn, strongly rubbed or hardened, replace a diaphragm assembled.
Examine the lever 3 (see fig. 2.101) and its axis. If on working surfaces of details there is a noticeable wear, replace them.
Check whether is not present on the valve 3 (see fig. 2.103), its plate 2 and a holder 4 забоин, рисок and deep development which can break tightness of the valve. If there are defects, replace details.
Check elasticity of a spring 1. The effort of the spring compressed up to the height of 5,5 mm has to be (0,234±0,04) N or (23±4) kgfs.
Check a condition of a sealant 11 (see fig. 2.101) drafts of a diaphragm. If it is strongly rubbed, hardened or edges of its opening are strongly worn-out, replace it.
Examine rubber laying of a cover. Replace the torn, strongly pressed out or hardened laying.
Collect the pump in the return sequence taking into account the following:
– having collected all details on shafts of holders of valves, press holders in a case head body, maintaining at the same time the size of (1,5±0,1) mm (see fig. 2.103);
– having installed a pump head on the case (having combined the tags made when dismantling) and наживив all six screws on one-two rounds, do not tighten them finally. At first wring out the lever of the manual drive in extreme top situation to lower a diaphragm down to an emphasis, then wrap two opposite screws 4 (see fig. 2.101) to the full and release the drive lever. After that evenly (cross-wise) tighten all other screws.
Disassemble the pump 2101-1106010 in the following order.

       PREVENTION
If not to observe the described order of tightening of screws of fastening of a head, the diaphragm during the work will excessively stretch and will have obviously lowered resource.

1. Turn off a bolt of fastening of a cover 5 (see fig. 2.102), uncover also the plastic mesh filter 2.
2. Mark a relative positioning of a head 3 and cases 13, unscrew six screws of fastening of a head to the case and separate them.
3. Wring out a plate of the 16th diaphragm down, turn it clockwise on 90 ° and, having brought a diaphragm rod out of gearing with the balance weight 11, take out from the case a diaphragm with a spring, external 15 and internal 14 remote laying.
It is not recommended to sort a pump housing and to take out other details. If details of the case are strongly worn-out, replace the pump assembled.
Wash out all details gasoline and blow compressed air.
Check an integrity of springs of the pump.
Check whether there is no jamming of valves 6 and 17 or the shift of their locking elements because of excessive wear. If necessary to a vypressuyta valves from a head, previously having removed the kerneniye fixing them. After a press fitting of valves you zakernit their saddles in three places.
Check a diaphragm integrity. On its petals there should not be stratifications, attritions, cracks and hardenings. If there are defects, recommend to replace a diaphragm assembled. In urgent cases it is possible to replace only diaphragm petals for what turn off a nut of fastening of a package of diaphragms on a rod.
Strongly pressed out or deformed pump cover filter performing and function of sealing laying of a cover, replace.
Collect the pump upside-down, tightening screws of fastening of its head to the case in the same sequence, as well as for the pump B7A (see above). 15 (see fig. 2.102) orient external remote laying so that its drainage openings were directed from the engine.
Installation of the fuel pump on the engine

Fig. 2.104. Installation of the fuel pump on the engine of fashion. 331: 1 – bar; 2 – heat-insulating laying; 3 – fuel pump; 4 – adjusting laying; 5 – sealing laying; 6 – head of the block of cylinders


For ensuring normal giving of the fuel pump it is necessary to install it on the engine correctly. Before installation of the pump B7A on the engine of fashion. 331 it is necessary to adjust vystupany bars of 1 (fig. 2.104) of the drive of the pump for the plane of adjusting laying at a size B equal of 1-1,5 mm.
Select adjusting laying for thickness and quantity in the following order.
1. Slowly rotating a bent shaft, install the camshaft so that the bar of 1 drive of the fuel pump leaned on the clown's nape that will provide the minimum vystupaniye of a bar.
2. Establish sealing 5 and heat-insulating 2 laying on hairpins of fastening of the fuel pump to a head of the block of cylinders and densely press them.
3. A caliper measure the size A of a vystupaniye of a bar 1 for heat-insulating laying.
Determine the number of adjusting laying by the size A 4 0,3 mm thick to provide the size B (vystupany bars for the plane of adjusting laying).

       NOTE
The number of adjusting laying can be from one to four.

Establish on block head hairpins the picked-up laying, then the fuel pump and tighten nuts of its fastening. Similarly install on the engine of fashion. 331 and pumps 700-1106010, 412-1106010-03.
For the correct installation of the fuel pump 2101-1106010 on the engine of fashion. 2106 use two of three specified laying thickness, in mm:
And....... 0,27–0,33
In....... 0,7–0,8
With....... 1,1–1,3
Pick up laying and install the pump on the engine in the following order.

