d8791262

2.5. Assembly of the engine

You make assembly of the engine as follows.
Install the pure block of cylinders on the stand and wrap in it the absent hairpins. Establish an arm of fastening of the generator and fix it by two bolts.
Oil engine inserts of bearings and persistent half rings of a bent shaft, and also pistons and epiploons. At assembly of the engine after repair establish new epiploons of a bent shaft.

Установка упорных полуколец коленчатого вала в гнезда среднего коренного подшипника
Fig. 2.17. Installation of persistent half rings of a bent shaft in nests of the average radical bearing

Establish in the 1st, 2nd, 4th and 5th nests of the block of cylinders inserts with a flute, and in the 3rd nest of the block of cylinders and in covers of radical bearings — inserts without flute. Lay a bent shaft in radical bearings and insert persistent half rings (fig. 2.17) into a nest of the average radical bearing.

       PREVENTION
Half rings have to be turned by flutes towards persistent surfaces of a bent shaft (from flutes the antifrictional layer is applied on a surface of a half ring). On an average support of a bent shaft from fastening of a flywheel the ceramic-metal half ring (yellow color), and from the opposite side — steel-aluminum is put.


Метки на крышках коренных подшипников. Счет крышек ведется от стороны привода распределительного вала
Fig. 2.18. Tags on covers of radical bearings. Count of covers is kept from the party of the drive of the camshaft

Establish covers of radical bearings according to tags which are put on their external surface (fig. 2.18). Develop covers so that tags on each of them were from installation of the generator. Tighten bolts of fastening of covers.


Проверка осевого свободного хода коленчатого вала
Fig. 2.19. Check of an axial free wheeling of a bent shaft

Check the free axial wheeling of a bent shaft. For this purpose turn the block of cylinders the back party up and establish on it a rack with the indicator so that the leg of the indicator rested against a flange of a bent shaft. Moving a shaft up and down (for example, screw-drivers), measure the indicator the free axial wheeling of a shaft (fig. 2.19). It has to be within 0,06–0,26 mm. If the course is more, then normalize it, having replaced old half rings new or having established half rings of the increased thickness.

Держатель заднего сальника коленчатого вала. Стрелками показаны выступы для центрирования держателя относительно фланца коленчатого вала
Fig. 2.20. Holder of a back epiploon of a bent shaft. Shooters showed ledges for centering of the holder concerning a flange of a bent shaft

Mandrel 67.7853.9571 press a back epiploon of a bent shaft in the holder (fig. 2.20). Put on the holder with an epiploon a mandrel 67.7853.9572 and move it from a mandrel on a flange of a bent shaft. Establish laying under the holder and attach him to the block of cylinders bolts with spring washers.

Блокировка маховика фиксатором 67.7820.9526
Fig. 2.16. Blocking of a flywheel clamp 67.7820.9526

Establish a flywheel on a bent shaft so that the tag (a cone-shaped hole) about a rim was against an axis of a conrod neck of the fourth cylinder. Establish a washer and bolts of fastening of a flywheel. Block a flywheel a clamp 67.7820.9526 (see fig. 2.16) and tighten fastening bolts. Before installation apply UG-6 sealant on bolts of fastening of a flywheel. For a reliable skhvatyvaniye of sealant, before its drawing degrease bolts and carving openings in cranked to a shaft.


Установка поршня с поршневыми кольцами в цилиндр при помощи регулируемой втулки 67.7854.9519
Fig. 2.21. Installation of the piston with piston rings in the cylinder by means of the adjustable plug 67.7854.9519

Pick up pistons to cylinders for a class and one group on weight and collect pistons with rods as it is specified in subsection. "Conrod and piston group". By means of the adjustable plug 67.7854.9519 insert into cylinders pistons with rods (fig. 2.21).

       PREVENTION
The opening for a finger on the piston is displaced from an axis on 1,2 mm therefore at installation of pistons into the shooter's cylinders on the bottom of the piston it has to be turned towards the camshaft drive.

Establish inserts in rods and covers of rods. Establish rods and covers on necks of a bent shaft, tighten conrod bolts. Covers of rods need to be established so that number of the cylinder on a cover was against number of the cylinder on the lower head of a rod.
Mandrel 67.7853.9580 press a forward epiploon of a bent shaft in a cover of the oil pump. Fill in in the oil pump of a little engine oil and turn several times its leading gear wheel. Install on a mandrel 67.7853.9580 oil pump with a forward epiploon of a bent shaft and turn the leading gear wheel in such situation that it could be put on a neck of a bent shaft. Move the pump from a mandrel on a shaft, establish laying under the pump and attach it to the block of cylinders.


