5.3.11. Repair of the engine

Need under repair of ZMZ-4061,-4063 engines comes after the run of 200 — 250 thousand km depending on service conditions. To this run gaps reach the sizes causing falling of power, 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.
Sizes of gaps in interfaces of the main details owing to wear should not exceed the sizes specified for ZMZ-4025,-4026 engines.
Operability of the engine can be restored or replacement of worn-out details new the standard size, or restoration of worn-out details and application of the new details of the repair size interfaced to them.
For this purpose the release of pistons, piston rings, inserts of conrod and radical bearings of a bent shaft, the directing plugs of inlet and final valves and some other details of the repair size is provided.
Removal of the engine from the car
For removal of the engine the car needs to be installed on a viewing ditch or a platform with the general and figurative lighting. 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, to turn off four bolts of fastening it to loops and to remove a cowl;
- to merge cooling liquid from the engine cooling system, having turned off a stopper on a radiator and having opened faucets on the block of cylinders and a heater. At the same time the stopper of a broad tank has to be removed;
- to merge oil from a case of the engine and 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.
The works which are carried out on the left side of the car:
- to disconnect sockets and plugs of wires from coils of ignition and sensors: index of pressure of oil, alarm lamp of emergency pressure of oil, alarm lamp of an overheat of cooling liquid, index of temperature of cooling liquid, temperature condition of the engine;
- to disconnect hoses from a radiator, the pump of cooling liquid and a cover of the thermostat and to remove them;
- to disconnect a wire of "weight";
- to turn off a bolt of fastening of the left pillow to an arm on the engine.
The works which are carried out on the right side of the car:
- to disconnect wires from the generator and a starter;
- to disconnect sockets of wires from sensors of a detonation and the provision of a bent shaft (the synchronization sensor);
- to disconnect an airintaking hose from the air filter and an airintaking branch pipe and to remove a hose;
- to disconnect hoses of ventilation of a case from branch pipes of a cover of valves, the air filter and a tube of the carburetor, to remove them;
- 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 a rope of the drive of butterfly valves and draft of the air gate from the carburetor;
— to disconnect a tip of a rope of the drive of butterfly valves from an arm on the engine;
— to disconnect from the carburetor a fuel restart-up fuel-supply line hose, hoses to the electromagnetic valve of system of the economizer of compulsory idling;
— to disconnect two hoses of a heater from the engine;
- to disconnect hoses of the vacuum amplifier of the drive of brakes and the sensor of absolute pressure from an inlet pipe;
— to disconnect the bringing hose from the filter of thin purification of fuel;
- 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 of the car:
— to remove a lattice of facing of a radiator, having weakened fastening bolts;
- to disconnect a cowl lock cable;
- to turn 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 turn off bolts of fastening of a radiator and to remove it;
- to hook on the engine for cargo eyes and to pull a waist chain.
The works which are carried out in a car body:
- to tighten an external rubber sealant of a floor to the gear shifting lever handle;
- to remove a rubber protective sealant from a gear shifting lever case mouth cap;
- to turn off a cap from a mouth of the case of the lever and to take out the lever from a mouth up;
- to close an opening in a mouth a pure napkin.
The works which are carried out from below the car:
- to remove the driveshaft assembled;

Fig. 4.40. Transmission extender stopper cap




- to establish a stopper cap (see fig. 4.40) in a transmission extender opening;
- to disconnect wires from the backing light switch on the transmission;
- to disconnect a speedometer drive cable from 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 an arm of fastening of reception pipes of system of production of the fulfilled gases from the transmission;
- to disconnect reception pipes of system of production of the fulfilled gases from a final collector;
- to turn off nuts of fastening of a back support of the engine to the transmission;
- to disconnect a cross-piece from arms of longerons of the car;
- to remove a cross-piece;
- to take out the engine assembled with coupling and the transmission.
Dismantling of the engine
The engine before dismantling has to be carefully cleared of dirt. Dismantling and assembly of the engine is recommended to be made at the stand allowing to install the engine in the provisions providing free access to all details during dismantling and assembly.
Dismantling and assembly of engines need to be made 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. For this purpose such details as pistons, piston fingers, piston rings, rods, inserts, valves, hydropushers, etc., at removal them from the engine it is necessary to mark in any way which is not causing damage of details (a kerneniye, inscribing, an attachment of labels, etc.), or to shelve them with the numbered offices, in the order corresponding to their arrangement on the engine.
At the depersonalized method of repair of engines it is necessary to remember that covers of rods with rods, covers of radical bearings with the block of cylinders, covers of support of camshafts with a head of cylinders are processed assembled and therefore they cannot be razukomplektovyvat.
Bent shaft, flywheel and coupling at the plant are balanced separately therefore they are interchanged. The case of coupling is processed separately from the block of cylinders and also we interchange.
In gidronatyazhitel the case razukomplektation with a plunger is not allowed. 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 a case of coupling and a starter;
- to install the engine on the stand for dismantling;
- to weaken bolts of fastening of a pulley of the pump of cooling liquid;
- to weaken a bolt of fastening of a tension roller;
- to weaken a belt tension by a vyvertyvaniye of a bolt of movement of a tension roller, to take off a belt;
- to turn off bolts of fastening of a pulley of the pump of cooling liquid, to remove a pulley, a pulley reflector;
- to remove wires with tips from spark plugs, to turn out candles;
- to disconnect wires of high voltage from sockets of coils of ignition, to remove wires assembled with tips;
- to turn off cap nuts from unions of an inlet pipe and a final collector, to pick up the recirculation phone;
- to turn off bolts of fastening of a cover of valves, to uncover valves assembled with ignition coils, bolts, brackets and washers;
— to remove a fuel-supply line from the fuel pump to the filter of thin purification of fuel;
- to remove the fuel pump;
- to remove a forward cover of a head of cylinders;
- to remove the top and average uspokoitel of a chain;
- to uncover with laying of the top gidronatyazhitel of a chain;
- to take out a gidronatyazhitel;
- to turn off a bolt of fastening of an asterisk of the camshaft of inlet valves, to remove the clown and an asterisk;
- to remove a driving chain from asterisks of camshafts;
- to remove an asterisk from the camshaft of final valves;
- to turn off bolts of fastening of covers of camshafts, to uncover, flanges persistent;
- to remove camshafts;
- to take out hydropushers by means of a prisos or a magnet, to arrange them in the order of numbering of cylinders;
- to weaken screws of collars of hoses of heating of an inlet path, to remove hoses from unions;
- to weaken a coupling bolt of the top arm of the generator;
- to turn off a nut of a bolt of fastening of the generator to the top arm, to remove a bolt, the plug;
- to turn off a nut of a bolt of fastening of the generator to the lower arm, to remove the generator;
- to remove hoses of system of recirculation from unions of the carburetor, the thermal vacuum switch, the recirculation valve;
- to weaken the fuel-supply line tube collar screw on the carburetor union, to remove a hose from the union;
- to turn off nuts of fastening of the carburetor, to remove washers, the carburetor, laying, a pro-rate;
- to turn off nuts of fastening of the valve of recirculation, to remove washers, the valve, laying;
- to turn off a bolt of fastening of the filter of thin purification of fuel, to remove the filter assembled with tubes of fuel-supply lines;
- to turn out the thermal vacuum switch;
- to turn off nuts of fastening of an inlet pipe, to remove washers of an inlet pipe, laying;
- to turn off nuts of fastening of a final collector, to remove washers, a final collector, laying;
- to weaken thermostat case hose collars;
- to unscrew screws of fastening of the case of the thermostat, to remove the case, laying;
- to turn out the union of sensors of pressure of oil;
- to turn off bolts of fastening of a head of the block of cylinders, to remove bolts with washers;
- to remove a head of the block of cylinders;

