"Gazelle" Gas-2705>> The engine>> Engines ZMZ-4061, ЗМЗ-4063>> Engine repair
Necessity under repair engines ZMZ-4061,-4063 comes after run of 200-250 thousand in km depending on service conditions. To this run backlashes reach the sizes causing falling of capacity, reduction of pressure of oil in an oil highway, sharp increase in the expense of oil (over 0,25 l/100 of km), excessive дымление the engine, the raised expense of fuel, and also the raised knocks.
Sizes of backlashes in interfaces of the basic details owing to deterioration should not exceed the sizes specified for engines ZMZ-4025,-4026.
Working capacity of the engine can be restored or replacement of the worn out details new the standard size, or restoration of the worn out details and application of the new details of the repair size interfaced to them.
For this purpose release of pistons, piston rings, loose leaves шатунных and radical bearings of the cranked shaft, directing plugs of inlet and final valves and of some other details of the repair size is provided.
Removal of the engine from the car
For removal of the engine the car is necessary for establishing on a viewing ditch or a platform with the general and portable illumination. The workplace should be equipped талью or other elevating device by load-carrying capacity not less than 300 kg.
Work on engine removal to make in a following order:
- To open a cowl, to turn away four bolts of its fastening to loops and to remove a cowl;
- To merge cooling liquid from system of cooling of the engine, having turned away a stopper on a radiator and having opened краники on the block of cylinders and a heater. Thus the stopper of a broad tank should be removed;
- To merge oil from картера the engine and a transmission, having turned away a stopper of drain apertures. After plum of oil of a stopper to put into place and hardly to tighten;
- To remove the storage battery.
The works spent on the left side of the car:
- To disconnect sockets and plugs of wires from coils of ignition and gauges: the index of pressure of oil, an alarm lamp of emergency pressure of oil, an alarm lamp of an overheat of a cooling liquid, the index of temperature of a cooling liquid, a temperature condition of the engine;
- To disconnect hoses from a radiator, the pump of a cooling liquid and a cover of the thermostat and to remove them;
- To disconnect "a weight" wire;
- To turn away a bolt of fastening of the left pillow to an arm on the engine.
The works spent on the right side of the car:
- To disconnect wires from the generator and a starter;
- To disconnect sockets of wires from gauges of a detonation and position of a cranked shaft (the synchronisation gauge);
- To disconnect воздухозаборный a hose from the air filter and воздухозаборного a branch pipe and to remove a hose;
- To disconnect ventilation hoses картера from branch pipes of a cover of valves, the air filter and a carburettor tube, to remove them;
- To uncover and a filtering element of the air filter;
- To unbend moustaches of lock washers and to turn away a nut of fastening of the case of the air filter, cautiously to remove nuts and lock washers, having excluded their hit in the engine;
— To remove the case of the air filter with a flange and linings, to close the carburettor a pure napkin;
— To disconnect from the carburettor a rope of a drive throttle заслонок and draught air заслонки;
— To disconnect a tip of a rope of a drive throttle заслонок from an arm on the engine;
— To disconnect from the carburettor a hose топливопровода fuel restart-up, hoses to the electromagnetic valve of system экономайзера compulsory idling;
— To disconnect two hoses of a heater from the engine;
- To disconnect hoses of the vacuum amplifier of a drive of brakes and the gauge of absolute pressure from an inlet pipe;
— To disconnect from the filter of thin clearing of fuel bringing hose;
- To turn away a bolt of fastening of the right pillow to an arm on the engine.
The works spent in front of the car:
— To remove a lattice of facing of a radiator, having weakened fastening bolts;
- To disconnect a cable of the lock of a cowl;
- To turn away bolts, to remove the top panel of facing of a radiator;
— Having turned away bolts, to remove a lath of the bottom 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 away bolts of fastening of a radiator and to remove it;
- To hook on the engine for cargo eyes and to pull a chain тали.
The works spent in a body of the car:
- To tighten to the handle of the lever of a gear change an external rubber sealant of a floor;
- To remove a rubber protective sealant from a cap of a mouth of the case of the lever of a gear change;
- To turn away a cap from a mouth of the case of the lever and to take out the lever from a mouth upwards;
- To close an aperture in a mouth a pure napkin.
The works spent from below of the car:
- To remove карданный a shaft in gathering;

