S40/V40
1. General information
2. Operation and maintenance of the car
3. Design and technical characteristics of engines
4. Repair of the engine
4.1. Removal of a head of the block of cylinders
4.2. Installation of a head of the block of cylinders
4.3. Removal and installation of support of the engine
4.4. Removal of the engine
4.5. Dismantling and assessment of a condition of details of the engine
4.5.1. Dismantling of the engine
4.5.2. Dismantling, troubleshooting and repair of a head of the block of cylinders
4.6. Assembly and installation of the engine
5. Transmission
6. Brake system
7. Forward suspension bracket and steering
8. Back suspension bracket
9. Control system of the Fenix 5.1 engine
10. Electric equipment. Conducting and components
11. Body
12. Schemes of electric equipment
 



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4-5-1-razborka-dvigatelya.html

4.5.1. Dismantling of the engine

The engine is removed from the car. All hinged equipment and a box of gear shifting is removed from the engine. Are removed: the conducting and conducted clutch plates and a flywheel of the engine. The engine is installed on the stand. The lifting mechanism is removed.
For dismantling of the engine make the following:
— remove a forward cover of a belt of the drive of camshafts;

Fig. 4.34. Removal of a damper of tortional fluctuations


— combine tags on cranked and camshafts (fig. 4.34);
— remove a damper of tortional fluctuations by means of the holder 999 5433 (see fig. 4.34);
— remove the lower cover of a belt of the drive, a natyazhitel, a gear belt;
— wrap two bolts of fastening of a damper of tortional fluctuations in a pulley of a gear belt manually against the stop;
— establish a universal stripper so that captures of a stripper influenced bolts, but not a pulley;

Fig. 4.35. Removal of a roller of a natyazhitel and uspokoitel of a gear belt


— shoot videos of a natyazhitel and an uspokoitel of a gear belt (fig. 4.35);

Removal and assessment of a state
oil pump

Sequence of actions:

Fig. 4.36. Removal of the oil pump


— turn out four bolts of fastening of the oil pump. Accurately turn the oil pump for its release; hook the screw-driver ledges of the case (fig. 4.36);
— clear the surfaces of consolidation and interface;
— turn out two screws with an internal hexagon and remove laying;
— you watch that details of the oil pump were not divided under the influence of a spring;
— examine details on existence of traces of damage and wear, paying special attention to the crescent site (a surface between cavities of absorption and forcing);
— replace the pump assembled if details have defect;

Fig. 4.37. Check of a spring of the regulator of pressure of oil


— check an oil pressure regulator spring. For this purpose squeeze it as shown in fig. 4.37 with rated effort (tab. 4.1);

       NOTE
The regulator of pressure of oil opens at 0,50 MPas.

— establish a big rotor of the pump into position by marking up;
— establish a small rotor of the pump;
— check a gap. If the measured gap between an external rotor and the case exceeds 0,35 mm, the pump is subject to replacement. Measure a gap by means of the probe.

Removal and assessment of a state
pump of cooling liquid

Sequence of actions:
— clear the surfaces of the socket and interface, having carefully removed all remains of consolidation;
— remove a back cover of a belt of the drive of camshafts;
— remove the thermostat of cooling liquid and its laying, the thermostat case;
— clear the surfaces of the socket and interface;
— check operation of the thermostat in the water heated to temperature of opening of 100 °C. The maximum opening has to happen within 2 minutes.

Dismantling and assessment of a state
block of cylinders and krivoshipno-conrod mechanism

Sequence of actions:
— remove an oil filter;
— turn off bolts of fastening and remove an oil case, carefully tapping on it with a rubber kiyanka;
— remove a maslozabornik with a tube of the oil pump;
— clear and examine a tube;
— remove a sealing ring of a tube of the oil pump and a sealing ring of the oil channel;
— remove intermediate section of the block;
— turn out all bolts of M7 and M8 of intermediate section, then turn out all bolts of M10;
— remove intermediate section, carefully tapping on it with a plastic kiyanka;
— remove a back epiploon of a bent shaft, without allowing a provorachivaniye of the last;
— check marking on covers and rods. If it is absent or is vague, by means of a core or a font put new marking to exclude a possibility of a razukomplektovyvaniye of rods (covers of rods are individual, are not subject to a depersonalization as each rod is chiseled assembled with the cover). Also to arrive with covers of radical bearings;
— uncover rods;
— check a condition of inserts of bearings in rods and covers;

       PREVENTION
It is impossible to interchange the position of connecting rods of different bearings. Not to allow rotation of a bent shaft.

— take a bent shaft from the block of cylinders;
— put a bent shaft two external radical necks on V-shaped supports. Remove inserts of radical bearings;
— mark the provision of an insert of the persistent bearing;

       NOTE
It is impossible to interchange the position of inserts of different radical bearings.

— trying not to scratch the surface of cylinders, a hand serially take pistons assembled with rods;
— accurately, by means of the plastic pallet, clear the surfaces of the socket of the block of cylinders, intermediate section and an oil case. If necessary use means for removal of pro-masonry mastic;
— wipe cylinders absolutely and examine them;
— measure the maximum wear at right angle to the axial line of cylinders of the engine directly under the top dead point in a zone of the first compression ring;
— measure the minimum wear in the direction of the axial line at the lower dead point. Each cylinder has marking (With, D, E, or G) which is beaten out in a back part of the block.