Fig. 2.105. Installation of the fuel pump on the engine of fashion. 2106: 1 – bar; 2 – heat-insulating pro-rate; 3 – fuel pump; 4 – laying In; 5 – laying And; 6 – block of cylinders


1. Slowly rotating a bent shaft, establish a shaft of the drive of auxiliary units so that the bar of 1 (fig. 2.105) of the drive of the fuel pump leaned on the clown's nape that will provide the minimum vystupaniye of a bar.
2. Install a heat-insulating pro-rate 2 on the block of cylinders 6, having put between them laying 5, and on the pro-rate plane which is interfaced to the pump 3, place laying 4. A caliper measure d distance (the minimum size of a vystupaniye of a bar). If the size d is in limits of 0,8-1,3 mm, fix the pump on the engine; if d is less than 0,8 mm, In replace laying with laying And; if d is more than 1,3 mm, then In replace laying with laying of Page. Double-check the size d and fix the pump on the engine.

       NOTE
Between a heat-insulating pro-rate and the block of cylinders always there has to be a laying And.

Carburetor
Features of a design

Fig. 2.106. Carburetor 2140-70: 1 – EPHH pneumatic valve; 2 – screw of adjustment of composition of mix


Fig. 2.107. Carburetor 2107-1107010: 1 – air gate; 2 – starting arrangement; 3 – trekhplechy control lever air gate; 4 – telescopic draft; 5 – microswitch; 6 – lever of the drive of butterfly valves; 7 – the lever limiting opening of a butterfly valve of the second camera; 8 – returnable spring; 9 – pneumatic actuator rod; 10 – pneumatic actuator of a butterfly valve of the second camera


Table 2.9  Tarirovochny data of carburetors

On the engine of fashion. 331 install the DAAZ-2140-1107010-70 carburetor (fig. 2.106), on the engine of fashion. 2106 – DAAZ-2107-1107010 (fig. 2.107). Both carburetors of almost identical design also differ only with the device of a pneumatic valve of EPHH, the drive of a butterfly valve of the second camera (at the carburetor 2140-1107010-70 it mechanical, at fashion. 2107-1107010 – pneumatic) and tarirovochny data (tab. 2.9). Carburetors of emulsion type with the falling stream of gas mixture and pneumatic braking of fuel – two-chamber, with consecutive opening of butterfly valves.
Carburetors have the balanced float-operated camera, two main dosing systems (the first and second cameras), autonomous system of idling with the economizer of compulsory idling (ECI), transitional system of the secondary camera, эконостат, the diaphragm accelerating pump with the mechanical drive, the starting arrangement with the pneumatic drive, elements of system of ventilation of a case of the engine.
Removal and installation
1. Disconnect a hose of ventilation of a case of the engine from a branch pipe of the case of the air filter.
2. Uncover the air filter and take out from it the filtering element (see. "Operation and maintenance").
3. Disconnect a hose of a supply of warm air from a reception branch pipe of the case of the filter, turn off four nuts of fastening of the case, remove an overlay of sealing laying and remove the case together with laying.
4. Disconnect hoses from carburetor unions.

       PREVENTION
Do not drop remote plugs of laying which can easily drop out of its openings in a carburetor mouth. Hit of the plug in the carburetor and in an inlet pipe and the cylinder will lead further to emergency damage of the engine at start-up.

5. Disconnect draft of the drive of the air gate and a cable of the drive of butterfly valves from carburetor levers.
6. Disconnect wires from the EPHH system microswitch.
7. Turn off four nuts of fastening of the carburetor to an inlet pipe and remove the carburetor, trying not to damage the laying located under it.
Install the carburetor upside-down.

       PREVENTION
Tighten nuts of fastening of the carburetor gradually cross-wise, without using the excessive efforts not to deform its flange, and only on the cold engine. If to tighten nuts on the hot engine, after its cooling in connection there will be a gap in which air will podsasyvatsya.

Dismantling and assembly of the carburetor
As it was mentioned above, the design of carburetors of both engines is almost identical. Therefore in this section processes of dismantling and assembly of the carburetor 2107-1107010 having a bigger set of additional elements are considered.
Previously separate three main case details of the carburetor – a cover, actually the case of the carburetor and the case of butterfly valves.
1. Remove a returnable spring 8 (see fig. 2.107).
2. Take out the forelock from the lower end of draft of half-open of a butterfly valve of the first camera and disconnect draft from the lever of a butterfly valve.
3. Disconnect a rod of the 9th pneumatic actuator from the lever of the drive of a butterfly valve of the second camera, having taken out a lock washer from a lever pin groove.
4. Having squeezed telescopic draft 4, disconnect its lower end from the trekhplechy lever 3.
5. Turn out five screws of fastening of a cover and accurately remove it together with a float and laying, trying not to damage them.
6. Turn out from below the carburetor two screws of fastening of the case of butterfly valves and disconnect it from the carburetor case, trying not to damage the transitional plugs of fuel-air channels pressed in the carburetor case and a nest of plugs in the case of butterfly valves.
7. Carefully separate heat-insulating laying from the carburetor case.
Sort a carburetor cover in the following order.