Fig. 4.51. Removal of valvate springs




- by means of adaptation (see 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 compression of springs with the hammer handle a plate devices;
- to take valves, to arrange them in the order of numbering of cylinders;
- a stripper to remove maslootrazhatelny caps from the directing plugs. Removal of valves is recommended to be made at repair of a head of the block of cylinders;
- to turn the engine an oil case up;
- to turn off bolts of fastening of the amplifier of a case of coupling to the block, to remove washers, the amplifier;
- to turn off bolts and nuts of fastening of an oil case, to remove washers, an oil case, laying;
- to turn off a bolt of fastening of the holder of the oil pump on the third cover of the radical bearing;
- to turn off bolts of fastening of the oil pump, to remove the oil pump, laying, the six-sided roller of the drive of the oil pump;
- to turn off a coupling bolt of a bent shaft, to remove a bolt, a spring washer;
- by means of adaptation to remove a pulley of a bent shaft;
- to turn off bolts of fastening of the pump of cooling liquid to a chain cover, to remove bolts with washers, the pump of cooling liquid, laying;
- to turn off a bolt of fastening of a tension roller, to shoot a tension video;
- to uncover also laying of a gidronatyazhitel of the first step, to remove a gidronatyazhitel;
- to turn off a bolt of fastening of the sensor of synchronization, to remove the sensor;
- to unscrew screws of fastening of a cover of a chain, to uncover, a generator arm lower;
- to remove a chain of the second step of the drive of camshafts from the leading asterisk of an intermediate shaft;
- to raskontrit bolts of fastening of asterisks of an intermediate shaft, to remove asterisks, a chain;
- to turn off bolts of fastening of a flange of an intermediate shaft, to remove bolts with washers, a flange;
- to turn off bolts of fastening of a cover of the drive of the oil pump, to uncover, laying;
- to turn off a nut of the leading gear wheel of the drive of the oil pump, to remove a gear wheel assembled with a nut;
- to take out an intermediate shaft;
- to vypressovat a spline from an intermediate shaft;
- by means of a stripper to remove the plug and an asterisk from a bent shaft;
- to turn off a bolt of fastening of a boot of a natyazhitel of a chain of the first step of the drive of camshafts, to take off a boot;
- to turn off a bolt of fastening of a boot of a natyazhitel of a chain of the second step of the drive of camshafts, to take off a boot;
— to turn out the boot bolt extender, to remove the extender;
- to turn off bolts of fastening of the lower uspokoitel of a chain, to remove an uspokoitel;
- to turn off nuts of fastening of covers of the first and fourth rods, to uncover rods with inserts, to take out inserts from beds of covers of rods;
- to take out pistons with rods assembled from the first and fourth cylinders;
- to establish a bent shaft so that the second and third conrod necks were in the top situation, to turn off nuts of fastening of covers of the second and third rods, to uncover rods with inserts, to take out inserts from beds of covers of rods;
- to take out pistons with rods from the second and third cylinders;
- to insert into vents of the conducted disk a mandrel shlitsevy;
- to turn off serially, in stages, bolts of fastening of a press clutch plate, to remove a disk;
- to remove the conducted clutch plate with a shlitsevy mandrel;
- to raskontrit bolts of fastening of a flywheel, to remove a flywheel from a pin;
- to turn off bolts of fastening of a back cover, to remove a back cover assembled with a rubber cuff;
- to turn off bolts of fastening of covers of radical bearings, to remove bolts;
- to uncover radical bearings a stripper, semi-washers of the persistent bearing of a bent shaft top;
- to remove a bent shaft, semi-washers of the persistent bearing of a bent shaft lower;
- to take out radical inserts from beds of the block of cylinders and from covers of radical bearings;
- to install covers of radical bearings in the block according to numbering;
- to fix covers of radical bearings by bolts;
- to turn off a nut of fastening of the sensor of a detonation, to remove a washer, the sensor;
- to turn off an oil filter;
- to turn out a drain faucet from the block of cylinders;
- to take out connecting rods from rods;
- to establish covers of rods on fastening bolts, to screw nuts;

Fig. 4.52. Removal of piston rings from the piston




- to remove from pistons compression oil scraper rings by means of a stripper (see fig. 4.52);
- to remove lock rings;

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 vypressovat by means of adaptation and a mandrel piston fingers from pistons (see fig. 4.53).
Repair of details, knots, units and systems of the engine
Block of cylinders, pistons, rods, intermediate shaft
The block of cylinders with holes of walls of cylinders, a water shirt and a case or with cracks of the top plane and the edges supporting radical bearings is subject to replacement.
As a result of wear cylinders of the block get on length a form of the wrong cone, and on a circle — an oval. Wear reaches the largest size in the top part of cylinders around the top compression ring, at position of the piston in VMT; the smallest — in the lower part, at position of the piston in NMT.
At repair of cylinders two repair sizes are provided: the 1st and 2nd. With the same repair sizes pistons and piston rings are issued.
All cylinders of the block have to be processed, as a rule, for the same repair size with the mm deviations established for cylinders of the nominal size except for cases when it is required "to remove" superficial scratches on a mirror of cylinders (within increase in diameter of the cylinder by 0,10 mm) — in this case correction only of defective cylinders is allowed.
If for repair there is a limited number of pistons, it is recommended to calculate diameter deviations for each cylinder (proceeding from the actual size of diameter of a skirt of the piston intended for work in this cylinder with providing a gap of 0,036 — 0,060 mm) and under these sizes to chisel cylinders.
Deviations of a form of cylinders have to settle down in a tolerance zone of dimensional troupe on diameter of the cylinder.

