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
4.6. Assembly and installation of the engine
4.6.1. Installation of the transmission
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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4.6. 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.

Fig. 4.56. Marking of a bent shaft and block of cylinders


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).
It is possible to install in the block of cylinders only radical bearings which are picked up according to tab. 4.2.

       NOTE
At installation plentifully grease bearings from a bent shaft.

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;


Fig. 4.57. Measurement of an axial side play


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;

Fig. 4.58. Press fitting of an epiploon of a bent shaft


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).

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;

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)


13) establish piston rings (fig. 4.59);
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.

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.

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