Fig. 2.108. Carburetor 2107-1107010 cover details: 1 – adjusting screw; 2 – cover of the starting arrangement; 3 – spring; 4 – diaphragm; 5 – diaphragm rod; 6 – case of the starting arrangement; 7 – telescopic draft; 8 – axis of the air gate; 9 – air gate; 10 – carburetor cover; 11 – laying; 12 – filter; 13 – filter stopper; 14 – saddle of the needle valve; 15 – needle valve; 16 – float axis; 17 – float; 18 – laying; 19 – draft of the starting arrangement


1. Accurately clamp a cover in a vice with soft sponges and turn off a stopper of 13 (fig. 2.108) of the fuel filter 12. Then take out the filter from a cover cavity.
2. A mandrel or a piece of a copper wire of the suitable size carefully push out axis 16 of a float 17 of cover arm racks.

       NOTE
Push out an axis towards a rack with a section.

Trying not to injure float uvulas, remove it together with the needle valve 15.
3. Disconnect telescopic draft 7 from the lever of axis 8 of the air gate, turning its unbent end in a figured opening of the lever before coincidence of a ledge of the lever to an opening groove.
4. Uncover cardboard laying 11, turn out a saddle of the 14th needle valve and take out from its nest in a cover aluminum sealing laying 18.
5. Turn out two screws of fastening of the case 6 of the starting arrangement and remove it, trying not to damage the sealing rubber ring located under a case flange. At the same time, inclining the case 6 aside, bring out of gearing with draft the 19th rod of the 5th diaphragm of the starting arrangement.
6. Remove draft 19, separating it with the lever of an axis of the air gate, the same as removed telescopic draft 7.
7. Unscrew three screws of fastening of a cover 2 starting arrangements and uncover with the adjusting screw 1, a spring 3 and a diaphragm 4.
8. For removal of axis 8 turn out two screws of fastening of the air gate, having sawn round a file their raskernenny ends, and remove the last. After that the axis is freely taken out from a cover.

       PREVENTIONS
1. Without emergency do not remove the air gate and its axis as at a vyvertyvaniye even of the sawn round screws it is possible to damage a carving in axis openings. Besides, the shift of the air gate of rather former situation, possible at assembly, can lead to its jamming that will cause failure of the starting arrangement.
2. Do not press off from a cover air and fuel jets of an ekonostat in order to avoid their damage and weakening of landing to nests.

Disassemble the carburetor case in the following order.

Fig. 2.109. Carburetor 2107-1107010 case details: 1 – rod of a pneumatic actuator of the second butterfly valve; 2 – pneumatic actuator case; 3 – diaphragm; 4 – pneumatic actuator cover; 5 – fuel jet of transitional system of the second camera; 6 – case of a fuel jet; 7 – small diffuser of the second camera; 8 – spray of the accelerating pump; 9 – screw valve of the accelerating pump; 10 – main air jet of the second camera; 11 – emulsion tube of the second camera; 12 – main air jet of the first camera; 13 – emulsion tube of the first camera; 14 – main fuel jet of the second camera; 15 – main fuel jet of the first camera; 16 – adjusting screw of the accelerating pump; 17 – fuel jet of system of idling; 18 – case of a fuel jet; 19 – returnable spring of the accelerating pump; 20 – diaphragm of the accelerating pump; 21 – cover of the accelerating pump; 22 – small diffuser of the first camera; 23 – returnable spring of the lever; 24 – trekhplechy control lever of the air gate; 25 – draft of communication with a butterfly valve; 26 – arm of a returnable spring of butterfly valves


1. Turn out two screws of fastening of a pneumatic actuator of a butterfly valve of the second camera and remove a pneumatic actuator, trying not to damage the cardboard laying located under its flange. If necessary unscrew three screws of fastening of a cover of 4 (fig. 2.109) of a pneumatic actuator and remove a cover, a spring and a diaphragm 3 with a rod.
2. Turn out the screw of fastening of the trekhplechy lever 24 drives of the air gate, remove an arm of the 26th ottyazhny spring, the lever 24 and a spring 23. Disconnect from the lever 24 draft 25 in the same way as it was done at a detachment of draft of the starting arrangement.
3. Turn out four screws of fastening of a cover of 21 accelerating pumps, uncover with the lever, a diaphragm 20 and a returnable spring 19.
4. Turn out the main air jets 10 and 12, turn the case and, slightly tapping on it, remove from wells emulsion tubes 11 and 13.

       NOTE
If it is not possible to shake out emulsion tubes, screw the self-cutting screws in their canals and take out tubes, having taken heads of screws pincers like "anaconda".

5. Turn out cases 6 and 18 of fuel jets of transitional system and idling together with jets 5 and 17.
6. Turn out the screw valve 9 and remove a spray 8 of the accelerating pump with aluminum laying.
7. Turn out the screw 16 of adjustment of giving of the accelerating pump.
8. Take out small diffusers 7 and 22, overcoming effort of spring holders.