Fig. 4.40. A stopper-zaglushka of the extension piece of a transmission




- To establish a stopper-zaglushku (fig. 4.40 see) in an aperture of the extension piece of a transmission;
- To disconnect wires from the switch of light of a backing on a transmission;
- To disconnect a cable of a drive of a speedometer from a transmission;
- To turn away two bolts of fastening of the working cylinder of a drive of deenergizing of coupling and to disconnect the cylinder from картера couplings;
- To disconnect an arm of fastening of reception pipes of system of release of the fulfilled gases from a transmission;
- To disconnect reception pipes of system of release of the fulfilled gases from a final collector;
- To turn away a nut of fastening of a back support of the engine to a transmission;
- To disconnect a cross-beam from arms of longerons of the car;
- To remove a cross-beam;
- To take out the engine in gathering with coupling and a transmission.
Engine dismantling
The engine before dismantling should be carefully cleared of a dirt. Dismantling and engine assemblage is recommended to be made at the stand, allowing to establish the engine in the positions providing an easy approach to all details during dismantling and assemblage.
It is necessary to make dismantling and assemblage of engines the tool of the corresponding size (wrenches, strippers, adaptations) which working surface should be in a good condition.
At an individual method of repair of a detail, suitable for the further work, should be established on the former places. For this purpose such details as pistons, etc., at their removal from the engine it it is necessary to mark piston fingers, piston rings, rods, loose leaves, valves, hydropushers in any way which is not causing damage of details (кернение, надписывание, an attachment of labels, etc.) or to stack them on racks with the numbered branches, in an 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 in gathering and consequently them разукомплектовывать it is impossible.
The cranked shaft, flywheel and coupling at factory are balanced separately, therefore they are interchangeable. Carter of coupling is processed separately from the block of cylinders and also is interchangeable.
In гидронатяжителях разукомплектация cases with плунжером it is not supposed. Engine dismantling is recommended to be carried out in a following order:
- To take out a plug of deenergizing of coupling;
- To remove from the engine a transmission;
- To remove the fan;
- To remove картер couplings and a starter;
- To establish the engine on the stand for dismantling;
- To weaken bolts of fastening of a pulley наcoca a cooling liquid;
- To weaken a bolt of fastening of a tension roller;
- To weaken a tension of a belt by вывертывания a bolt of moving of a tension roller, to remove a belt;
- To turn away bolts of fastening of a pulley of the pump of a 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 a high voltage from sockets of coils of ignition, to remove wires in gathering with tips;
- To turn on накидные nuts from unions of an inlet pipe and a final collector, to lift the receiver рециркуляции;
- To turn away bolts of fastening of a cover of valves, to uncover valves in gathering with ignition coils, bolts, скобами and washers;
— To remove топливопровод from the fuel pump to the filter of thin clearing of fuel;
- To remove the fuel pump;
- To remove a forward cover of a head of cylinders;
- To remove top and average успокоители chains;
- To uncover with a lining top гидронатяжителя chains;
- To take out гидронатяжитель;
- To turn away a bolt of fastening of an asterisk of a camshaft of inlet valves, to remove the clown and an asterisk;
- To remove приводную a chain from asterisks of camshafts;
- To remove an asterisk from a camshaft of final valves;
- To turn away bolts of fastening of covers of camshafts, to remove covers, flanges persistent;
- To remove camshafts;
- To take out hydropushers with the help присоса 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 away a nut of a bolt of fastening of the generator to the top arm, to remove a bolt, the plug;
- To turn away a nut of a bolt of fastening of the generator to the bottom arm, to remove the generator;
- To remove system hoses рециркуляции from unions of the carburettor, the thermovacuum switch, the valve рециркуляции;
- To weaken the screw of a collar of a tube топливопровода on the carburettor union, to remove a hose from the union;
- To turn away a nut of fastening of the carburettor, to remove washers, the carburettor, linings, the prorate;
- To turn away a nut of fastening of the valve рециркуляции, to remove washers, the valve, a lining;
- To turn away a bolt of fastening of the filter of thin clearing of fuel, to remove the filter in gathering with tubes топливопроводов;
- To turn out the thermovacuum switch;
- To turn away a nut of fastening of an inlet pipe, to remove washers of an inlet pipe, a lining;
- To turn away a nut of fastening of a final collector, to remove washers, a final collector, linings;
- To weaken collars of a hose of the case of the thermostat;
- To turn away screws of fastening of the case of the thermostat, to remove the case, a lining;
- To turn out the union of gauges of pressure of oil;
- To turn away 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 клапанных springs




- By means of the adaptation (fig. 4.51 see) to make dismantle of springs of valves. That the plate of springs of the valve has descended from crackers, it is necessary to strike slightly after compression of springs the hammer handle on an adaptation plate;
- To take valves, to arrange them in the order of numbering of cylinders;
- Stripper to remove from directing plugs маслоотражательные caps. Removal of valves is recommended to be made at repair of a head of the block of cylinders;
- To turn the engine oil картером upwards;
- To turn away bolts of fastening of the amplifier картера couplings to the block, to remove washers, the amplifier;
- To turn away bolts and nuts of fastening oil картера, to remove washers, oil картер, a lining;
- To turn away a bolt of fastening of the holder of the oil pump on the third cover of the radical bearing;
- To turn away bolts of fastening of the oil pump, to remove the oil pump, a lining, шестигранный the platen of a drive of the oil pump;
- To turn away a coupling bolt of a cranked shaft, to remove a bolt, a spring washer;
- By means of the adaptation to remove a pulley of a cranked shaft;
- To turn away bolts of fastening of the pump of a cooling liquid to a chain cover, to remove bolts with washers, the pump of a cooling liquid, a lining;
- To turn away a bolt of fastening of a tension roller, to remove a tension roller;
- To uncover and a lining гидронатяжителя the first step, to remove гидронатяжитель;
- To turn away a bolt of fastening of the gauge of synchronisation, to remove the gauge;
- To turn away screws of fastening of a cover of a chain, to uncover, an arm of the generator the bottom;
- To remove a chain of the second step of a drive of camshafts from a leading asterisk of an intermediate shaft;
- расконтрить bolts of fastening of asterisks of an intermediate shaft to remove asterisks, a chain;
- To turn away bolts of fastening of a flange of an intermediate shaft, to remove bolts with washers, a flange;
- To turn away bolts of fastening of a cover of a drive of the oil pump, to uncover, a lining;
- To turn away a nut of a leading gear wheel of a drive of the oil pump, to remove a gear wheel in gathering with a nut;
- To take out an intermediate shaft;
- выпрессовать шпонку from an intermediate shaft;
- By means of a stripper to remove the plug and an asterisk from a cranked shaft;
- To turn away a bolt of fastening of a boot натяжителя chains of the first step of a drive of camshafts, to remove a boot;
- To turn away a bolt of fastening of a boot натяжителя chains of the second step of a drive of camshafts, to remove a boot;
— To turn out the extension piece of a bolt of a boot, to remove the extension piece;
- To turn away bolts of fastening bottom успокоителя chains, to remove успокоитель;
- To turn away a nut of fastening of covers of the first and fourth rods, to remove covers of rods with loose leaves, to take out loose leaves from beds of covers of rods;
- To take out pistons with rods in gathering from the first and fourth cylinders;
- To establish a cranked shaft so that the second and the third шатунные necks were in the top position, to turn away a nut of fastening of covers of the second and third rods, to remove covers of rods with loose leaves, to take out loose leaves from beds of covers of rods;
- To take out pistons with rods from the second and third cylinders;
- To insert in шлицы a conducted disk оправку шлицевую;
- To turn on serially, in stages, bolts of fastening of a press disk of coupling to remove a disk;
- To remove a conducted disk of coupling with шлицевой оправкой;
- расконтрить bolts of fastening of a flywheel to remove a flywheel from a pin;
- To turn away bolts of fastening of a back cover, to remove a back cover in gathering with a rubber cuff;
- To turn away bolts of fastening of covers of radical bearings, to remove bolts;
- To remove covers of radical bearings a stripper, semiwashers of the persistent bearing of a cranked shaft the top;
- To remove a cranked shaft, semiwashers of the persistent bearing of a cranked shaft the bottom;
- To take out radical loose leaves from beds of the block of cylinders and from covers of radical bearings;
- To establish covers of radical bearings in the block according to numbering;
- To fix covers of radical bearings bolts;
- To turn away a nut of fastening of the gauge of a detonation, to remove a washer, the gauge;
- To turn away the oil filter;
- To turn out from the block of cylinders drain краник;
- To take out шатунные loose leaves 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 компрессионные маслосъемные rings by means of a stripper (fig. 4.52 see);
- To remove lock rings;