Направляющие штифты масляного насоса
Fig. 2.22. The directing pins of the oil pump

For the correct installation of the pump in its case two directing pins (fig. 2.22) which have to enter the corresponding openings of the block of cylinders are pressed.

Снятие масляного насоса
Fig. 2.15. Removal of the oil pump: 1 – oil pump; 2 – laying of the oil pump; 3 – receiver of the oil pump; 4 – laying of a case; 5 – case; 6 – sensor of provision of a bent shaft

Insert into an opening of the oil pump an oil receiver with a sealing ring, attach it to the oil pump and to a cover of the second radical bearing of a bent shaft (see fig. 2.15).
Establish an oil case 5 with laying 4 and fix it.
Oil engine a sealing ring of an oil filter and establish an oil filter, having manually tightened it to the union on the block of cylinders.

Втулки для центрирования головки на блоке цилиндров
Fig. 2.23. Plugs for centering of a head on the block of cylinders

Порядок затягивания болтов головки цилиндров
Fig. 2.24. Order of tightening of bolts of a head of cylinders

Insert two aligning plugs (fig. 2.23) into the block of cylinders and establish on them laying of a head of cylinders. At correctly established laying the opening for oil pass (it is edged by a copper tape) has to be in a zone of the 5th bolt of fastening of a head of cylinders (number of a bolt see fig. 2.24).

       PREVENTION
At assembly of the engine it is always necessary to establish new laying under a head of cylinders. Use of the laying which was in the use is not allowed.
Before installation of laying it is necessary to remove oil from the interfaced surfaces of the block and a head of cylinders. Laying has to be pure and dry. Hit of oil on the surface of laying is not allowed.

Turn a bent shaft so that pistons were in a middle part of cylinders.

Порядок затягивания болтов головки цилиндров
Fig. 2.24. Order of tightening of bolts of a head of cylinders

Establish the head of cylinders collected according to indications of the subsection "Head of Cylinders" on the aligning plugs. Tighten bolts of fastening of a head of cylinders in a certain sequence (fig. 2.24). To provide reliable consolidation and to exclude tightening of bolts at maintenance of the car, tighten bolts of fastening of a head of cylinders in four receptions:
1 reception — tighten bolts the moment of 20 N · m (2 kgfs · l);
2 reception — tighten bolts the moment of 69,4-85,7 N · m (7,1–8,7 kgfs · l);
3 reception — tighten bolts on 90 °;
4 reception — again tighten all bolts on 90 °;

Болт крепления головки цилиндров
Fig. 2.61. Bolt of fastening of a head of cylinders


       PREVENTION
Bolts of fastening of a head of cylinders are allowed to be applied repeatedly only if they were extended to length of L no more than 135,5 mm (see fig. 2.61). If length of a bolt is more, then replace it new.
Before assembly of the engine beforehand grease a carving and heads of bolts, having dipped them into engine oil. Then let's flow down to surplus of oil, having sustained bolts not less than 30 min. Remove oil or cooling liquid from openings in the block of cylinders under bolts of fastening of a head of cylinders.


Insert into a nest of the block of cylinders the pump of cooling liquid with laying. Establish a back cover of a gear belt and attach it together with a pump cover to the block of cylinders. In addition attach a cover a bolt to the block of cylinders and a nut to a hairpin on a head of cylinders.
Enclose in nests on the forward ends of cranked and distributive shaft segment splines and install cogged pulleys. Having blocked a camshaft pulley from a provorachivaniye, fix it by a bolt with a washer.

       PREVENTION
Replacement of bolts of fastening of a flywheel by a bolt of fastening of a pulley of the camshaft and back in connection with their various covering is forbidden. Bolts of fastening of a flywheel fosfatirovanny, and a bolt of fastening of a pulley of the camshaft — oxidized.

Проверка совпадения установочных меток на шкиве распределительного вала и задней защитной крышке
Fig. 2.25. Check of coincidence of adjusting tags on a pulley of the camshaft and a back protective cover

Adaptation 67.7811.9509 turn the camshaft before combination of a tag on a pulley with an adjusting short mustache on a back cover of a gear belt (fig. 2.25).
Проверка совпадения установочных меток на шкиве коленчатого вала и крышке масляного насоса
Fig. 2.26. Check of coincidence of adjusting tags on a pulley of a bent shaft and a cover of the oil pump