       PREVENTION
Take out small diffusers only at a congestion in their channels of the deposits which are not deleted by washing together with the carburetor case. Their dismantle and the return installation without emergency will lead to weakening of landing in the case and, as a result, loss of tightness of connection with its channels.

9. Turn out the main fuel jets 14 and 15 of a wall of the float-operated camera.

       PREVENTION
Do not press off without emergency from the lower plane of the case brass connecting plugs of channels of system of idling and transitional system, and also a branch pipe of a supply of crankcase gases in order to avoid weakening of their landing in nests.

Disassemble the case of butterfly valves in the following order.

Fig. 2.110. Details of the case of butterfly valves of the carburetor 2107-1107010: 1 – lever of the drive of butterfly valves; 2 – the lever limiting opening of a butterfly valve of the second camera; 3 – plug; 4 – lever of contact with the air gate; 5 – the lever fixed on an axis of a butterfly valve of the second camera; 6 – spring; 7 – the lever connected with a pneumatic actuator; 8 – case of butterfly valves; 9 – returnable spring of the first butterfly valve; 10 – axis of the second butterfly valve; 11 – butterfly valves; 12 – axis of the first butterfly valve; 13 – restrictive plugs; 14 – screw of adjustment of quality of mix of idling; 15 – sealing ring; 16 – laying; 17 – case of the economizer of compulsory idling; 18 – economizer cover; 19 – screw of adjustment of amount of mix of idling; 20 – economizer diaphragm; 21 – economizer needle; 22 – needle saddle; 23 – arm of fastening of the microswitch; 24 – microswitch; 25 – zolotnik; 26 – zolotnik spring; 27 – the lever fixed on an axis of the first butterfly valve


1. Break heads of restrictive plugs 13 (fig. 2.110) if they were not removed in use, turn out adjusting screws 14 and 19 and remove the remains of plugs from their shafts.
2. Unscrew 23 microswitches 24 two diametrically located screw of fastening of a pneumatic valve of EPHH and an arm, remove a pneumatic valve and an arm.
3. If necessary unscrew two screws of fastening of a cover 18 and take out from the case 17 a diaphragm 20 with a needle 21.

       NOTE
The pneumatic valve of EPHH of the carburetor 2140-1107010-70 has a non-demountable design and is fixed in a nest of the case of butterfly valves by a clamping plate. For its removal unscrew screws of fastening of a plate and take out a pneumatic valve from a case nest.

       PREVENTION
Do not press off without emergency from the case of butterfly valves a saddle 22 pneumatic valves as it at the same time will be inevitably damaged.

4. Unbend a short mustache of a lock washer and turn off a nut of fastening of levers on axis 12 of a butterfly valve of the first camera.
5. Remove from an axis of the gate of the first camera a lock washer, levers 1, 2, 4 and 27 with washers and the plug 3, and then a podzhimny spring of the 26th zolotnik and a zolotnik 25.
6. Turn off a nut of fastening of levers on axis 10 of a butterfly valve of the second camera and remove levers 5 and 7 with washers and a spring 6.
7. For extraction of axes 10 and 12 of butterfly valves from the case saw round the raskernenny ends of screws of fastening of gates, turn out screws then take out gates and their axes.

       PREVENTION
Without emergency do not remove butterfly valves as at a vyvertyvaniye even of the sawn round screws it is possible to damage a carving in openings of axes. Besides, the shift of butterfly valves of rather former situation, possible at assembly, can lead to their jamming in air channels of the case that, in turn, can destabilize the frequency of rotation of a bent shaft idling and cause refusal of a pneumatic actuator of a butterfly valve of the second camera.

       NOTE
The main details of the case of butterfly valves (gates and their axes) are individually adjusted and not interchanged therefore at their damage replace all case assembled.

Cleaning and check of technical condition
Wash out carburetor details (except laying and rubber sealing rings) in kerosene, unleaded gasoline or solvent and blow compressed air. Wash out laying and sealing rings only in gasoline.

       NOTES
1. We do not recommend to wipe details with the cleaning ends as their microscopic fibers will litter channels of the carburetor subsequently.
2. Do not clean jets the metal tool or a wire as it will break their calibration. At a strong contamination clean openings of jets a needle from a soft tree or a kapron scaffold.

Fuel filter. Check a condition of the filter and the condensing conic corbel of a stopper of the filter. If the filter is torn, deformed or the stopper is damaged, replace them new.
Float-operated mechanism. The float should not have damages and any distortions of a form. The mass of a float has to make 11,5-12,5. On the surface of a uvula of an arm of a float zaboina and deep development in the place of its contact with the damping ball of the needle valve are not allowed. On the conic surfaces of the needle valve and its saddle there should not be damages and the deep development breaking tightness of the valve. The valve has to freely, but without excessive cross side play to move in the nest, and its ball should not hang in the wrung-out situation. If necessary replace the needle valve and its saddle at the same time in a set.
Carburetor cover. Examine the cover surfaces interfaced to the case of the carburetor and the air filter. If they are damaged or strongly deformed, replace a cover. The insignificant buckling of the lower surface of a cover in the locations of openings for screws of its fastening caused by excessive efforts of an inhaling of screws can be eliminated with grinding in on a testing plate. The union of a supply of fuel has to be densely, without side play is pressed in a cover opening.