Fig. 4.53. Выпрессовка a piston finger from the piston a stripper: 1 — the piston; 2 — a piston finger; 3 — оправка; 4 — the stripper screw




- выпрессовать by means of the adaptation and оправки piston fingers from pistons (fig. 4.53 see).
Repair of details, knots, units and engine systems
The block of cylinders, pistons, rods, intermediate shaft
The block of cylinders with holes of walls of cylinders, a water shirt and картера or with cracks of the top plane and the edges supporting radical bearings, is subject to replacement.
As a result of deterioration block cylinders get on length the form of a wrong cone, and on a circle — an oval. The greatest size deterioration reaches in the top part of cylinders around top компрессионного rings, at piston position in ВМТ; the least — in the bottom part, at piston position in НМТ.
At repair of cylinders two repair sizes are provided: 1st and 2nd. With the same repair sizes pistons and piston rings are issued.
All cylinders of the block should be processed, as a rule, under the same repair size with the deviations of mm established for cylinders of the nominal size, except for cases when it is required to "deduce" superficial scratches on a mirror of cylinders (within increase in diameter of the cylinder at 0,10 mm) — correction only defective cylinders in this case is supposed.
If for repair there is a limited quantity of pistons, it is recommended to calculate deviations of diameter for each cylinder (proceeding from the actual size of diameter of a skirt of the piston intended for work in the given cylinder with maintenance of a backlash of 0,036-0,060 mm) and under these sizes to chisel cylinders.
Deviations of the form of cylinders should settle down in the field of the admission of dimensional troupe for diameter of the cylinder.

Fig. 4.120. An intermediate shaft: 1 — a bolt; 2 — a lock plate; 3 — a leading asterisk; 4 — a conducted asterisk; 5 — the forward plug of a shaft; 6 — an intermediate shaft; 7 — a pipe of an intermediate shaft; 8 — a conducted gear wheel of a drive of the oil pump; 9 — a nut; 10 — a leading gear wheel of a 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 опop an intermediate shaft consists in their replacement on repair (the increased thickness), with the subsequent расточкой under the nominal or repair size with the admission established for support of the nominal size — depending on degree of deterioration of basic necks of a shaft. Before repair of support it is necessary to remove a pipe 7 (fig. 4.120 see). At installation of repair plugs it is necessary to provide coincidence of apertures of oil channels. Расточку support of an intermediate shaft to make for one installation for maintenance соосности.
Necks of an intermediate shaft grind under the repair size with the admission established for necks of the nominal size, in case of the deterioration exceeding as much as possible admissible.
Damages of carving apertures to a kind забоин or failure of a carving less than two threads restore a tap under the nominal size.
The carving apertures having deterioration or failure of a carving more of two threads, are restored нарезанием carvings of the increased size, statement carving ввертышей with the subsequent нарезанием in them carvings of the nominal size or installation of carving spiral inserts. Last way is most effective and is less labour-consuming.
Controllable parametres at repair of the block of cylinders, pistons, rods and an intermediate shaft are resulted in tab. 4.12.

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


Cranked shaft
In the presence of cracks of any character the cranked shaft is subject to replacement.
For removal of products of deterioration in cavities шатунных necks and in oil channels of a cranked shaft it is necessary to turn out stoppers of necks, to stitch (a solution каустической soda, нагретом to 80 °) and metal ершиком to clean cavities and channels. After clearing they are necessary for washing out kerosene, to blow and dry up compressed air, then to wrap stoppers the moment of 38-42 Nanometers (3,8—4,2 кгс·м).
At damage of a carving to apertures to two threads it restore a tap under the nominal size. If it is broken two and more threads repair make as follows:
- Carvings in apertures under bolts of fastening of a flywheel — installation of carving spiral inserts;
- Carvings in an aperture under a ratchet — нарезанием a repair carving;
- Carvings in apertures under stoppers — нарезанием a repair carving.
Шатунные and the radical necks which have been worn out within the repair size, grind under the next 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 конусным the abrasive tool, and then necks subject to polishing.
Controllable parametres at repair of a cranked shaft are resulted in tab. 4.13

Table 4.13. Controllable parametres at repair of a cranked shaft

Head of cylinders, клапанный the mechanism and camshafts
In the presence of holes, прогара and cracks on walls of chambers of combustion and destruction of crosspieces between nests of saddles of valves it is necessary to replace a head of cylinders with the new.
Repair of carving apertures is similar specified for carving apertures of the block of cylinders.

Fig. 4.133. Removal клапанных springs




For check of tightness of valves it is necessary to fill in kerosene serially in inlet and final channels of a head of cylinders. Course of kerosene from under plates of valves testifies about them негерметичности. Not tight valves are taken from a head of cylinders by means of the adaptation for compression of springs of valves (fig. 4.133).
At dismantling valves to lay in an order corresponding to their arrangement in a head, for their subsequent installation on former places.
Before valve grinding in it is necessary to check up, whether is not present коробления a plate of the valve and a valve and saddle burn-out. In the presence of these defects to restore tightness of the valve grinding in it is impossible and it is necessary to process at first расточкой a saddle, and the damaged valve to replace new. If the backlash between a core of the valve and the directing plug exceeds 0,20 mm follows the valve and the plug to replace new.
For spare parts valves are issued the nominal size, and directing plugs — with an allowance on processing on internal diameter after запрессовки in a head and with external diameter of three repair sizes: the first — with increase at 0,02 mm from nominal, the second — with increase at 0,2 mm from nominal, the third — with increase at 0,02 mm from the second repair size (tab. 4.14).

