Need under repair of the engine comes after the run about 150 000 km. To this run gaps reach the sizes causing falling of engine capacity, reduction of pressure of oil in the oil highway, sharp increase in a consumption of oil (over 0,25 l / 100 km), excessive smoking of the engine, the increased fuel consumption, and also the increased knocks.

Approximately gaps in interface of the main details owing to wear should not exceed the following sizes, mm:

- a piston skirt — a cylinder sleeve..... 0,25

- a piston ring — a flute in the piston (on height)..... 0,15

- lock of a piston ring..... 2,5

- the piston — a piston finger..... 0,015

- the top head of a rod — a piston finger..... 0,03

- conrod and radical

- bearings..... 0,15

- a valve core — the plug..... 0,20

- axial side play of the camshaft..... 0,25

- axial side play of a bent shaft..... 0,40

Operability of the engine can be restored by replacement of worn-out details new the standard size or regrinding of worn-out details and application of the new details of the repair size interfaced to them.

The following details of the repair sizes are issued: pistons, piston rings, inserts of radical and conrod bearings of a bent shaft, saddle of inlet and final valves, the semi-processed plugs of the camshaft and the directing plugs of valves.

For removal of the engine the car needs to be installed on a viewing hole. The workplace has to be equipped a waist or other lifting device with a loading capacity not less than 300 kg. To perform work on removal of the engine in the following order:

- to open a cowl and to remove it, having turned off four bolts of its fastening to loops;

- to merge cooling liquid from the cooling system, having turned off a stopper on a radiator and having opened faucets on the block of cylinders and a heater. To remove a stopper of a broad tank;

- to merge oil from a case of the engine and from the transmission, having turned off traffic jams of drain openings. After discharge of oil of a stopper to put into place and to tighten hardly;

- to remove the rechargeable battery;

- to hook on the engine for cargo eyes and to pull a waist chain.

The works which are carried out from below the car:

- to remove the driveshaft in collecting (see the subsection "Cardan Broadcast");

Fig. 4.40. Transmission extender stopper cap

Fig. 4.41. Block of cylinders and piston

Fig. 4.42. Krivoshipno-shatunny mechanism

Fig. 4.43. Installation of a case of coupling and transmission

Fig. 4.44. Gas-distributing mechanism

Fig. 4.45. Camshaft drive

Fig. 4.46. Drive of the oil pump and sensor distributor of ignition, oil pump

Fig. 4.47. Pump of cooling liquid

Fig. 4.48. Fan drive

Fig. 4.49. Tension roller

- to establish a stopper cap (fig. 4.40) in a transmission extender opening;

- to turn off nuts of fastening of a back support of the engine to a cross-piece;

- to disconnect a cross-piece from a frame of the car and to remove a cross-piece;

- to disconnect a speedometer shaft from the transmission;

- to disconnect an arm of fastening of reception pipes of system of production of the fulfilled gases from the transmission;

- to disconnect reception pipes from a final collector of the engine;

- to disconnect wires from the backing light switch on the transmission;

- to turn off two bolts of fastening of the working cylinder of the drive of switching off of coupling and to disconnect the cylinder from a coupling case.

— to disconnect from the distributor of ignition of a wire of high and low voltage, the ignitions going to the coil, wires from a starter, from sensors of pressure and emergency pressure of oil on an oil filter, from the sensor of the index of temperature of cooling liquid on the case of the thermostat and the sensor of a signaling device of an overheat of cooling liquid in a cover of a head of cylinders;

- to disconnect a fuel-supply line hose from the fuel pump;

- to turn off a bolt of fastening of the left pillow to an arm on the engine.