       PREVENTION
Weakening of landing of the union can lead to the fire during the operation of the engine as pressure developed by the fuel pump can be sufficient for its vypressovka of a cover opening.

Starting arrangement. The diaphragm of the starting arrangement should not have stratifications and anguishes. Its connection with draft has to be reliable.

       NOTE
We recommend at each dismantling of the carburetor for increase in reliability of the starting arrangement to replace a diaphragm new as the deformed working diaphragm at repeated installation will reach other position and will have obviously reduced resource.

Links of telescopic draft have to move without jamming relatively each other to the full size of the course and come back also freely to a starting position a returnable spring. The case and a cover of the starting arrangement should not have deformations, chips and damages of a carving.
Jets and emulsion tubes. Fuel and air jets should not have damages of a carving and shliyets under the screw-driver. The calibrated openings of jets and emulsion tubes have to be absolutely pure.
Carburetor case. If washing did not succeeded to remove all pollution from channels and emulsion wells, clear them special development. Examine the condensed surfaces of the case, at their damage replace the case new. Eliminate the insignificant buckling of the surfaces interfaced to a cover of the carburetor and the case of butterfly valves in the locations of openings for screws of fastening of a cover and pass of hairpins of fastening of the carburetor, caused by excessive efforts at an inhaling of fasteners with grinding in on a testing plate. At damage of carving openings of fastening of elements of the case of the carburetor replace the case.
Accelerating pump. Check ease of movement of a ball in the screw valve 9 (see fig. 2.109) and a condition of the condensed surfaces and laying. The calibrated opening in a sock of a spray 8 has to be absolutely pure and without damages which can lead to a fuel stream deviation from the set trajectory. Check ease of movement of mobile elements of the pump (the lever, its roller, diaphragm details). Jammings are not allowed. The diaphragm has to be whole, without stratifications and deformations.
Pneumatic actuator of a butterfly valve of the second camera. The diaphragm should not have gaps and stratifications. The plug of a rod has to be reliably a zavaltsovana in a basic plate of a diaphragm and without damages of a carving. The case 2 and a cover 4 should not have deformations and damages of carving openings.
Case of butterfly valves and its detail. The case should not have deformations, mechanical damages and the broken carving openings. Channels and cavities of the case have to be pure, and openings for axes of butterfly valves – without noticeable development.

       NOTE
At strong wear of openings for axes of butterfly valves replace the case assembled with axes and gates: they approach the case individually and have no complete interchangeability.

Assembly
Collect the carburetor in the sequence, the return dismantling. At the same time pay attention to the following:
– the float has to shake freely on the axis, without touching camera walls;
– the needle valve has to move freely in the nest, without distortions and jammings, and the wire earring of the valve should not hinder the movement of a uvula of a float.
That at assembly not to mix in places jets of the first and second cameras, pay attention to marking of jets and at their installation be guided by tab. 2.9.
The main air jets 10 and 12 (see fig. 2.109) are marked on the top plane of a head of a jet by figures (for example, "150") which designate diameter of an opening of a jet (1,50 mm).
At the main fuel jets of the 14 and 15 figure apply also on the top plane ("112") and they designate diameter of an opening of a jet (1,12 mm) too.
Emulsion tubes of 13 and 11 first and second cameras at this carburetor identical. However other models of carburetors can have them different. Therefore on a cylindrical surface, in the lower part of tubes, put figures which designate number of calibrating of a tube.
On small diffusers 7 and 22 there are also figures (for example, "4,5") designating number of calibrating of an opening of a spray.
Beat out from fuel jets of the 17 and 5 idling and transitional system of figure on a cylindrical corbel (for example, "50" or "60"). They specify diameter of an opening (0,50 mm or 0,60 mm).
Adjustment and check of the carburetor after assembly
Installation of level of fuel in the float-operated camera

Fig. 2.111. Adjustment of level of fuel in the float-operated camera of DAAZ-2141, 2107 and DAAZ-2140-70 carburetors: 1 – carburetor cover; 2 – saddle of the needle valve; 3 – emphasis; 4 – needle valve; 5 – ball of the needle valve; 6 – earring of the needle valve; 7 – float lever uvula; 8 – float; 9 – laying of a cover of the carburetor


1. Establish the cover of 1 (fig. 2.111) collected with the float-operated mechanism and laying, the fuel supply union vertically up. At the same time the needle valve 4 has to be closed, and the uvula of the 7th lever of a float has to touch a ball of the 5th needle valve, without squeezing a ball spring.
2. Check in this situation a gap And between a middle part of a float and the surface of the laying 9 which is densely pressed to a cover flange. The gap has to be equal (6,5±0,25) mm.

