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4.6. Assembly and installation of the engine
Before assembly of the engine do the following operations:
— clear nests of inserts of radical bearings. Make sure that details pure and have no damages;
— pay special attention to cleaning of a deposit in nests of locks of inserts;
— check marking on the block of cylinders and cranked to a shaft.
Besides, it is necessary to make classification of radical bearings of a bent shaft for reliable operation of the engine.
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Fig. 4.56. Marking of a bent shaft and block of cylinders
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Each nest of radical bearings is marked by number of the cylinder, and also the letter designating a class of the block of cylinders and a bent shaft (fig. 4.56).
NOTE
At installation plentifully grease bearings from a bent shaft.
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Engine balance of assembly:
1) apply полимеризующуся pro-masonry mastic (É/M 1 161 059-9) on intermediate section. Cover a surface completely, but avoiding smudges that mastic did not get to canals and openings for bolts. Use the roller with a short bristle 951 1205;
2) establish inserts of bearings in intermediate section. The surface of nests of bearings has to be dry;
3) plentifully grease inserts of bearings and persistent inserts.
4) establish a bent shaft. The shaft cannot be turned until the intermediate section is not fixed on the place;
5) establish intermediate section. Tighten bolts of intermediate section and a bent shaft in 5 receptions. To finish performance of each reception before starting the following. The most admissible length of a bolt of M10 — 118 mm:
— tighten all bolts of M10 the moment of 20 N · m;
— tighten M10 bolts the moment of 45 N · m;
— tighten M8 bolts the moment of 24 N · m;
— tighten M7 bolts the moment of 17 N · m;
— tighten M10 bolts on 90 °;
6) be convinced that the bent shaft rotates smoothly, without jammings;
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Fig. 4.57. Measurement of an axial side play
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7) measure an axial side play, using the indicator of hour type, a magnetic plate and a magnetic rack (fig. 4.57). The axial side play has to make 0,08 — 0,19 mm;
8) establish a back epiploon of a bent shaft;
9) grease the surfaces of interface: neck of a shaft and working edges of an epiploon. Put on an epiploon a mandrel;
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Fig. 4.58. Press fitting of an epiploon of a bent shaft
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10) press an epiploon (fig. 4.58) against the stop of a mandrel in a bent shaft. If on a neck of a bent shaft there is a wear track, to press an epiploon more deeply, than it settled down earlier;
11) collect pistons and rods;
NOTE
The arrow on a head of the piston has to be directed towards a forward part of the engine, i.e. towards a belt of the drive of camshafts. Digital marking on a rod has to be turned to the inlet party of the block (the party where the starter is located).
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12) put a lock spring ring of a piston finger and be convinced that it was recorded in a pro-point. The section of a lock ring has to be turned down;
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Fig. 4.59. Installation of piston rings: 1 — a compression ring (marking up); 2 — a compression ring (a facet down); 3 — an oil scraper ring (marking up)
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14) using the device for compression of piston rings, establish rings so that their locks were divorced on a corner about 120 °;
15) clear and dry nests of bearings in rods and covers;
16) establish inserts of bearings in rods and covers;
17) establish protective technological caps on a carving of conrod bolts;
NOTE
At reuse of old inserts of bearings the last need to be established on their own places.
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18) oil engine walls of cylinders, pistons and inserts of bearings;
19) install pistons in cylinders;
NOTE
The bent shaft cannot be turned until bolts of a cover of the lower head of the established rod are tightened.
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20) at installation of each piston to turn a bent shaft so that the conrod neck corresponding to the inserted piston was in the lowermost situation;
21) check compliance of classes of pistons. Insert serially pistons into cylinders, using the device for compression of piston rings;
22) remove protective caps and establish covers of conrod bearings;
23) check compliance of marking of rods and covers of conrod bearings;
24) tighten conrod bolts in two steps (to use new conrod bolts. Before installation oil bolts):
— tighten bolts the moment of 20 N · m;
— tighten on 90 °;
25) be convinced that rods easily move in the cross direction;
26) establish a maslozabornik of the oil pump with a tube;
27) establish laying on a tube of a maslozabornik;
28) connect a tube. Tighten with the moment 17 N · m;
29) establish new consolidations of oil channels;
30) establish an oil case. By means of the roller with a short bristle to apply the polymerized pro-masonry mastic (RLM 1 161 059-9) on a case;
31) insert four bolts and to establish a case level with the back surface of the block. Tolerance of ±0,025 mm. For check use a caliper and the probe;
32) tighten bolts until 17 N · m, since a forward part and moving ahead back;
33) establish a new oil filter;
34) install the hinged equipment, units and details as it should be, the return to dismantling;
35) establish a flywheel / a drive plate using a gear clamp 999 5112 and special bolts 999 5593;
36) establish a flywheel, using three special bolts and tighten them until 45 N · m;
37) establish other standard bolts (new) and tighten them until 45 N · m;
38) replace three special bolts with new standard and tighten them until 45 N · m;
39) tighten all bolts of fastening of a flywheel on 65 °;
40) install the engine on the car.
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