Fig. 4.120. Intermediate shaft: 1 — a bolt; 2 — a lock plate; 3 — the leading asterisk; 4 — the conducted asterisk; 5 — the forward plug of a shaft; 6 — an intermediate shaft; 7 — a pipe of an intermediate shaft; 8 — the conducted gear wheel of the drive of the oil pump; 9 — a nut; 10 — the leading gear wheel of the drive of the oil pump; 11 — the back plug of a shaft; 12 — the block of cylinders; 13 — a flange of an intermediate shaft; 14 — a pin




Repair of plugs of support of an intermediate shaft consists in their replacement on repair (the increased thickness), with the subsequent boring under the nominal or repair size with the admission established for support of the nominal size — depending on degree of wear of basic necks of a shaft. Before repair of support it is necessary to remove a pipe 7 (see fig. 4.120). At installation of repair plugs it is necessary to provide coincidence of openings of oil channels. To make boring of support of an intermediate shaft for one installation for ensuring coaxiality.
Necks of an intermediate shaft grind under the repair size with the admission established for necks of the nominal size in case of the wear exceeding the most admissible.
Damages of carving openings to a look забоин or failure of a carving restore less than two threads a tap under the nominal size.
The carving openings having wear or failure of a carving more than two threads are restored by cutting of a carving of the increased size, statement carving a carving of the nominal size, vvertyshy with the subsequent cutting, in them or installation of carving spiral inserts. The last way is most effective and less labor-consuming.
Controlled parameters at repair of the block of cylinders, pistons, rods and an intermediate shaft are specified in tab. 4.12.

Table 4.12. Controlled parameters at repair of the block of cylinders, pistons, rods and an intermediate shaft


Bent shaft
In the presence of cracks of any character the bent shaft is subject to replacement.
For removal of products of wear in cavities of conrod necks and in oil channels of a bent shaft it is necessary to turn out traffic jams of necks, to stitch (solution of the caustic soda, heated to 80 °C) and the metal brush to clean cavities and channels. After cleaning they need to be washed out kerosene, to blow and dry up compressed air then to wrap traffic jams the moment of 38 — 42 Nanometers (3,8 — 4,2 kgfs · м).
At damage of a carving to openings to two threads it is restored a tap under the nominal size. If two and more threads are broken, then make repair as follows:
- carvings in openings under bolts of fastening of a flywheel — installation of carving spiral inserts;
- carvings in an opening under a ratchet — cutting of a repair carving;
- carvings in openings under traffic jams — cutting of a repair carving.
The conrod and radical necks which are worn out within the repair size grind under the closest repair size (1st, 2nd or 3rd) with the admission established for necks of the nominal size (all necks grind under one repair size). Sharp edges of facets of oil channels dull with the conical abrasive tool, and then necks subject to polishing.
Controlled parameters at repair of a bent shaft are specified in tab. 4.13

Table 4.13. Controlled parameters at repair of a bent shaft

Head of cylinders, valvate mechanism and camshafts
In the presence of holes, a progar and cracks on walls of combustion chambers and destructions of crossing points between nests of saddles of valves the head of cylinders needs to be replaced with new.
Repair of carving openings is similar specified for carving openings of the block of cylinders.

Fig. 4.133. Removal of valvate springs




For check of tightness of valves it is necessary to fill in kerosene serially to inlet and final canals of a head of cylinders. Course of kerosene from under plates of valves testifies to their leakage. Untight valves are taken from a head of cylinders by means of the device for compression of springs of valves (fig. 4.133).
When dismantling to lay valves in the order corresponding to their arrangement in a head for the subsequent their installation on former places.
Before grinding in of the valve it is necessary to check whether there is no plate buckling of the valve and a burn-out of the valve and a saddle. With these defects it is impossible to restore tightness of the valve grinding in and it is necessary to process at first boring a saddle, and to replace the damaged valve new. If the gap between a core of the valve and the directing plug exceeds 0,20 mm, then it is necessary to replace the valve and the plug new.
For spare parts valves are issued the nominal size, and the directing plugs — with an allowance for processing on internal diameter after a press fitting in a head and with the outer diameter of three repair sizes: the first — with increase by 0,02 mm from nominal, the second — with increase by 0,2 mm from nominal, the third — with increase by 0,02 mm from the second repair size (tab. 4.14).

Table 4.14. Controlled parameters at repair of a head of cylinders of the valvate mechanism and camshafts



Fig. 4.134. Vypressovka of the directing plugs of valves




Vypressovka is made by a worn-out guide of the plug by means of a mandrel (fig. 4.134).
Before a vypressovka of the directing plugs it is necessary to define maintainability of a head of the block of cylinders.
The head of the block of cylinders is maintainable if after processing of a saddle of the valve the distance from a camshaft axis to an end face of a core of the valve pressed to a working facet of a saddle makes not less than 35,5 mm. If this condition is not satisfied, the head of cylinders is not subject to repair. The head of the block of cylinders is also not subject to repair if the surface adjacent to the block has not planeness more than 0,1 mm.
At installation of new guides of plugs they should be cooled in carbon dioxide ("artificial ice") up to the temperature minus 40 — 45 °C, and to heat a head of cylinders to temperature plus 160 — 175 °C. Plugs at assembly have to be inserted into a head opening freely or with easy effort.
Plugs of the first repair size are installed in a head without additional processing of openings in a head, plugs of the second and third repair sizes — with preliminary boring (development) of openings to diameter of 14,2 mm.