       NOTE
The gap can be checked in special caliber, and at its absence a shaft of a drill of suitable diameter.

If necessary carefully turn in a uvula of the 7th arm of a float for receiving the required gap. The uvula has to be perpendicular axes of the needle valve, and its contact surface from a ball – without damages which can be the cause of lag of the valve.
3. Check a full speed of a float which has to be (8±0,25) mm, if necessary adjust it, turning in an emphasis 3 arms.
4. After adjustments check whether the earring 6 of the needle valve interferes with its free movement.

       NOTE
Installing a cover 1 on the carburetor case, be convinced that the float freely moves, without touching walls of the float-operated camera.

Installation of a pneumatic actuator of a butterfly valve of the second camera 
Attach a rod of the 9th pneumatic actuator (see fig. 2.107) installed on the carburetor case to the lever on an axis of a butterfly valve of the second camera in the following order.
1. Establish a butterfly valve of the second camera in vertical position.
2. Drown a rod in the pneumatic actuator camera against the stop and, holding the plate plug of a diaphragm from a provorachivaniye, unscrew or wrap a rod, changing its length so that the opening in a tip of a rod appeared against a pin on the lever.
3. Put on a rod a pin of the lever and fix by a lock washer.
4. Record a rod a lock-nut, holding other key the plate plug of a diaphragm from a provorachivaniye.
Adjustment of provision of butterfly valves 
Check completeness of opening of butterfly valves turn of levers of their drive against the stop.

Fig. 2.112. Adjustment of provisions of butterfly valves of the carburetor 2107-1107010: and – partial opening of a butterfly valve of the first camera; – full opening of butterfly valves; 1 – the lever on an axis of a butterfly valve of the second camera; 2 – the lever limiting opening of a butterfly valve of the second camera; 3 – the lever which is rigidly connected with an axis of a butterfly valve of the first camera; 4 – lever of the drive of gates; 5 – butterfly valve of the first camera; 6 – butterfly valve of the second camera


Adjust the size of the maximum opening of a butterfly valve of the first camera (13±0,1) of mm a podgibaniye in the necessary party of the lower short mustache of the lever 3 (fig. 2.112).
Adjust the size of the maximum opening of a butterfly valve of the second camera (17±0,1) of mm a wraparound or an otvorachivaniye of a rod of a pneumatic actuator as it was described above.

       NOTE
The size of the maximum opening of a butterfly valve of the second camera of the carburetor 2140-1107010-70 is set by the sizes of details of the drive and is not regulated.

The size of partial opening of a butterfly valve of the first camera at the time of contact of the top short mustache of the lever 3 with the lever 2 (see fig. 2.112, a) has to be (6±0,25) mm. This size is regulated a podgibaniye of the top short mustache of the lever 3.
Adjustment of position of the microswitch

Fig. 2.113. Adjustment of position of the microswitch: 1 – the lever fixed on an axis of a butterfly valve of the first camera; 2 – lever of the drive of butterfly valves; 3 – microswitch; And – a lever 1 short mustache


The microswitch 3 (fig. 2.113) has to be switched off at turn of the lever 2 clockwise against the stop. At turn of the lever 2 of a starting position counterclockwise until contact with a short mustache And the lever 1 microswitch has to turn on. The moment of inclusion and switching off of the microswitch can be determined by characteristic click.
For adjustment of the moments of inclusion and switching off of the microswitch weaken screws of its fastening to an arm and turn the microswitch of rather top screw in required position then tighten fastening screws.
Adjustment of the starting arrangement
At turn of the lever 3 (see rice 2.107) counterclockwise against the stop the air gate has to be completely closed. At this position of the lever the end of draft 19 (see fig. 2.108) has to be in the end of a groove of a rod of the 5th starting arrangement, but not move a rod yet. For implementation of this requirement turn in draft 19, changing thereby its length.
At completely closed air gate the butterfly valve of the first camera has to be slightly opened on 0,9–1,0 mm (a gap With – distance between the gate and a wall of the camera in the location of transitional openings of system of idling). This gap is regulated a podgibaniye of draft 25 (see fig. 2.109), changing thereby its length.
Completely closed air gate has to be slightly opened on (5,5±0,25) mm (a gap In) by a rod 5 (see fig. 2.108) the starting arrangement at its movement manually in the device case against the stop. This size is regulated the screw 1, access to which opens after a reversing from a cover 2 stoppers caps. At a screw wraparound 1 gap In increases, at a reversing – decreases.
Check of giving of the accelerating pump
The volume of the fuel given the accelerating pump for ten full turns (courses) of the lever 6 (see fig. 2.107) the drive of butterfly valves, has to make 5,25–8,75 cm3.
For measurement of volume of the fuel which arrived from a pump spray for these ten courses bring together him in a beaker. Before check make ten trial courses the lever 6 for filling of channels of the accelerating pump. Giving of the accelerating pump can be adjusted the screw 16 (see fig. 2.109) only towards reduction. At insufficient giving check correctness of assembly of the pump.
Check of tightness of the needle valve
The valve is checked at the stand providing supply of fuel to the carburetor under pressure of 30 kPa (3 m of water column). After stabilization of level in a control test tube of the stand its decrease during 10–15 pages is not allowed. If fuel level in a test tube goes down, so there is a leak of fuel via the needle valve.
Adjustment of system of idling
The maintenance of CO and CH in the fulfilled gases of the cars equipped with the carburetor agrees to the change No. 1 which is put into operation in the territory of the Russian Federation since January 1, 2000 to GOST 17.2.2.03-87 define during the operation of the engine on two modes with a different frequency of rotation of a bent shaft – the minimum frequency of idling of nmin and raised – npov. Values of frequency of rotation establish manufacturers of cars in specifications and maintenance instructions. If they are not specified, then is accepted:
n_min=(800+50) of mines-1;
n_pov = (3000+100) min.-1.