Table 4.14. Controllable parametres at repair of a head of cylinders клапанного the mechanism and camshafts



Fig. 4.134. Выпрессовка directing plugs of valves




Выпрессовка the worn out directing plug it is made with the help оправки (fig. 4.134).
Before выпрессовкой 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 distance from an axis of a camshaft to an end face of a core of the valve pressed to a working facet of a saddle, will make not less than 35,5 mm. If the given condition is not executed, the head of cylinders is not subject to repair. The head of the block of cylinders also is not subject to repair if the surface adjoining to the block, has неплоскостность more than 0,1 mm.
At installation of new directing plugs they should be cooled in carbon dioxide («dry ice») to temperature a minus 40—45 °C, and a head of cylinders to heat up to temperature plus 160 175 ° S.Vtulki at assemblage should be inserted into a head aperture freely or with easy effort.
Plugs of the first repair size are established in a head without additional processing of apertures in a head, plugs of the second and third repair sizes — with preliminary расточкой (development) of apertures till the diameter of 14,2 mm.

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




After installation and development of plugs of a facet of saddles to process (grinding or расточкой), aligning the tool on an aperture in the plug. At processing it is necessary to maintain the sizes specified in fig. 4.135, and to provide концентричность facets on a saddle of the valve with an aperture in the plug (palpation of a working facet of a saddle concerning a plug aperture is supposed 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 grew grey at an angle 30 ° till the size "in", 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 притирочную the paste made of one part of micropowder М-20 and two parts of oil И-20А.
Before подсборкой heads of the block of cylinders it is necessary to clear chambers of combustion and inlet, final channels from a deposit and adjournment, preliminary having moistened a deposit with kerosene, it prevents deposit dispersion at its removal and warns hit of a poisonous dust at breath. To wipe and blow their compressed air.
On the established directing plugs of valves it is necessary to establish simultaneously with the help оправки basic washers of springs and напрессовать маслосъемные caps. Cores of valves to oil, applied to the engine, to insert valves into plugs according to an order of their installation and to collect them with springs by means of the adaptation (fig. 4.51 see). To be convinced that crackers have entered into ring flutes of valves. To fill in kerosene in inlet, final channels and to be convinced of tightness of valves.
For backlash definition in bearings of camshafts it is necessary to establish all covers of bearings 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 are necessary for oiling them, applied to the engine. The centering of the specified covers is made by means of cylindrical оправки in diameter 35–0,02 mm, laid in bed. After an inhaling of covers the moment 19—23 Н·м (1,9—2,3 кгс·м) оправку to take towards a back end face of a head of cylinders (thus the back cover of a head of cylinders should be removed). If in one of bearings the backlash appears more than 0,15 mm it is necessary to replace or a head of the block of cylinders, or a camshaft.
The backlash in an aperture under a hydropusher and a hydropusher should not exceed 0,15 mm. At большем a backlash it is necessary to replace either a hydropusher, or a head of the block of cylinders.
Surfaces of basic necks and cams should be without задиров and deep bowls and not have износов, exceeding maximum permissible. After check of shaft it is necessary to smooth out and polish surfaces of necks and cams.
Controllable parametres at repair of heads of cylinders, клапанного the mechanism and camshafts are resulted in tab. 4.14.
Гидронатяжитель
At engine repair гидронатяжители it is necessary to disassemble, wash out their details and to collect (to "charge").
Dismantling гидронатяжителя is made in a following order:

Fig. 4.119. Гидронатяжитель in gathering: 1 — the valve in gathering; 2 — запорное a ring; 3 — плунжер; 4 — the case; 5 — a spring; 6 — a lock ring




— To turn out the case of the valve 1 (fig. 4.119 see) of the case 4 гидронатяжителя;
— To take out from the case 4 spring 5 and плунжер 3.
Assemblage гидронатяжителя is made in a following order:

Fig. 4.136. Оправка for assemblage гидронатяжителя




— To establish the case 4 гидронатяжителя on fixed vertically оправку (fig. 4.136);
— To insert into the case гидронатяжителя плунжер 3 (fig. 4.119 see) against the stop a lock ring 6 on плунжере in оправку, preliminary having oiled pair, applied to the engine;
— To insert in плунжер a spring 5. On a spring to establish the case of the valve 1 гидронатяжителя and, compressing a spring, to turn in the case, thus a lock ring on плунжере should be in проточке cases and interfere with moving плунжера in the case.

Preventions
1. It is not supposed on collected гидронатяжителе pressing a nouse acting from the case плунжера in order to avoid an exit плунжера from gearing with the case under the influence of the compressed spring.
2. It is not supposed to clamp at assemblage the case гидронатяжителя in order to avoid geometry infringement плунжерной pair.

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

Fig. 4.80. Напрессовка naves of a pulley of the pump of a cooling liquid on a shaft




Difference consists only that at напрессовке on the bearing platen (fig. 4.80 see) naves of a pulley of the pump it is necessary to maintain the size (106±0,2) mm.
The oil pump
At malfunctions in system of the greasing, caused by malfunctions in work of the oil pump, it is necessary for disassembling.
For dismantling it is necessary to make the following:
— To unbend moustaches of a skeleton of a grid, to remove a skeleton and a grid;

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




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

Fig. 4.125. The reduktsionnyj valve: 1 — плунжер; 2 — a spring; 3 — a washer; 4 — шплинт