Fig. 4.135. Profiles of saddles of valves: And — inlet; In — final; b — facet width




After installation and development of plugs of a facet of saddles to process (grinding or boring), aligning the tool on an opening in the plug. When processing it is necessary to maintain the sizes specified fig. 4.135 and to provide concentricity of a facet on a valve saddle with an opening in the plug (the beating of a working facet of a saddle concerning an opening of the plug is allowed no more than 0,05 mm).
After processing of facets it is necessary to reduce their width by means of processing of an internal surface of saddles at an angle 30 ° to in the size equal (2±0,4) mm at saddles of inlet valves, (2±0,3) mm at saddles of final valves.
Then to grind in valves, using the pritirochny paste made of one part of the micropowder M-20 and two parts of I-20A oil.
Before subassembly of a head of the block of cylinders it is necessary to clear combustion chambers and inlet, final channels of a deposit and deposits, previously having moistened a deposit with kerosene, it prevents dispersion of a deposit during its removal and prevents hit of poisonous dust at breath. To wipe and blow them compressed air.
It is necessary to install on the installed directing plugs of valves at the same time by means of a mandrel basic washers of springs and to napressovat oil scraper caps. To oil cores of valves, applied to the engine, to insert valves into plugs according to an order of their installation and to bring together them with springs by means of adaptation (see fig. 4.51). To be convinced that crackers entered ring flutes of valves. To fill in kerosene to inlet, final canals and to be convinced of tightness of valves.
For definition of a gap it is necessary to install all covers of bearings in bearings of camshafts according to their numbers.
Before installation of covers "1", "2", "3", "4", "5", "6", "7" and "8" beds of a head of the block of cylinders them need to be oiled, applied to the engine. Centering of the specified covers is made by means of the cylindrical mandrel with a diameter of 35-0,02 mm laid in a bed. After an inhaling of covers the moment of 19 — 23 N · m (· l) a mandrel to take 1,9 — 2,3 kgfs towards a back end face of a head of cylinders (at the same time the back cover of a head of cylinders has to be removed). If in one of bearings the gap appears more than 0,15 mm, then it is necessary to replace either a head of the block of cylinders, or the camshaft.
The gap in an opening under a hydropusher and a hydropusher should not exceed 0,15 mm. At a bigger gap it is necessary to replace either a hydropusher, or a head of the block of cylinders.
The surfaces of basic necks and cams have to be without zadir and deep sinks and not have the iznos exceeding maximum permissible. After check of shaft it is necessary to smooth out and polish the surfaces of necks and cams.
Controlled parameters at repair of heads of cylinders, the valvate mechanism and camshafts are specified in tab. 4.14.
Gidronatyazhitel
At repair of the engine gidronatyazhitel it is necessary to sort, wash out their details and to collect ("to load").
Dismantling of a gidronatyazhitel is made in the following order:

Fig. 4.119. Gidronatyazhitel assembled: 1 — the valve assembled; 2 — a locking ring; 3 — a plunger; 4 — the case; 5 — a spring; 6 — a lock ring




— to turn out the valve 1 case (see fig. 4.119) from the case 4 gidronatyazhitel;
— to take out from the case 4 a spring 5 and a plunger 3.
Assembly of a gidronatyazhitel is made in the following order:

Fig. 4.136. A mandrel for assembly of a gidronatyazhitel




— to install the case 4 gidronatyazhitel on the mandrel (fig. 4.136) fixed vertically;
— to insert into the case of a gidronatyazhitel a plunger 3 (see fig. 4.119) against the stop a lock ring 6 on a plunger in a mandrel, previously having oiled couple, applied to the engine;
— to insert into a plunger a spring 5. On a spring to install the case of the valve of 1 gidronatyazhitel and, squeezing a spring, to turn in the case, at the same time the lock ring on a plunger has to be in a pro-point of the case and interfere with movement of a plunger in the case.

Preventions
1. Pressing the plunger nose acting from the case in order to avoid a plunger exit from gearing with the case under the influence of the compressed spring is not allowed on a collected gidronatyazhitel.
2. It is not allowed to clamp at assembly the case of a gidronatyazhitel in order to avoid violation of geometry of plunger couple.

Pump of cooling liquid
Dismantling and assembly of the pump are similar to the specified operations for ZMZ-4025,-4026 engines.

Fig. 4.80. Napressovka of a nave of a pulley of the pump of cooling liquid on a shaft




Difference consists only that at a napressovka on the bearing roller (see fig. 4.80) naves of a pulley of the pump it is necessary to maintain the size of (106±0,2) mm.
Oil pump
At the malfunctions in the lubrication system caused by malfunctions in operation of the oil pump it needs to be sorted.
For dismantling it is necessary to make the following:
— to unbend grid framework moustaches, to remove a framework and a grid;

Fig. 4.124. Oil pump: 1 — the leading gear wheel; 2 — the case; 3 — the roller; 4 — an axis; 5 — the conducted gear wheel; 6 — a partition; 7 — a reception branch pipe with a grid




— to turn off four bolts, to remove a reception branch pipe 7 (see fig. 4.124) and a partition 6;
— to take out from the case the conducted gear wheel 5 and the roller 3 with the leading gear wheel 7 assembled;

Fig. 4.125. Reducing valve: 1 — a plunger; 2 — a spring; 3 — a washer; 4 — the forelock




— to take out a washer 3 (see fig. 4.125) a spring 2 and a plunger of the 7th reducing valve from a reception branch pipe, previously having removed the forelock 4;
— to wash out details and to blow compressed air.
For check of operation of the reducing valve it is necessary to be convinced that its plunger moves in the opening freely, without jammings, and the spring is in good repair.
Spring length in a free state has to be 50 mm. The effort to a spring at its compression on 10 mm has to be 46 N (4,6 kgfs). When easing effort the spring needs to be replaced.
If on the plane of a partition of the oil pump development from gear wheels is found, then it is necessary to proshlifovat it before elimination of traces of development "as it is pure". At big iznosa of the case the pump should be replaced new.
For assembly of the pump, it is necessary to make the following:
- to establish a plunger, a spring and a washer of the reducing valve in an opening in a reception branch pipe and to fix by the forelock, previously having oiled a plunger, applied to the engine;
- to install in the case of the oil pump the roller assembled with the leading gear wheel and to check ease of its rotation;
— to install the conducted gear wheel in the case and to check ease of rotation of both gear wheels;
— to establish a partition, a reception branch pipe and to tighten them to the case four bolts with washers the moment of 14 — 18 N · m (1,4 — 1,8 kgfs · l);
— to establish a grid, a framework of a grid and to zavaltsevat framework moustaches on edges of the receiver of the oil pump;
— to check pressure developed by the pump. Pressure is checked at a certain resistance at the exit. For this purpose on special installation the jet with a diameter of 1,5 mm and 5 mm long joins an output branch pipe of the pump. The pump with a reception branch pipe and a grid has to be in the tank which is filled in with the mix consisting of 90% of kerosene and 10% of M8V or M-53/10-G1 oil. Mix level in a tank has to be 20 — 30 mm lower than the plane of the socket of the case and a partition of the oil pump. The pump is given to rotation from an electric motor. With a frequency of rotation of a shaft of the pump 250 mines-1 pressure developed by the pump has to be not less than 120 kPa (1,2 kgfs/cm2), and at 750 min.-1 — from 400 to 500 kPa (from 4 to 5 kgfs/cm2).
Power supply system
Repair of a power supply system is similar to the repair of ZMZ-4025, ZMZ-4026 engines described above in the present manual.
Assembly of the engine
The sizes of the interfaced details which need to be observed at assembly of the engine and its knots are specified in tab. 4.15.