Table 2.10 Maximum permissible values of maintenance of CO and CH in the fulfilled gases

Maximum permissible values of maintenance of CO and CH in the fulfilled gases of cars are given in tab. 2.10. The maintenance of NOx is not normalized now. In cases of excess of the norms specified in the table, the car is considered technically faulty and can be out of service.

Fig. 2.114. Adjusting elements of system of idling of the DAAZ-2140-70 carburetor: 1 – EPHH case; 2 – restrictive plug of the screw of quality of mix


Fig. 2.115. Screws of adjustment of system of idling of the carburetor 2107-1107010: 1 – screw of amount of mix; 2 – screw of quality of mix


Adjusting elements of the carburetor 2140-1107010-70 are shown in fig. 2.114, the carburetor 2107-1107010 – in fig. 2.115. In drawings adjusting screws are closed by plastic restrictive plugs which allow to turn screws only half way and by that interfere with violation of factory adjustment of the carburetor. If with plugs it is not possible to adjust the maintenance of CO and CH in the fulfilled gases, break their heads, having wrapped screws against the stop, then turn out adjusting screws, remove the remains of plugs from their shafts and wrap screws on the former place.
As it was already mentioned (see. "Operation"), the system of idling of the carburetor is regulated directly on the engine. The last needs to be warmed up up to the working temperature, and – to adjust system of ignition and the valvate mechanism.
Adjustment of system of idling will require the tachometer and a gas analyzer controlling the content in the fulfilled gases as WITH, and SN. However in practice it is possible to use the gas analyzer determining content only WITH as on concentration of SN generally estimate technical condition of the engine in general and its separate systems. At their serviceability contents WITH in normal limits automatically involves the optimum maintenance of SN.
At adjustment of system of idling avoid a mistake which is very often made by employees of service stations and ecological posts. Seeking to provide with guarantee minimum content WITH, they excessively pereobednyat gas mixture. At the same time because of interruptions in operation of the engine, even absolutely serviceable, caused by admissions of ignition of the regrown poor mix, the maintenance of SN sharply increases. Besides, the gas analyzer accurately fixes change of contents WITH only at values not less than 0,4%. Therefore never adjust the carburetor on contents ABOUT less this value.
Regulate system of idling in the following order:
1. Enter into an opening of an exhaust pipe the gas analyzer probe on depth not less than 200 mm and warm up it during the operation of the engine on the idling mode within 30 min.
2. Or the screw of 1 quantity (see fig. 2.115) on a tachometer establish by turn of the case 1 EPHH (see fig. 2.114) the frequency of rotation of bent shaft 850 mines-1. The screw 2 qualities (in both drawings) achieve concentration WITH in the fulfilled gases within 0,5–1,2% at invariable position of the EPHH case or screw 1. At a rotation frequency deviation from set by the EPHH case or the screw 1 restore it in former limits.
3. Through 20–30 from operation of the engine check the maintenance of CO and CH in the fulfilled gases. If necessary slow turn of the screw of quality it is consecutive on 1/2, 1/4 and 1/8 turns bring this size to the required value.
4. Modify position of the EPHH case or screw of quantity, restoring the frequency of rotation of a bent shaft to the value stated above. If after that the maintenance of CO and CH in the fulfilled gases changed or the engine unstably works at the idling mode, repeat adjusting operations, having checked serviceability of the carburetor.
For preliminary check of correctness and quality of adjustment sharply press an accelerator pedal, and then at once release it. If the engine stops, increase the EPHH case or the screw of amount of mix the frequency of rotation of a bent shaft on the idling mode a little, but no more than for 50 min.-1 in comparison with nominal. If it is not possible to achieve steady operation of the engine on the idling mode (cyclic change of frequency of rotation of a bent shaft or interruptions is observed), check serviceability of a pneumatic valve of EPHH of the carburetor, having removed from its union a depression supply hose from the electromagnetic valve of the EPHH system. The engine at the same time has to stop immediately. If it does not occur, check serviceability of a pneumatic valve. If it is serviceable, check the engine, its systems and eliminate the revealed defects.
After adjustment check the maintenance of CO and CH with the increased frequency of rotation of a bent shaft. Excess of the values given in tab. 2.10 indicates the malfunction of the carburetor influencing its work at big loadings and also the increased wear of tsilindroporshnevy group.
In the absence of a gas analyzer the system of idling can be adjusted with the acceptable accuracy degree, controlling the frequency of rotation of a bent shaft a tachometer, and at sufficient skill of the performer – and aurally. On the working engine, consistently rotating the quality screw in both parties, establish it in situation at which the frequency of rotation of a bent shaft on the mode of idling is maximum. Then establish by the EPHH case or the screw of quantity the frequency of 850 min.-1 and after that increase it still approximately for 100 min.-1. For more exact installation of the screw of quality repeat these operations once again. After that, without changing position of the EPHH case or screw of quantity and wrapping the quality screw, reduce rotation frequency to nominal (for the same 100 min.-1). This way, especially with application of an exact tachometer, on condition of serviceability of the engine and its systems guarantees contents WITH in the fulfilled gases of 1,5-2,0%, i.e. within norm.