— To take out a washer 3 (fig. 4.125) a spring 2 see and плунжер 7 редукционного the valve from a reception branch pipe, preliminary having removed шплинт 4;
— To wash out details and to blow compressed air.
For work check редукционного the valve it is necessary to be convinced that it плунжер moves in the aperture freely, without jammings, and the spring is in good repair.
The length of a spring a free condition should be 50 mm. The effort to a spring at its compression on 10 mm should be 46 Н (4,6 кгс). At easing of effort it is necessary to replace a spring.
If on a plane of a partition of the oil pump development from gear wheels it is necessary прошлифовать it before elimination of traces of development «as purely» is found out. At big износах the pump it is necessary to replace cases new.
For pump assemblage, it is necessary to make the following:
- To establish плунжер, a spring and a washer редукционного the valve in an aperture in a reception branch pipe and to fix шплинтом, preliminary having greased плунжер with the oil applied to the engine;
- To establish in the case of the oil pump the platen in gathering with a leading gear wheel and to check up ease of its rotation;
— To establish in the case a conducted gear wheel and to check up 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 14—18 Н·м (1,4—1,8 кгс·м);
— To establish a grid, a skeleton of a grid and завальцевать skeleton moustaches on edges of the receiver of the oil pump;
— To check up the pressure developed by the pump. Pressure is checked at certain resistance on an exit. For this purpose on special installation the jet in diameter joins a target branch pipe of the pump of 1,5 mm and length 5 mm. The pump with a reception branch pipe and a grid should be in the tank which has been filled in with a mix, consisting of 90 % of kerosene and 10 % of oil М8В or М-53/10-Г1. Mix level in a tank should be on 20—30 mm below a plane of a socket of the case and a partition of the oil pump. The pump is resulted in rotation from the electromotor. At frequency of rotation of a shaft of the pump of 250 mines-1 the pressure developed by the pump, should be not less than 120 кПа (1,2 kgs/sm 2), and at 750 mines-1from 400 to 500 кПа (from 4 to 5 kgs/sm 2).
The power supply system
Power supply system repair is similar to repair of engines ZMZ-4025, ЗМЗ-4026, described above in the present management.
Engine assemblage
The sizes of interfaced details which are necessary for observing at assemblage of the engine and its knots, are resulted in tab. 4.15.



Fig. 4.137. The block of cylinders and the piston




Fig. 4.138. The krivoshipno-shatunnyj mechanism




Fig. 4.139. An intermediate shaft




Fig. 4.140. A drive of valves




Fig. 4.141. The oil pump, редукционный the valve and a drive of the oil pump




Fig. 4.142. The pump of a cooling liquid



The disbalance of rotating details and knots, admissible at engine assemblage, is specified in tab. 4.16.

Table 4.16. A disbalance of rotating details and knots, admissible at engine assemblage
Disbalance of rotating details and knots, admissible at engine assemblage
Detail, knot
Balancing method
Admissible disbalance, г·см, no more
Way of elimination of a disbalance
Cranked shaft
The dynamic
18 on each end
Metal drilling in a radial direction from counterbalances a drill in diameter of 14 mm on depth to 25 mm
Flywheel with contour
The static
15
Metal drilling from outside, opposite to coupling fastening, on radius of 115 mm a drill in diameter of 14 mm on depth of 12 mm taking into account a drill cone. To drill no more than 10 apertures. Distance between axes of apertures - not less than 18 mm
Press a disk of coupling with a casing in gathering
The static
10
Installation and приклепыванием in an aperture of a flange of a casing of coupling. Drilling in a flange of a casing of apertures in diameter of 9 mm located at diameter of 273 mm between apertures under balancing грузики is supposed
Pulley of a cranked shaft with демпфером
The static
10
Metal drilling in a radial direction from a disk демпфера a drill in diameter of 10 mm on depth no more than 10 mm. To drill no more than 3 apertures. Distance between axes of apertures - not less than 18 mm


Preparatory operations before assemblage of engines ZMZ-4061, ЗМЗ-4063 the same, as before assemblage of engines ZMZ-4025, ЗМЗ-4026.
Engine assemblage is necessary for making in a following order:
— To fix the block of cylinders at the stand, attentively to examine a mirror of cylinders, if necessary it is necessary to remove шабером not worn out corbel over top компрессионным a ring. Metal should be removed level with the worn out surface of the cylinder;
- To turn out stoppers of oil channels and to blow all oil channels the compressed air, to wrap stoppers into place;

The note
The cranked shaft, flywheel and coupling in gathering are not balanced

— To wipe a bed napkin under loose leaves in the block and in a cover of radical bearings;
— To establish in block bed top (with flutes) loose leaves of radical bearings, and in bed of covers — bottom (without flutes);
- To wipe loose leaves a napkin and to grease with their engine oil;
— To wipe a napkin radical and шатунные necks of a cranked shaft, to grease with their pure engine oil and to establish a shaft in the block of cylinders;
— To grease with engine oil and to establish semiwashers of the persistent bearing: top — in проточки the third radical bed of the block of cylinders (aнтифрикционным a layer to a cheek of a cranked shaft); bottom — together with a cover of the third radical bearing. Short moustaches of semiwashers should come into cover grooves;
- To establish covers of other support on corresponding radical necks, to wrap and tighten bolts of fastening of covers of radical bearings the moment 100—110 Н·м (10—11 кгс·м), preliminary having greased a carving of bolts with engine oil;
— To turn a cranked shaft, its rotation should be free at small effort;
- To take a cover with a rubber epiploon of the back end of a cranked shaft, to check up suitability of an epiploon to the further work. If the epiploon has the worn out working edges or poorly covers a flange of a cranked shaft, to replace its new. Запрессовку an epiploon in a cover it is recommended to make with the help опpaвки;
- To fill on 2/3 cavities between a working edge and пыльником an epiploon greasing ЦИАТИМ-221, to establish and fix a cover to the block bolts the moment 12—18 Н·м (1,2—1,8 кгс·м). A cover centering to make with the help оправки;
- To establish a flywheel on the back end of a cranked shaft so that in a flywheel the aperture was combined with a pin;
- To establish a washer of bolts of a flywheel, наживить and to tighten bolts the moment 72—80 Н·м (7,2—8,0 кгс·м);
- To establish in a flywheel распорную the plug and запрессовать the ball bearing 80203АС9 with protective washers.
To make подсборку shatunno-piston group.
To block cylinders, and also piston fingers to pistons and rods it is necessary to make selection of pistons at temperature of details (20±3) ° C.
Pistons on external diameter and cylinders on internal diameter are sorted on five dimensional groups (tab. 4.17 see).