- to disconnect wires from the generator;

- to disconnect hoses of an intake of warm and cold air from the air filter, branch pipes of an intake of air, the thermoprotective screen of an exhaust pipe and to remove them;

— to disconnect a hose of ventilation of a case from the air filter, a cover of yokes and to remove it;

- to uncover also the filtering element of the air filter;

- to unbend moustaches of lock washers and to turn off nuts of fastening of the case of the air filter, to carefully remove nuts and lock washers, having excluded hit them in the engine;

- to remove the case of the air filter with a flange and laying, to close the carburetor a pure napkin;

- to disconnect wires from the carburetor;

- to disconnect a rope of the drive of butterfly valves and draft of the air gate from the carburetor;

- to disconnect a fuel restart-up fuel-supply line hose from the carburetor;

- to disconnect hoses from the electromagnetic valve of system of the economizer of compulsory idling;

- to disconnect two hoses of a heater from the engine;

- to disconnect a faucet of discharge of cooling liquid;

- to disconnect a hose of the vacuum amplifier of brakes from an inlet pipe;

- to disconnect a wire of "weight";

- to turn off a bolt of fastening of the right pillow to an arm on the engine.

The works which are carried out in front:

- to remove a lattice of facing of a radiator, having weakened fastening bolts;

- to disconnect a cowl lock cable;

- having turned off bolts, to remove the top panel of facing of a radiator;

- having turned off bolts, to remove a level of the lower fastening of facing of a radiator;

- to disconnect hoses from a broad tank to the case of the thermostat and a distributive branch pipe;

- to disconnect hoses from a radiator and from the engine, to remove hoses;

- to turn off bolts of fastening of a radiator and to remove it.

- to lift a rubber sealant to the gear shifting lever handle;

- to turn off a cap of fastening of the lever on a mouth of a cover of the transmission and to pull out the lever up;

- to close an opening in a mouth a pure napkin.

To take out the engine assembled with coupling and the transmission. Installation of the engine is into place made in the sequence, the return to removal.

Gaps and tightnesses, and also technical requirements which need to be observed at assembly of the engine and its knots are given in table 4.6.

The engines coming to repair have to be carefully cleared of dirt. Dismantling of the engine, as well as assembly, it is recommended to make at the stand allowing to install the engine in the provisions providing free access to all details during dismantling and assembly with the tool of the corresponding size (wrenches, strippers, devices) which working surface has to be in good shape.

At an individual method of repair of a detail, suitable for further work, have to be established on the former places. Pistons, piston rings, sleeves of cylinders, rods, piston fingers, inserts, valves, bars, yokes and pushers at removal need to be marked in any way, without causing damage of details (a kerneniye, inscribing, an attachment of labels, etc.).

At the depersonalized repair of engines it is necessary to remember that covers of rods with rods and covers of radical bearings with the block of cylinders are processed assembled and therefore they cannot be razukomplektovyvat. It is not recommended to razukomplektovyvat a bent shaft with a flywheel and coupling as these knots at the plant are exposed to balancing in assembled form.

Gear wheels of the gas-distributing mechanism are selected on noise and a gap in gearing therefore it is necessary to avoid their razukomplektovaniye.

The coupling case (the top part) is processed together with the block therefore it is possible to disconnect it from the block only at repair or replacement with new.

Dismantling of the engine is recommended to be carried out in the following order:

- to take out a coupling switching off fork;

- to remove the transmission from the engine;

- to remove the fan;

- to remove the generator and a starter;

- to disconnect wires of high voltage from candles, to pick up the phone of the vacuum regulator and to remove the ignition sensor distributor;

- to turn out candles;

- to remove the filter of thin purification of fuel with an arm, the fuel pump and fuel-supply lines;

- to remove the carburetor together with laying and a safety guard, previously having removed tubes of ventilation of a case and recirculation of the fulfilled gases;

- to remove the filter of purification of oil, previously having removed sensors of the index of pressure and emergency pressure of oil and an oil supply tube;

- to pick up the phone of the index of level of oil together with the index;

- to remove the valve of recirculation of the fulfilled gases;

- to remove the gas pipeline and laying of the gas pipeline;