Fig. 4.137. Block of cylinders and piston




Fig. 4.138. Krivoshipno-shatunny mechanism




Fig. 4.139. Intermediate shaft




Fig. 4.140. Drive of valves




Fig. 4.141. Oil pump, reducing valve and drive of the oil pump




Fig. 4.142. Pump of cooling liquid



The imbalance of the rotating details and knots, admissible at assembly of the engine, is specified in tab. 4.16.

Table 4.16. An imbalance of the rotating details and knots, admissible at assembly of the engine
Imbalance of the rotating details and knots, admissible at assembly of the engine
Detail, knot
Balancing method
Admissible imbalance, · cm, no more
Way of elimination of an imbalance
Bent shaft
Dynamic
18 on each end
Drilling of metal in the radial direction from counterbalances a drill with a diameter of 14 mm on depth to 25 mm
Flywheel with contour
Static
15
Metal drilling from outside, opposite to coupling fastening, on the radius of 115 mm a drill with a diameter of 14 mm on depth of 12 mm taking into account a drill cone. To drill no more than 10 openings. Distance between axes of openings - not less than 18 mm
Press a clutch plate with a casing assembled
Static
10
Installation and priklepyvaniye in a coupling casing flange opening. Drilling in a flange of a casing of the openings with a diameter of 9 mm located on diameter of 273 mm between openings under balancing small weights is allowed
Pulley of a bent shaft with a damper
Static
10
Drilling of metal in the radial direction from a damper disk a drill with a diameter of 10 mm on depth no more than 10 mm. To drill no more than 3 openings. Distance between axes of openings - not less than 18 mm


Preparatory operations before assembly of ZMZ-4061, ZMZ-4063 engines the same, as before assembly of ZMZ-4025, ZMZ-4026 engines.
Assembly of the engine needs to be made in the following order:
— to fix the block of cylinders at the stand, to attentively examine a mirror of cylinders, if necessary it is necessary to remove a shaber not worn-out corbel over the top compression ring. Metal should be removed level with the worn-out surface of the cylinder;
- to turn out traffic jams of oil channels and to blow all oil channels compressed air, to wrap traffic jams into place;

Note
The bent shaft, flywheel and coupling assembled are not balanced

— to wipe with a bed napkin under inserts in the block and in a cover of radical bearings;
— to establish in a block bed top (with flutes) inserts of radical bearings, and in a bed of covers — lower (without flutes);
- to wipe inserts with a napkin and to oil them engine;
— to wipe with a napkin radical and conrod necks of a bent shaft, to oil them pure engine and to install a shaft in the block of cylinders;
— to oil engine and to establish semi-washers of the persistent bearing: top — in pro-points of the third radical bed of the block of cylinders (an antifrictional layer to a cheek of a bent shaft); lower — together with a cover of the third radical bearing. Short moustaches of semi-washers have to come into cover grooves;
- to establish covers of other support on the corresponding radical necks, to wrap and tighten bolts of fastening of covers of radical bearings the moment of 100 — 110 N · m (10 — 11 kgfs · l), previously having oiled a carving of bolts engine;
— to turn a bent shaft, its rotation has to be free at small effort;
- to take a cover with a rubber epiploon of the back end of a bent shaft, to check suitability of an epiploon to further work. If the epiploon has worn-out working edges or poorly covers a flange of a bent shaft, to replace it new. The epiploon press fitting in a cover is recommended to be made by means of a mandrel;
- to fill on 2/3 cavities between a working edge and a boot of an epiploon TsIATIM-221 lubricant, to establish and fix a cover to the block by bolts the moment of 12 — 18 N · m (· м). Centering of a cover to produce 1,2 — 1,8 kgfs by means of a mandrel;
- to establish a flywheel on the back end of a bent shaft so that the opening in a flywheel was combined with a pin;
- to establish a washer of bolts of a flywheel, profit and to tighten bolts the moment of 72 — 80 N · m (7,2 — 8,0 kgfs · l);
- to install the expansion plug in a flywheel and to press the ball bearing 80203AC9 with protective washers.
To make subassembly of conrod and piston group.
Selection of pistons to block cylinders, and also piston fingers to pistons and rods it is necessary to produce (20±3) °C at a temperature of details.
Pistons by outer diameter and cylinders are sorted by internal diameter on five dimensional groups (see tab. 4.17).

Table 4.17. Dimensional groups of pistons and cylinders of the block
Dimensional groups of pistons and cylinders of the block
Repair increase
Designation of group
Diameter of the piston (skirt), mm
Diameter of the cylinder, mm
-
And
92,000-91,988
92,036-92,048
 
B
92,012-92,000
92,048-92,060
 
In
92,024-92,012
92,060-92,072
 
92,036-92,024
92,072-92,084
 
Д
92,048-92,036
92,084-92,096
0,5
 
 
 
 
And
92,500-92,488
92,536-92,548
 
B
92,512-92,500
92,548-92,560
 
In
92,524-92,512
92,560-92,572
 
92,536-92,524
92,572-92,584
 
Д
92,548-92,536
92,584-92,596
1
 
 
 
 
And
93,000-92,988
93,036-92,048
 
B
93,012-93,000
93,048-93,060
 
In
93,024-93,012
93,060-93,072
 
93,036-93,024
93,072-93,084
 
Д
93,048-93,036
93,084-93,096


It is necessary to install pistons of dimensional groups, identical with cylinders, in the chiseled or new cylinders of the block.