Fig. 2.116. Installation of restrictive plugs on screws of adjustment of system of idling of the carburetor 2107-1107010; and – on the screw of amount of mix; – on the screw of quality of mix


After the end of adjustment to a napressuyta on screws restrictive plastic plugs, focusing vents of plugs of rather adjusting ledges, as shown in fig. 2.116.

       NOTE
At the carburetor 2140-1107010-70 the restrictive plug is installed only on the quality screw.

Fuel tank
Removal and installation
1. Disconnect a wire from the mass rechargeable battery.

Fig. 2.117. Installation of the fuel tank: 1 – the valve is dvukhkhodovy; 2 – bulk pipe; 3 – nut of fastening of a collar; 4 – coupling; 5 – draft; 6 – laying; 7 – fuel tank; 8 – bolt of fastening of the fuel tank; 9 – fuel pipe tube; 10 – fuel pipe hose; 11 – nut; 12 – sensor of the index of level of fuel; 13 – the tube which is airtaking away; 14 – collar of fastening of a bulk pipe; 15 – stopper


2. Disconnect electric wires and a hose of 10 (fig. 2.117) of a fuel pipe from the sensor 12 of the index of level of fuel.
3. Remove a stopper 15 from a mouth of a bulk pipe 2.
4. Disconnect a bulk pipe 2 and the airtaking-away tube 13 from the fuel tank, having weakened collars of their fastening.
5. Turn off two bolts 8 (in fig. 2.117 one bolt is shown, the second is closed by a wall of the fuel tank) and a nut of the 11th draft of the 5th fastening of the fuel tank and remove the fuel tank.
Install the fuel tank upside-down.

System of production of the fulfilled gases
Removal and installation of the muffler, resonator, reception pipe

Fig. 2.118. System of production of gases: 1 – reception pipe of the muffler; 2 – collar; 3 – the ring is sealing; 4 – bolt; 5 – nut; 6 – muffler; 7 – suspension bracket pillow; 8 – resonator; 9 – nuts of fastening of a flange of a reception pipe; 10 – washer; 11 – laying; 12 – bolt; 13 – washer; 14 – the washer is spring; 15 – nut


1. For removal of the muffler 6 (fig. 2.118) weaken a collar 2 fastenings of a back pipe of the resonator 8 to a branch pipe of the muffler and remove the muffler from three rubber pillows 7.
2. For removal of the resonator 8 remove the muffler (see item 1), weaken a collar 2 fastenings of a reception pipe to a forward pipe of the resonator and remove the resonator from a pillow 7.
3. For removal of a reception pipe 1 muffler and the resonator can be not separated, it is enough to weaken a collar of fastening of a reception pipe to a forward pipe of the resonator and to remove the resonator together with the muffler from suspension bracket pillows. Then turn off at the engine of fashion. 331 three nuts of the 9th fastening of a flange of a reception pipe to a flange of a final collector, and at the engine of fashion. 2106 – four nuts. Turn off a nut of the 15th bolt of the 12th fastening of a reception pipe to an arm on a transmission case, remove washers 13 and 14 and, having taken out a bolt 12 from an arm opening, remove a reception pipe and its laying 11 from hairpins of a final collector.

       NOTE
We recommend to replace at each removal of a reception pipe laying 11 new.

Replace the torn or hardened rubber pillows of a suspension bracket of elements of system.
The muffler and the resonator have a non-demountable design, and at failure (a progara, corrosion or mechanical damage) replace them.
Before installation of the muffler and resonator, being in operation, but suitable for further use, tap them the wooden hammer and blow compressed air for removal of scale, soot and resinous deposits.