- to uncover yokes with laying, trying not to damage the last;

- to remove an axis of yokes with racks and to sort it;

- to take out bars of pushers;

- to remove a head of cylinders. If there is no need for dismantling and repair of the case of the thermostat, the gas pipeline and a head of cylinders, the head of cylinders can be removed together with these knots;

- to shoot a tension video and the drive of the fan;

- to remove the water pump;

Fig. 4.50. Fixing of sleeves with plugs clips

- to fix by plugs clips of a sleeve of cylinders in order to avoid their drop-out of the block in the course of further dismantling of the engine (fig. 4.50);

Fig. 4.51. Removal of valvate springs

- by means of adaptation (fig. 4.51) to make dismantle of springs of valves. That the plate of springs of the valve descended from crackers, it is necessary to strike slightly after a preliminary inhaling of the screw with the hammer handle a plate stripper brackets. To take out valves;

- to mark valves according to their arrangement;

- to remove the sensor distributor drive;

- to uncover a box of pushers;

- to take out pushers from nests and to lay them one after another;

- to remove the lower part of a case of coupling;

- to remove an oil case;

- to turn out the coupling screw from a forward end face of a bent shaft and to remove it together with a gear washer;

- to remove a pulley nave together with a pulley damper of a bent shaft by means of a stripper;

- to uncover distributive gear wheels;

- to remove the same stripper a gear wheel of the camshaft and a gear wheel of a bent shaft, having removed previously a maslootrazhatel;

- to remove a persistent flange of the camshaft with the expansion plug;

- to carefully take out the camshaft. It can be taken out assembled with a persistent flange and a gear wheel. In this case it is necessary to turn off a face key through openings in a gear wheel two bolts of fastening of a persistent flange to the block;

- to pick up the phone of lubricant of distributive gear wheels;

- to remove a persistent washer of a bent shaft;

- to remove a forward washer of the persistent bearing of a bent shaft;

- to remove the oil pump;

- to uncover conrod bearings together with inserts;

- to take out pistons together with rods. Before dismantling of conrod and piston group it is necessary to double-check correctness of tags on rods and their covers, and also their compliance to serial numbers of cylinders;

Fig. 4.52. Removal of piston rings from the piston

- to remove a stripper piston rings from pistons (fig. 4.52);

Fig. 4.53. Vypressovka of a piston finger from the piston a stripper: 1 — the piston; 2 — a piston finger; 3 — a mandrel; 4 — the stripper screw

- to take out lock rings from pistons. To Vypressovat by means of a stripper piston fingers from pistons (fig. 4.53).

- to remove the holder of stuffing of a bent shaft;

- to uncover radical bearings with inserts. To check correctness of tags on covers of 2, 3 and 4 radical bearings;

- to take out a bent shaft from the block of cylinders;

- to remove a back washer of the persistent bearing of a bent shaft;

- to take out stuffing of back consolidation of a bent shaft from the block of cylinders and the holder;

- to remove press and conducted clutch plates;

- to remove a flywheel;

Fig. 4.54. A stripper for a bearing vypressovka from a bent shaft: 1 — capture; 2 — a hairpin; 3 — baizes; 4 — the handle

- by means of a stripper (fig. 4.54) to vypressovat the bearing from a bent shaft.

Before assembly of the engine it is necessary to clear all its details of a deposit and resinous deposits. It is impossible to wash out in alkaline solutions of a detail, made of aluminum alloys (the block, a head of cylinders, pistons, etc.) as these solutions corrode aluminum.