Tighten a bent shaft towards a smaller angle of rotation before combination of an adjusting tag on a pulley with a tag on a cover of the oil pump (fig. 2.26). It is possible to turn a bent shaft a key for a bolt, temporarily wrapped up in the forward end of a bent shaft.
Establish a tension roller with a remote washer and enshrine it in the provision of the minimum tension of a belt.
Put on a gear belt a pulley of the camshaft and, pulling both branches of a belt, get the left branch for a tension roller and put on it a pulley of the pump of cooling liquid. Put on a belt a pulley of a bent shaft and slightly pull it a tension roller, turning a roller counterclockwise. At installation of a belt avoid its sharp excesses.
Turn a bent shaft on two turns in the direction of rotation and check coincidence of adjusting tags (see fig. 2.25 and 2.26). If tags do not coincide, then weaken a belt tension, remove it from a camshaft pulley, turn a pulley on a necessary corner, put on a belt, slightly pull it a tension roller, again turn a bent shaft on two turns and check coincidence of adjusting tags.
At coincidence of tags adjust a belt tension as it is described in the subsection "Camshaft and Its Drive".
Adjust gaps in the valvate mechanism as it is specified in subsection. "Head of cylinders". Establish a forward cover of a gear belt and fix it by bolts. From the back party of the engine attach to a head of cylinders and to the case of bearings a cap with laying.
Accurately lay laying in a groove of a cover of a head of cylinders on all perimeter. Establish a cover on a head of cylinders, put on rubber plugs hairpins and acquire nuts with washers. If plugs have destruction traces, then replace them new. Nuts tighten evenly in stages against the stop washers in a hairpin. Remember that tightness of a cover depends on care of performance of all operations on its installation.
Turn in a head of cylinders of a spark plug and sensors of the index of temperature of cooling liquid and a control lamp of pressure of oil. Install the ignition module with an arm and high-voltage wires.
Establish on a head of cylinders the taking-away cooling shirt branch pipe with laying and fix it by two nuts. Wrap temperature sensor in a branch pipe. Establish laying and attach a flange of the bringing pipe of the pump of cooling liquid to the block of cylinders. Put on the hoses going to the thermostat a branch pipe and the bringing pipe, install the thermostat and fix hoses by collars.
Establish a hose of the exhaust ventilation of a case and fix it by collars on branch pipes of the block and a cover of a head of cylinders. Establish the index of level of oil.

Снятие ресивера и впускной трубы
Fig. 2.9. Removal of a receiver and inlet pipe: 1 – the supporting arm; 2 – inlet pipe; 3 – laying of a receiver; 4 – receiver; 5 – an arm for an accelerator drive cable tip; 6 – arm; 7 – screen of a final collector; 8 – basic arm

Put on hairpins of a head of cylinders of laying, establish a final collector and tighten the central nut of its fastening. Then establish an inlet pipe with an arm 6 (see fig. 2.9) and the screen 7 and fix them by nuts. Establish the supporting and basic arms of an inlet pipe and fix them by bolts and nuts.

Снятие топливной рампы с форсунками
Fig. 2.10. Removal of a fuel stage with nozzles: 1 – stage of nozzles; 2 – pressure regulator; 3 – vacuum hose; 4 – inlet pipe; 5 – nozzle; 6 – nozzle latch

Establish a stage 1 (see fig. 2.10) nozzles with nozzles and the regulator of pressure of fuel and attach it bolts to a head of cylinders. Oil sealing rings of nozzles before installation engine. Establish a plait of wires of nozzles and connect wires to nozzles.
Put on hoses of the exhaust ventilation of a case branch pipes of a cover of a head of cylinders and fix them by collars.

Снятие ресивера и впускной трубы
Fig. 2.9. Removal of a receiver and inlet pipe: 1 – the supporting arm; 2 – inlet pipe; 3 – laying of a receiver; 4 – receiver; 5 – an arm for an accelerator drive cable tip; 6 – arm; 7 – screen of a final collector; 8 – basic arm

Establish a receiver 4 (see fig. 2.9) with laying 3 and an arm of fuel-supply lines and attach it nuts to an inlet pipe and an arm 6. Establish the vacuum hose going from a receiver to the fuel pressure regulator.
Establish tubes of a supply and discharge of fuel, having attached them to a fuel stage, to the regulator of pressure of fuel and to an arm on a receiver.
Attach to a receiver a throttle branch pipe with laying. Attach to a throttle branch pipe hoses of a supply and removal of cooling liquid, and also a hose of the exhaust ventilation of a case idling.
Put on a pulley of the drive of the generator a bent shaft and fix it by a bolt with a washer. Establish a tension level and the generator. Put on a belt pulleys of a bent shaft and the generator and adjust its tension as it is specified in subsection. "Generator".
Fill in oil in the engine through a mouth on a cover of a head of cylinders.