Fig. 4.38. Control of a micrometer


The repair sizes of cylinders are designated by means of an abbreviation of OS1 or OS2 respectively. This marking has to be added after boring. If wear exceeds 0,10 mm, boring of cylinders is necessary. The sizes of cylinders are specified in the section "Design and Technical Characteristics".

       NOTES
For measurement of diameter of the cylinder the indicator-nutromer with a head of hour type (75 — 100 mm), a micrometer and a rack of a micrometer (fig. 4.38) is used. Adjust a micrometer on the value of diameter of the cylinder increased by the maximum admission specified on the block.
Calibrate the indicator-nutromer by means of a micrometer.


Check of a state
bent shaft


Fig. 4.39. Arrangement of points of measurement of ovality and conicity of radical and conrod necks


When checking a condition of a bent shaft the micrometer is used: for necks of radical bearings with a range of measurement of 50 — 75 mm, for necks of conrod bearings — 25 — 50 mm. Measure ovality and conicity of radical and conrod necks (fig. 4.39).
To perform measurement in several points on a circle and on length. The sizes of conrod and radical necks are specified in the section "Design and Technical Characteristics".
Check of straightforwardness of a bent shaft with use an indicator head of hour type with the extender of a leg and a magnetic rack:
— put a bent shaft two extreme radical necks on V-shaped prisms;
— turning a bent shaft, measure a radial beating of an average radical neck. The maximum radial beating — 0,032 mm.

Check of a state
piston group

For check of a condition of pistons:
1) remove piston rings. Remove a deposit;
2) clear flutes under piston rings;
3) examine pistons on existence of damages, cracks, wear;
4) check an axial gap of piston rings, using new rings and a set of probes;

Fig. 4.40. Piston sizes: And — the general height of the piston; In — height from an opening axis under a piston finger; D — diameter of the piston measured at right angle to an opening of a piston finger at distance With from a skirt edge


5) measure pistons, as shown in fig. 4.40. The sizes of pistons are specified in the section "Design and Technical Characteristics";

Fig. 4.41. A gap between the cylinder and the piston. Example of calculation. Let's allow:
— the measured diameter of the cylinder: 96,02 — 96,03 mm;
— the measured diameter of the piston: 96,01 —
96,00 mm;
Then a gap between the piston and the cylinder: 0,01 mm (min) — 0,03 mm (max).
Admissible gap between the piston and the cylinder: 0,01 — 0,03 mm.


6) calculate a gap between the piston and the cylinder (fig. 4.41);
7) separate rods from pistons. Before separation to check existence of marking on each piston and a rod. If marking indistinct, by means of a felt-tip pen write number of the cylinder and draw to the shooter, specifying the direction to a forward part of the engine;
8) smooth out openings of a piston finger;
9) accurately remove a lock ring by means of the screw-driver;
10) take a piston finger hand pressure;
11) clear rods, covers of bearings and bolts and examine them on existence of damages, wear and cracks;
12) measure length of bolts of covers of conrod bearings by a caliper. The most admissible length is 55 mm;
13) check landing of piston fingers in pistons. The finger side play in the piston has to be absent. When pressing by a hand the piston finger has to slip through an opening without side play. In the presence of a side play replace the piston;
14) check landing of piston fingers in rods. Under pressing of a thumb of a hand the piston finger has to slip easily through an opening without notable side play. In the presence of a side play measure diameter of a piston finger and, in case of need, replace the plug of the top head of a rod;
15) examine connecting rods. In the presence of zadir, flakings and a vykroshivaniye of a working layer replace inserts;

       NOTE
Diameter of a piston finger — 23,0 — 0,004 mm.

16) check straightforwardness of a rod;
17) check rods for a bend and twisting of a core;

       NOTE
Diameter for conrod bearings — 50,0+0,013 mm. The maximum ovality — 0,006 mm.


Fig. 4.42. Check of the clamping rod surface


18) be convinced that round clamping a fork surface and has no zadir (fig. 4.42);

       NOTE
Between checks of straightforwardness to release and tighten adaptation dilator on lower rod heads.


19) if necessary replace plugs of the top head of a rod, for this purpose:
— establish a rod by the top head on a support and by means of a mandrel to a vypressuyta the plug;

Fig. 4.43. A plug press fitting in a rod


— press the new plug, moving a mandrel vertically (fig. 4.43);
— check landing of a piston finger in the new plug. If it is necessary — pick up other plug;

       PREVENTION
It is necessary to provide combination of an opening in the plug with an opening of the oil channel in a rod.

20) if necessary replace a rod. The rod has the symmetric form and if necessary can be turned. But at assembly it is necessary to mark a rod;
21) collect a rod (to tighten bolts until 20 N · l) also be convinced that the cover of the lower head of a rod is turned into the necessary party (locks of inserts of a rod and cover of a rod have to be turned into one party);
22) fix the lower head in a vice with soft sponges and beat out number of the cylinder on both parts of the lower head by means of a core or a font.

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4.5.2. Dismantling, troubleshooting and repair of a head of the block of cylinders