Table 4.17. Dimensional groups of pistons and block cylinders
Dimensional groups of pistons and block cylinders
Repair increase
Group designation
Diameter of the piston (skirt), mm
Diameter of the cylinder, mm
-
AND
92,000-91,988
92,036-92,048
92,012-92,000
92,048-92,060
IN
92,024-92,012
92,060-92,072
Г
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
92,512-92,500
92,548-92,560
IN
92,524-92,512
92,560-92,572
Г
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
93,012-93,000
93,048-93,060
IN
93,024-93,012
93,060-93,072
Г
93,036-93,024
93,072-93,084
Д
93,048-93,036
93,084-93,096


In the chiseled or new cylinders of the block it is necessary to establish pistons of dimensional groups identical with cylinders.

Fig. 4.60. Piston selection to a sleeve by means of a tape-shchupa and a dynamometer 24-at-17202




Selection from the next groups is supposed, thus, as well as at selection of pistons in working cylinders, selection is made on effort протягивания tapes-shchupa in the thickness of 0,05 mm and width 10 mm. The Tape-shchup is put between the cylinder and the piston on all height of the piston and takes places in a plane, a perpendicular axis of a piston finger on the greatest diameter of the piston. The effort to a dynamometer connected to a tape-shchupom (fig. 4.60 see) should be 35—45 Н (3,5—4,5 кгс).
Marks of pistons
- The letter designating group, is beaten out on the piston bottom;
- The repair increase is designated by an inscription «406» (the standard size) or «406АР» (repair increase 0,5), or «406БР» (repair increase 1,0), cast on a lateral wall of one of lugs under a piston finger.
The letter designating group of the cylinder, is put by a paint on an 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 in process 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
Marks
Finger
Apertures in бабышке the piston
Apertures in the rod plug
Rod finger
The piston
22,0000-21,9975
22,0000-21,9975
22,0070-22,0045
The white
I
21,9975-21,9950
21,9975-21,9950
22,0045-22,0020
The green
II
21,9950-21,9925
21,9950-21,9925
22,0020-21,9995
The yellow
III
21,9925-21,9900
21,9925-21,9900
21,9995-21,9970
The red
IV


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

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




At selection the piston finger should enter densely, but without jammings into an aperture of the top head of a rod under effort of a thumb of a hand (fig. 4.61 see). The piston finger should be slightly greased by engine oil.
As linear expansion of a material of the piston approximately in 2 times more than finger material at a normal room temperature the finger enters into an aperture of lugs of the piston with a tightness. Dimensional groups of the piston and a finger should coincide.
The piston complete with a piston finger, piston rings and a rod in gathering should be supervised on weight. The difference of complete sets on weight on one engine should not exceed 10
After a selection of pistons and piston fingers it is necessary to continue подсборку shatunno-piston group in a following order:

Fig. 4.59. Deposit clearing in flutes of pistons




- To clear the bottoms of pistons and a flute for piston rings of a deposit (fig. 4.59 see);
- запрессовать a piston finger in the piston and a rod by means of the adaptation (fig. 4.60 see). Thus the piston to heat up to temperature 60—80 ° With (запрессовка a finger in the cold piston can lead to damage of a surface of apertures in piston lugs, and also to deformation of the piston). Rods and pistons before assemblage with a piston finger should be сориентированы as follows: an arrow on the piston bottom (or an inscription "BEFORE", located on lug lateral aspect under a finger), a ledge on a lateral surface of a cover of a rod and a ledge on кривошипной to a rod head should be directed to one party;

Fig. 4.63. Selection of piston rings to the cylinder




- To pick up for cylinders piston rings. The thermal backlash measured in locks of rings, placed in the cylinder (fig. 4.63 see), should be 0,3—0,6 mm at компрессионных rings and 0,5—1,0 mm — at steel disks маслосъемных rings. In the worn out cylinders the least backlash to do 0,3 mm — at компрессионных rings and 0,5 mm — at steel disks маслосъемных rings;

Fig. 4.64. Check of a lateral backlash between a piston ring and a flute in the piston




- To check up щупом a backlash between rings and a wall of a piston flute (fig. 4.64 see). Check to make on a piston circle in several points. The backlash size should be for top and bottom компрессионных rings within 0,050—0,087 mm, for modular маслосъемного rings — 0,115—0,365 mm;

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




- To put on by means of the adaptation piston rings the piston. Bottom компрессионное a ring to put internal bore upwards to a piston bottom (fig. 4.4 see). Rings in flutes should move freely;
- To insert pistons into cylinders as follows:
- сориентировать shatunno-piston group so that an arrow on the piston bottom (or the inscription "BEFORE" on a lug) has been turned forward;
- To wipe a napkin of bed of rods and their covers, to wipe and insert into them loose leaves;
- To turn a cranked shaft so that cranks of the first and fourth cylinders have occupied the position corresponding НМТ;
- To grease loose leaves, the piston, шатунную a neck of a shaft and the first cylinder with pure engine oil;
- To dissolve locks компрессионных rings at an angle 180 ° to each other, locks of disks маслосъемного rings also at an angle 180 ° to each other and on 90 ° in relation to locks компрессионных rings. The lock of a two-functional dilator to establish thus at an angle 45 ° to the lock of one of ring disks;
- To put on bolts of rods safety brass tips, to compress rings обжимкой or using оправкой for installation in the piston cylinder;

Fig. 4.65. Installation of the piston with rings in the cylinder with the help оправки