Fig. 4.60. Selection of the piston to a sleeve by means of a tape probe and a dynamometer 24-U-17202




Selection from the next groups is allowed, at the same time, as well as at selection of pistons in the working cylinders, selection is made on effort of drawing of a tape probe 0,05 mm thick and 10 mm wide. The tape probe is put between the cylinder and the piston on all height of the piston and is placed in the plane, a perpendicular axis of a piston finger on the largest diameter of the piston. The effort on the dynamometer connected to a tape probe (see fig. 4.60) has to be 35 — 45 N (3,5 — 4,5 kgfs).
Marking of pistons
- the letter designating group is beaten out on the piston bottom;
- repair increase is designated by the inscription "406" (the standard size) or "406AP" (repair increase 0,5), or "406BR" (repair increase 1,0), one of lugs cast on a sidewall under a piston finger.
The letter designating group of the cylinder is put with paint on the external surface of the block, on the right, against each cylinder.
For convenience of selection fingers, rods and pistons are divided into four dimensional groups on a measure of reduction of the size (tab. 4.18).

Table 4.18. Dimensional groups of fingers, pistons and rods
Dimensional groups of fingers, pistons and rods
Diameter, mm
Marking
Finger
Openings in a piston lug
Openings in the rod plug
Rod finger
Piston
22,0000-21,9975
22,0000-21,9975
22,0070-22,0045
White
I
21,9975-21,9950
21,9975-21,9950
22,0045-22,0020
Green
II
21,9950-21,9925
21,9950-21,9925
22,0020-21,9995
Yellow
III
21,9925-21,9900
21,9925-21,9900
21,9995-21,9970
Red
IV


Marking of fingers and rods
Fingers and rods are marked by paint: a finger — on an internal surface, a rod — on a head core. The piston — the Roman figures (knockout) on the bottom or paint on a weight lug.
The piston finger approaches the rod belonging to the same or next group with a gap from 0,0045 to 0,0095 mm.

Fig. 4.61. Selection of a piston finger to a rod




At selection the piston finger has to enter densely, but without jammings an opening of the top head of a rod under effort of a thumb of a hand (see fig. 4.61). The piston finger has to be slightly oiled by engine.
As linear expansion of material of the piston is approximately twice more, than finger material, at the normal room temperature the finger enters an opening of lugs of the piston with a tightness. Dimensional groups of the piston and a finger have to coincide.
The piston complete with a piston finger, piston rings and a rod assembled have to be controlled on weight. The difference of sets on weight on one engine should not exceed 10 g.
After a selection of pistons and piston fingers it is necessary to continue subassembly of conrod and piston group in following an order:

Fig. 4.59. Cleaning of a deposit in flutes of pistons




- to clear the bottoms of pistons and a flute for piston rings of a deposit (see fig. 4.59);
- to press a piston finger in the piston and a rod by means of adaptation (see fig. 4.60). At the same time to heat the piston to temperature of 60 — 80 °C (the finger press fitting in the cold piston can lead to damage of a surface of openings in piston lugs, and also to deformation of the piston). Rods and pistons before assembly with a piston finger have to be oriented as follows: an arrow on the piston bottom (or the inscription "BEFORE" located on the outer side of a lug under a finger), a ledge on a side surface of a cover of a rod and a ledge on a krivoshipny head of a rod have to be sent to one party;

Fig. 4.63. Selection of piston rings to the cylinder




- to pick up piston rings for cylinders. The thermal gap measured in locks of the rings placed in the cylinder (see fig. 4.63), has to be 0,3 — 0,6 mm at compression rings and 0,5 — 1,0 mm — at steel disks of oil scraper rings. In worn-out cylinders the smallest gap to do 0,3 mm — at compression rings and 0,5 mm — at steel disks of oil scraper rings;

Fig. 4.64. Check of a side gap between a piston ring and a flute in the piston




- to check the probe a gap between rings and a wall of a piston flute (see fig. 4.64). To make check on a piston circle in several points. The size of a gap has to be for the top and lower compression rings within 0,050 — 0,087 mm, for a combined oil scraper ring — 0,115 — 0,365 mm;

Fig. 4.4. Installation of piston rings on the piston: 1 — the top compression ring; 2 — the lower compression ring; 3 — a ring disk; 4 — an axial dilator; 5 — a radial dilator




- to put on by means of adaptation piston rings the piston. To put the lower compression ring internal bore to a piston bottom up (see fig. 4.4). Rings in flutes have to move freely;
- to insert pistons into cylinders as follows:
- to orient conrod and piston group so that the arrow on the piston bottom (or the inscription "BEFORE" on a lug) was turned forward;
- to wipe with a napkin of a bed of rods and their covers, to wipe and insert into them inserts;
- to turn a bent shaft so that cranks of the first and fourth cylinders reached the position corresponding to NMT;
- to grease inserts, the piston, a conrod neck of a shaft and the first cylinder with pure engine oil;
- to part locks of compression rings at an angle 180 ° to each other, locks of disks of an oil scraper ring also at an angle 180 ° to each other and on 90 ° in relation to locks of compression rings. To put the lock of a two-functional dilator at the same time at an angle 45 ° to the lock of one of ring disks;
- to put on safety brass tips bolts of rods, to squeeze rings snap or using a mandrel for installation in the piston cylinder;

Fig. 4.65. Installation of the piston with rings in the cylinder by means of a mandrel




- to insert the piston into the cylinder (see fig. 4.65). Before installation of the piston it is necessary to be convinced once again that numbers which are beaten out on a rod and its cover correspond to serial number of the cylinder, to check correctness of position of the piston and a rod in the cylinder;
- to tighten a rod for a krivoshipny head to a conrod neck, to remove brass tips from bolts, to put on a rod cover. The cover of a rod should be put so that numbers which are beaten out on a cover and a rod were turned into one party. To wrap nuts a dynamometer key the moment of 68 — 75 N · m (6,8 — 7,5 kgfs · l);
- to insert the piston of the fourth cylinder in the same order;
- to turn a bent shaft on 180 ° and to insert pistons of the second and third cylinders;
- to turn several times a bent shaft which has to rotate easily from small effort;
- to install the holder of the oil pump and the oil pump on the block and to fix them;
- to oil engine plugs of an intermediate shaft, to establish a spline in a groove on a shaft of an intermediate shaft and to install a shaft in the block of cylinders to a shaft exit;
- to establish a gear wheel of the drive of the oil pump with a nut on a shaft of an intermediate shaft and to wrap a gear wheel nut;
- to establish and fix a flange of an intermediate shaft, at the same time the smaller diameter of an opening on a flange has to adjoin to the block;
- to oil engine the roller with the conducted gear wheel of the drive of the oil pump and to insert it into an opening in the block to an entrance to gearing of gear wheels of the drive of the oil pump;
- to insert the six-sided roller of the drive of the oil pump into an opening of the plug of the roller;
- to establish laying and a cover of the drive of the oil pump, to fix a cover;
- to install drives of camshafts in the following order:

Fig. 4.116. Forward end of a bent shaft: 1 — a bolt (or a ratchet); 2 — a pulley damper with a synchronization disk; 3 — an epiploon; 4 — a chain cover; 5 — the plug; 6 — an asterisk; 7 — the block of cylinders; 8 — bearing inserts; 9 — a bent shaft; 10 — a bearing cover; 11 — an oil case; 12 — a rubber sealing ring; 13 — a lock washer




- to napressovat an asterisk 6 (see fig. 4.116) on a shaft of a bent shaft;
- to establish a rubber sealing ring 12 and the plug 5 by a big internal facet to a sealing ring on a shaft of a bent shaft;
- to establish a spline of a pulley of a bent shaft in a shponochny groove;

Fig. 4.118. Drive of camshafts: 1 — an asterisk of a bent shaft; 2 — a gidronatyazhitel of the lower chain; 3 — a shumoizolirushchy rubber washer; 4 — a stopper; 5 — a boot of a gidronatyazhitel of the lower chain; 6 — the lower chain; 7 — the conducted asterisk of an intermediate shaft; 8 — the leading asterisk of an intermediate shaft; 9 — a boot of a gidronatyazhitel of the top chain; 10 — a gidronatyazhitel of the top chain; 11 — the top chain; 12 — an adjusting tag on an asterisk; 13 — an adjusting pin; 14 — an asterisk of the camshaft of inlet valves; 15 — the top uspokoitel of a chain; 16 — an asterisk of the camshaft of final valves; 17 — the top plane of a head of the block of cylinders; 18 — an average uspokoitel of a chain; 19 — the lower uspokoitel of a chain; 20 — a chain cover; Ml and Sq.m — adjusting tags on the block of cylinders




- to turn a bent shaft of the engine before coincidence of a tag on an asterisk of a bent shaft with a tag of "Sq.m" on the block of cylinders (see fig. 4.118) that will correspond to position of the piston of the first cylinder in VMT. At the same time the tag on the block of cylinders has to be symmetrized concerning an axis of a hollow of teeths of an asterisk;
- to establish the lower uspokoitel of a chain 19, without twisting bolts of fastening it is final;
- to put on a chain 6 the conducted asterisk 7 (number of teeths — 38) an intermediate shaft and an asterisk of 1 bent shaft of the engine. To establish an asterisk with a chain on an intermediate shaft, at the same time the tag on the conducted asterisk of an intermediate shaft has to coincide with a tag of "M1" on the block of cylinders, and the leading branch of a chain passing through an uspokoitel has to be tense;
- to establish the leading asterisk 8 (number of teeths — 19) an intermediate shaft and to fix asterisks on intermediate to a shaft by bolts. To unbend a lock plate on the verge of bolts;
- to establish a boot 5 of a gidronatyazhitel of a chain of the first step (the lower chain) of the drive of camshafts;
- pressing a boot of a gidronatyazhitel, to pull a chain, to check correctness of installation of asterisks on tags and to fix finally the lower uspokoitel 19. After installation of a chain of the drive of an intermediate shaft rotation of a bent shaft until installation of a chain of the drive of camshafts and gidronatyazhitel is not allowed;
- to establish a boot 9 of a gidronatyazhitel of a chain of the second step (the top chain) of the drive of camshafts;
- to put on the leading asterisk of the 8th intermediate shaft a chain 11 second steps of the drive of camshafts;
- to take a chain cover with a rubber epiploon, to check suitability of an epiploon to further work. If the epiploon has worn-out working edges or poorly covers the plug of a bent shaft, to replace it new. The epiploon press fitting in a cover is recommended to be made by means of a mandrel;
- to fill on 2/3 cavity between a working edge and a boot of an epiploon TsIATIM1-221 lubricant;
- holding a chain of the second step from a soskakivaniye from an asterisk of an intermediate shaft, to establish and fix a cover of a chain and at the same time a generator arm, to tighten screws the moment of 22 — 27 N · m (2,2 — 2,7 kgfs · l);
- to establish and fix the pump of cooling liquid on a chain cover, having tightened a bolt of fastening of the pump to a chain cover the moment of 22 — 27 N · m (2,2 — 2,7 kgfs · l);
- to oil engine an opening under a gidronatyazhitel in a cover of a chain and to establish a collected gidronatyazhitel 2 to a contact in a boot emphasis, but not to press, for the purpose of an exception of operation of a clamp of a gidronatyazhitel;
- to establish in a cover of a gidronatyazhitel a noise-insulating rubber washer 3;
- to close a cover a gidronatyazhitel and to fix it by two bolts;
- to press a mandrel through an opening in a cover of a gidronatyazhitel on a gidronatyazhitel, moving it against the stop, then to release, at the same time the locking ring on a plunger will leave gearing with the case of a gidronatyazhitel and will give the chance to a plunger and the case to move under the influence of a spring. The case will move against the stop to a washer in a cover, and the chain through a boot will be tense;
- to wrap a stopper 4 in a cover of a gidronatyazhitel;
- to establish the hose connecting a pump branch pipe to a thermostat case branch pipe on a branch pipe of the pump of cooling liquid;
- to apply on a horizontal end face of a cover of a chain and a joint of a cover of a chain with the block of cylinders a thin layer of glue-sealant Elastosil 137-83;
- to install laying of a head of the block of cylinders on the directing plugs of the block and also to apply glue-sealant Elastosil 137-83 on the surface of the laying which is over a chain cover;