For cleaning of details of a deposit the following solutions are recommended:

- soda (Na2CO3)..... 18,5

- soap (green or economic)..... 10,0

- liquid glass..... 8,5

- water, l..... 1,0

- the caustic soda (NaOH)..... 25

- soda (Na2CO3)..... 33

- soap (green or economic)..... 8,5

- liquid glass..... 1,5

- water, l..... 1,0

At assembly of the engine it is necessary to meet the following conditions:

- to wipe all details with a pure napkin and to blow compressed air, and to oil all surfaces of friction pure engine;

- to examine details before statement on the place (whether there are no cracks, chips, забоин and other defects), to check reliability of landing of other details pressed in them. Defective parts are subject to repair or replacement with new;

- to grease the carving parts of details and knots leaving in a cavity of the oil highway and in a cooling system cavity with anaerobic Unigerm-6 sealant. It is possible to apply the minium or whitewash divorced on natural drying oil;

- motionless consolidations, especially joints of details (the lower planes of the block of cylinders and a cover of distributive gear wheels, the holder of stuffing — the block of cylinders) to grease with Elastosil 137-83 glue-sealant or UN-25 paste.

On the engine are not allowed to statement:

- the forelocks, a shplintovochny wire and lock plates which were in the use;

- the spring washers which lost elasticity;

- the damaged laying;

- the details having on a carving more than two the hammered or broken threads;

- bolts and hairpins with the extended carving;

- bolts and nuts with worn-out sides.

Bolts and nuts have to be as appropriate zakontrena (forelocks, a shplintovochny wire, springs and special washers and lock-nuts).

To make assembly of the engine in the following order:

- to clear all privalochny surfaces of the block of the laying which stuck and torn when dismantling;

- to fix the block of cylinders at the stand, to turn out from forward and back end faces of a stopper of the oil channel and to blow all oil channels compressed air. To wrap traffic jams into place.

Fig. 4.55. Check of concentricity of an opening of a case of coupling with an axis of a bent shaft

Fig. 4.56. Check of perpendicularity of a back end face of a case of coupling of an axis of a bent shaft

If replacement of a case of coupling is required or it is established on the block after repair, it is necessary to remove previously from the block two adjusting pins, then to fix a case on the block by bolts. On extreme inserts install a bent shaft to which flange the indicator rack fastens in the block. Rotating a bent shaft, check an opening beating for the aligning burt of the transmission, and also perpendicularity of a back end face of a case of coupling concerning an axis of a bent shaft, as shown in fig. 4.55 and 4.56. The beating of an opening of a case and an end face should not exceed 0,3 mm, an end face — 0,15 mm. If the beating of an opening exceeds the specified size, then it is necessary to weaken an inhaling of bolts and easy blows to a flange of a case to achieve its correct installation. After an inhaling of bolts of an opening for adjusting pins in a case and the block develop to the repair size. Blackness in openings is not allowed. After that in openings press pins which diameter is 0,015 — 0,051 m more than the sizes of openings. The beating of an end face of a case is eliminated with a shabrovka. It must be kept in mind that at the above described check it is necessary to use not worn-out bent shaft and inserts which need to be removed after replacement of a case;

- to replace defective sleeves of cylinders new as follows:

Fig. 4.57. Vypressovka of a sleeve from the block of cylinders the combined stripper: 1 — a sleeve; 2 — a pad; 3 — a nut; 4 — a hairpin; 5 — a bolt; 6 — an axis; 7 — the screw

- a) by means of the combined stripper (fig. 4.57) to vypressovat an old sleeve. Having implanted stripper pads into the engine cylinder, it is necessary to rest hairpins 4 against the block and to move apart pads a razzhimny bolt 5. Further, rotating the screw 7, to vypressovat a sleeve from the cylinder;

- b) to carefully clear of a scum and corrosion the landing surfaces and the surfaces of consolidation on a sleeve and on the block;

- c) to insert the repaired sleeve with laying from soft copper into the cylinder from which it was taken out. The sleeve has to enter the cylinder freely, without efforts and act over the block plane on 0,02 — 0,10 mm. It is more convenient to check previously sleeve utopaniye size in the cylinder without laying. Has to be Utopaniye within 0,20 — 0,25 mm;

- d) to fix a sleeve by the holder that it did not drop out;