- To insert the piston into the cylinder (fig. 4.65 see). Before piston installation it is necessary to be convinced once again that numbers which have been beaten out on a rod and its cover, correspond to a cylinder serial number, to check up correctness of position of the piston and a rod in the cylinder;
- To tighten a rod for кривошипную a head to шатунной to a neck, to remove from bolts brass tips, to put on a rod cover. The rod cover should be put so that numbers which have been beaten out on a cover and a rod, have been turned into one party. To wrap nuts динамометрическим a key the moment 68—75 Н·м (6,8—7,5 кгс·м);
- To insert in the same order the piston of the fourth cylinder;
- To turn a cranked shaft on 180 ° and to insert pistons of the second and third cylinders;
- To turn some times a cranked shaft which should rotate easily from small effort;
- To establish the holder of the oil pump and the oil pump on the block and to fix them;
- To grease with engine oil of the plug of an intermediate shaft, to establish шпонку in a groove on a shaft of an intermediate shaft and to establish a shaft in the block of cylinders to a shaft exit;
- To establish a gear wheel of a 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, thus smaller diameter of an aperture on a flange should adjoin to the block;
- To grease with engine oil the platen with a conducted gear wheel of a drive of the oil pump and to insert it into an aperture in the block to an input in gearing of gear wheels of a drive of the oil pump;
- Into an aperture of the plug of the platen to insert шестигранный the platen of a drive of the oil pump;
- To establish a lining and a cover of a drive of the oil pump, to fix a cover;
- To establish drives of camshafts in a following order:

Fig. 4.116. The forward end of a cranked shaft: 1 — a bolt (or a ratchet); 2 — a pulley-dempfer with a synchronisation disk; 3 — an epiploon; 4 — a chain cover; 5 — the plug; 6 — an asterisk; 7 — the block of cylinders; 8 — bearing loose leaves; 9 — a cranked shaft; 10 — a bearing cover; 11 — oil картер; 12 — a rubber sealing ring; 13 — a lock washer




- напрессовать an asterisk 6 (fig. 4.116 see) on a shaft of a cranked shaft;
- To establish a rubber sealing ring 12 and the plug 5 big internal facet to a sealing ring on a shaft of a cranked shaft;
- To establish шпонку a pulley of a cranked shaft in шпоночный a groove;

Fig. 4.118. A drive of camshafts: 1 — an asterisk of a cranked shaft; 2 — гидронатяжитель the bottom chain; 3 — шумоизолирущая a rubber washer; 4 — a stopper; 5 — a boot гидронатяжителя the bottom chain; 6 — the bottom chain; 7 — a conducted asterisk of an intermediate shaft; 8 — a leading asterisk of an intermediate shaft; 9 — a boot гидронатяжителя the top chain; 10 — гидронатяжитель the top chain; 11 — the top chain; 12 — an adjusting label on an asterisk; 13 — an adjusting pin; 14 — an asterisk of a camshaft of inlet valves; 15 — top успокоитель chains; 16 — an asterisk of a camshaft of final valves; 17 — the top plane of a head of the block of cylinders; 18 — average успокоитель chains; 19 — bottom успокоитель chains; 20 — a chain cover; Ml and М2 — adjusting labels on the block of cylinders




- To turn a cranked shaft of the engine before label coincidence on an asterisk of a cranked shaft with a label «М2» on the block of cylinders (fig. 4.118 see) that will correspond to position of the piston of the first cylinder in ВМТ. Thus the label on the block of cylinders should be symmetrized concerning an axis of a hollow of teeths of an asterisk;
- To establish bottom успокоитель chains 19, without twisting fastening bolts it is definitive;
- To put on a chain 6 a conducted asterisk 7 (number of teeths — 38) an intermediate shaft and on an asterisk of 1 cranked shaft of the engine. To establish an asterisk with a chain on an intermediate shaft, thus the label on a conducted asterisk of an intermediate shaft should coincide with a label «M1» on the block of cylinders, and the leading branch of a chain which are passing through успокоитель, should be tense;
- To establish a leading asterisk 8 (number of teeths — 19) an intermediate shaft and to fix asterisks on intermediate to a shaft bolts. A lock plate to unbend on the verge of bolts;
- To establish a boot 5 гидронатяжителя chains of the first step (the bottom chain) drive of camshafts;
- Pressing a boot гидронатяжителя, to pull a chain, to check up correctness of installation of asterisks on labels and definitively to fix bottom успокоитель 19. After installation of a chain of a drive of an intermediate shaft rotation of a cranked shaft till the moment of installation of a chain of a drive of camshafts and гидронатяжителей is not supposed;
- To establish a boot 9 гидронатяжителя chains of the second step (the top chain) drive of camshafts;
- To put on a leading asterisk 8 intermediate shaft a chain 11 second steps of a drive of camshafts;
- To take a cover of a chain with a rubber epiploon, to check up suitability of an epiploon to the further work. If the epiploon has the worn out working edges or poorly covers the plug of a cranked shaft, to replace its new. Запрессовку an epiploon in a cover it is recommended to make with the help оправки;
- To fill on 2/3 cavity between a working edge and пыльником an epiploon greasing ЦИАТИМ1-221;
- Keeping a chain of the second step from соскакивания from an asterisk of an intermediate shaft, to establish and fix a cover of a chain and simultaneously a generator arm, to tighten screws the moment 22—27 Н·м (2,2—2,7 кгс·м);
- To establish and fix the pump of a cooling liquid on a chain cover, having tightened a bolt of fastening of the pump to a cover of a chain the moment 22—27 Н·м (2,2—2,7 кгс·м);
- To grease with engine oil an aperture under гидронатяжитель in a cover of a chain and to establish collected гидронатяжитель 2 to a contact in a boot emphasis, but not to press, for the purpose of an exception of operation of a clamp гидронатяжителя;
- To establish in a cover гидронатяжителя шумоизоляционную a rubber washer 3;
- To close a cover гидронатяжитель and to fix its two bolts;
- To press оправкой through an aperture in a cover гидронатяжителя on гидронатяжитель, moving it against the stop, then to release, thus запорное the ring on плунжере leaves gearing with the case гидронатяжителя and will give the chance плунжеру and case to move under the influence of a spring. The case will move against the stop on a washer in a cover, and the chain through a boot will be tense;
- To wrap a stopper 4 in a cover гидронатяжителя;
- To establish on a branch pipe of the pump of a cooling liquid a hose connecting a branch pipe of the pump with a branch pipe of the case of the thermostat;
- To put 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-hermetic of Elastosil 137-83;
- To establish a lining of a head of the block of cylinders on directing plugs of the block and also to put glue-hermetic of Elastosil 137-83 on a surface of the lining which are over a cover of a chain;