Fig. 4.34. Sequence of an inhaling of nuts of fastening of a head of cylinders




- to install a subcollected head of the block of cylinders on the block and to tighten bolts of fastening of a head in two stages — a preliminary inhaling with the moment of 40 — 60 Nanometers (4 — 6 kgfs · l) and final — 130 — 145 N · m (13,0 — 14,5 kgfs · м). The sequence of an inhaling of bolts of fastening of a head of cylinders is specified rice. 4.34. To oil a carving of bolts before installation;
- to turn off bolts and to uncover camshafts, to wipe with a bed napkin under camshafts in a head and in covers;
- to oil engine, applied to the engine, an opening to a head to hydropushers and to establish hydropushers in a head of the block of cylinders. At repair of the engine without replacement of hydropushers to establish them according to the marking applied on them when dismantling at a hydropusher exit out of operation it is subject to replacement as is not under repair. It is necessary to take out hydropushers a sucker or a magnet;
- to install camshafts on a head of the block of cylinders, previously having greased beds in a head, cams and basic necks of camshafts with engine oil. The camshaft of inlet valves is installed by an asterisk pin up, and the camshaft of final valves — an asterisk pin to the right. At the expense of an angular arrangement of cams these provisions of camshafts are steady;
- to install a forward cover of camshafts with the persistent flanges established in it on adjusting plugs, at the same time due to longitudinal movement of camshafts to provide installation of persistent flanges in flutes;
- to establish covers No. 3 and No. 7 of camshafts and previously to tighten bolts of fastening of covers before contact of a surface of covers with the top plane of a head of cylinders;
- to establish all other covers according to marking and to tighten previously bolts of fastening of covers;
- to finally tighten bolts of fastening of covers of camshafts the moment of 19 — 23 N · m (1,9 — 2,3 kgfs · l);
- to oil all cams of camshafts engine and to check rotation of each camshaft in support for what to turn the camshaft a key for a special tetrahedron on distributive to a shaft to the provision of full compression of springs of valves of one of cylinders. At a further pro-collar the camshaft has to be turned independently under the influence of valvate springs to the provision of a contact of the following cams with pushers;
- to check ease of rotation of camshafts and then turn to orient them so that adjusting pins 13 (see fig. 4.118) under asterisks settled down approximately horizontally and were directed in different directions. These provisions of camshafts are steady and are provided with an angular arrangement of cams;
- to begin check of installation of angular position of camshafts with a shaft of final valves. For this purpose, having thrown with the 16th driving chain an asterisk, to establish an asterisk on a flange and a pin of the camshaft, at the same time for coincidence of a pin and an opening on an asterisk to turn the camshaft for a tetrahedron clockwise. Turn of the camshaft counterclockwise to pull the leading branch of a chain, at the same time the tag 12 on an asterisk has to coincide with the top plane of a head of cylinders 17. It is impossible to allow turn of a bent shaft;
- for angular installation of the camshaft of final valves to throw with the 14th driving chain an asterisk, to establish an asterisk on a flange and a pin of the camshaft at slightly sagged chain branch between asterisks. Turn of the camshaft counterclockwise to pull the chain, at the same time a tag 12 on an asterisk has to coincide with the top plane of a head of cylinders;
- to insert into a nest of an asterisk of the camshaft of inlet valves the clown of the drive of the fuel pump;
- to establish and tighten the moment 46 — 74 N · m (4,6 — 7,4 kgfs · l) bolts of fastening of asterisks (and the clown on distributive to a shaft of inlet valves), holding camshafts from a provorachivaniye a key for a tetrahedron;
- to establish a gidronatyazhitel of the 10th top chain of the drive of camshafts it is similar to installation of a gidronatyazhitel of a chain of the lower chain;
- to establish average 18 and the top 15 uspokoitel of a chain, without wrapping bolts of fastening it is final;
- to pull working branches of a chain of the second step turn of a bent shaft of the engine on the course of rotation and to fix finally average and top uspokoitel of a chain;
- to establish a pulley on a shaft of a bent shaft against the stop and to screw a bolt the moment of 104 — 128 N · m (10,4 — 12,8 kgfs · l);
- to make control of installation of camshafts upon termination of assembly. For this purpose to turn a bent shaft of the engine on the rotation course on two turns before coincidence of a tag on a damper of a bent shaft with a tag on a chain cover. At the same time tags on asterisks of camshafts have to coincide with the top plane of a head of cylinders;
- at the repair of the engine connected with removal of camshafts, heads of cylinders and asterisks on intermediate to a shaft to make installation of the drive of camshafts at assembly as it is stated above;
- in case at repair asterisks of an intermediate shaft and a cover of a chain are not removed, then before dismantling it is necessary to install the piston of the 1st cylinder in the provision of VMT on a compression step, at the same time risk on a pulley of a bent shaft has to coincide with a ledge on a chain cover, and tags on asterisks of camshafts have to be located horizontally, directed in different directions and coincide with the top plane of cooking of cylinders.
After removal of camshafts and a head of cylinders the turn of a bent shaft can be only with a reset or on 2 turns. The turn of a bent shaft on 1 turn even at coincidence of tags on a pulley and a cover of a chain will lead to the wrong installation of phases of gas distribution. At the wrong installation of camshafts and asterisks of a tag on asterisks will not coincide with the top plane of a head of cylinders. In this case it is necessary to remove asterisks, to turn a bent shaft on the rotation course on 1 turn and to repeat installation of asterisks as it is stated above;
- to establish and fix a pulley of the pump of cooling liquid;
- to collect a forward cover of a head of cylinders with the intermediate lever of the drive of the fuel pump and a spring;
- to establish and fix a forward cover of a head of the block of cylinders;
- to establish a thermostat case branch pipe in a hose on a branch pipe of the pump of cooling liquid and to fix the thermostat case on a head of cylinders, to tighten hose collars;
- to establish a final collector, an arm for raising of the engine and a water intake tube bracket on hairpins of a final collector, profit and to tighten fastening nuts;
- to press a tube of the rod index of level of oil and to establish the index;
- to establish and fix a cover of valves;
- to establish and fix the top arm of the generator and at the same time an arm for raising of the engine forward;
- to establish and fix a tension roller;
- to establish and fix an inlet pipe;
- to grease joints of the lower flange of the block of cylinders with a cover of a chain and with a back cover glue-sealant Elastosil 137-83 or UN-25 paste;
- to establish laying of the pallet of an oil case on the lower flange of the block of cylinders;
- to establish and fix the pallet of an oil case and the amplifier of a case of coupling;
- to establish and fix conducted and press clutch plates, aligning the conducted disk by means of a mandrel;
- to put details and units of the engine, (see. "Dismantling of the engine"), observing the return sequence;
- to remove the engine from the stand, to establish and attach a coupling case to the block of cylinders;
- to grease and put on a forward cover of the transmission the coupling switching off coupling assembled with the bearing;
- to put and fix the transmission;
- to put a coupling switching off fork.
Installation of the engine on the car
Installation of the engine on the car is made in the sequence, the return to its removal.