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




- To establish подсобранную a 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 кгс·м) and definitive — 130—145 Н·м (13,0—14,5 кгс·м). The sequence of an inhaling of bolts of fastening of a head of cylinders is specified on pис. 4.34. A carving of bolts before installation to oil;
- To turn away bolts and to remove covers of camshafts, to wipe a bed napkin under camshafts in a head and in covers;
- To grease with the engine oil applied to the engine, an aperture to a head under 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 marks put on them at dismantling, at a hydropusher exit out of operation it is subject to replacement as is not under repair. To take out hydropushers it is necessary a sucker or a magnet;
- To establish camshafts on a head of the block of cylinders, preliminary having greased beds in a head, cams and basic necks of camshafts with engine oil. The camshaft of inlet valves is established by an asterisk pin upwards, and a camshaft of final valves — an asterisk pin to the right. At the expense of an angular arrangement of cams the given positions of camshafts are steady;
- To establish a forward cover of camshafts with the persistent flanges established in it on adjusting plugs, thus at the expense of longitudinal moving of camshafts to provide installation of persistent flanges in flutes;
- To establish covers № 3 and № 7 camshafts and preliminary 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 marks and to tighten preliminary bolts of fastening of covers;
- Definitively to tighten bolts of fastening of covers of camshafts the moment 19—23 Н·м (1,9—2,3 кгс·м);
- To grease all cams of camshafts with engine oil and to check up rotation of each camshaft in support for what to turn a camshaft a key for a special tetrahedron on distributive to a shaft before position of full compression of springs of valves of one of cylinders. At the further procollar the camshaft should be turned independently under action клапанных springs before position of a contact of following cams with pushers;
- To check up ease of rotation of camshafts and then turn соориентировать them so that adjusting pins 13 (fig. 4.118 see) under asterisks settled down roughly horizontally and have been directed every which way. The given positions of camshafts are steady and are provided with an angular arrangement of cams;
- To begin прoвeркy installations of angular position of camshafts with a shaft of final valves. For this purpose, having thrown an asterisk 16 приводную with a chain, to establish an asterisk on a flange and a camshaft pin, thus for coincidence of a pin and an aperture on an asterisk to turn a camshaft for a tetrahedron clockwise. Camshaft turn counter-clockwise to pull a leading branch of a chain, thus the label 12 on an asterisk should coincide with the top plane of a head of cylinders 17. It is impossible to suppose turn of a cranked shaft;
- For angular installation of a camshaft of final valves to throw an asterisk 14 приводную with a chain, to establish an asterisk on a flange and a camshaft pin at slightly sagged branch of a chain between asterisks. Camshaft turn counter-clockwise to pull the chain, thus a label 12 on an asterisk should coincide with the top plane of a head of cylinders;
- To insert into a nest of an asterisk of a camshaft of inlet valves the clown of a drive of the fuel pump;
- To establish and tighten the moment 46—74 Н·м (4,6—7,4 кгс·м) bolts of fastening of asterisks (and the clown on distributive to a shaft of inlet valves), keeping camshafts from проворачивания a key for a tetrahedron;
- To establish гидронатяжитель 10 top chains of a drive of camshafts to similarly installation гидронатяжителя chains of the bottom chain;
- To establish average 18 and top 15 успокоители chains, without turning fastening bolts it is definitive;
- To pull working branches of a chain of the second step turn of a cranked shaft of the engine on a course of rotation and definitively to fix average and top успокоители chains;
- To establish a pulley on a shaft of a cranked shaft against the stop and to screw a bolt the moment 104—128 Н·м (10,4 12,8 кгс·м);
- To make the control of installation of camshafts upon termination of assemblage. For this purpose to turn a cranked shaft of the engine on a rotation course on two turns before label coincidence on демпфере a cranked shaft with a label on a chain cover. Thus labels on asterisks of camshafts should 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, installation of a drive of camshafts at assemblage to make, as it is specified above;
- In case at repair asterisks of an intermediate shaft and a chain cover before dismantling it is necessary to establish the piston of 1st cylinder in position ВМТ on a compression step do not act in film, thus risk on a pulley of a cranked shaft should coincide with a ledge on a chain cover, and labels on asterisks of camshafts should be located horizontally, directed every which way and coincide with the top plane of cooking of cylinders.
After removal of camshafts and a head of cylinders turn of a cranked shaft can be only with a reset or on 2 turns. Turn of a cranked shaft on 1 turn even at coincidence of labels on a pulley and a chain cover will lead to wrong installation of phases газораспределения. At wrong installation of camshafts and label asterisks 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 cranked shaft on a rotation course on 1 turn and to repeat installation of asterisks as it is specified above;
- To establish and fix a pulley of the pump of a cooling liquid;
- To collect a forward cover of a head of cylinders with the intermediate lever of a 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 branch pipe of the case of the thermostat in a hose on a branch pipe of the pump of a 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 lifting of the engine and скобу tubes of a fence of water on hairpins of a final collector, наживить and to tighten fastening nuts;
- запрессовать 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 simultaneously an arm for lifting of the engine the forward;
- To establish and fix a tension roller;
- To establish and fix an inlet pipe;
- To grease joints of the bottom flange of the block of cylinders with a cover of a chain and with a back cover glue-hermetic of Elastosil 137-83 or paste УН-25;
- To establish on the bottom flange of the block of cylinders a lining of the pallet oil картера;
- To establish and fix the pallet oil картера and the amplifier картера couplings;
- To establish and fix conducted and press coupling disks, aligning a conducted disk with the help оправки;
- To put details and engine units, («engine Dismantling» see), observing return sequence;
- To remove the engine from the stand, to establish and attach картер couplings to the block of cylinders;
- To grease and put on a forward cover of a transmission муфту coupling deenergizings in gathering with the bearing;
- To put and fix a transmission;
- To put a plug of deenergizing of coupling.
Engine installation on the car
Engine installation on the car is made in sequence, to return its removal.


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