All parts received for assembly must be cleaned of dirt, carbon deposits and scale, degreased, washed and dried
Oil channels and holes in parts must be cleaned, washed under pressure and blown with compressed air.
It is not allowed to wash parts made of aluminum and zinc alloys in alkaline solutions used for washing steel and cast iron parts, since aluminum and zinc dissolve in alkalis.
All units, as well as parts of disassembled units during repairs, can be anonymized, with the exception of the following parts:
- - cylinder block and main bearing caps;
- - connecting rod and connecting rod cap;
- - final drive gears;
- - differential bearing covers and final drive housing;
- - right and left differential gear boxes. It is permissible to assemble the main gear from serviceable used or new gears, subject to mandatory check of their engagement using a special device.
Chipping of gear teeth and chipping of the working surface of the teeth are not allowed.
Cylinder block
The cylinder block and main bearing caps should not be disassembled during disassembly, inspection and sorting, since they are processed together and therefore are not interchangeable.
Cylinder blocks arriving for assembly must be thoroughly cleaned of dirt and scale, and oil channels must be thoroughly cleaned of sludge and chips.
The main bearing shell seats must be bored to the nominal size if their size and misalignment exceed the permissible value.
The cleanliness of the bored sockets must correspond to class 6-b according to GOST 2789-51, and their maximum misalignment should not exceed 0.02 mm.
When checking, as well as when boring the sockets, the tightening torque of the fastening bolts and main bearing caps should be 11-12 kgm.
Traces of blackness are not allowed on the surface of the bored sockets of the liners.
Camshaft bushings pressed into the cylinder block must be bored to the nominal or one of the repair dimensions given in table. 1.
The cleanliness of the bored surfaces must correspond to class 7 according to GOST 2789-51, and the misalignment of the bushings must not exceed 0.025 mm.
The non-parallelism of the axes of the crankshaft and camshaft should not exceed 0.04 mm along the entire length, and the distance between the axes should be within 125.5 ± 0.025 mm.
The deviation from the perpendicularity of the axis of the holes for the cylinder liner to the axis of the crankshaft is allowed within 0.015 mm over a length of 100 mm, and the axis of the holes for the pushers to the camshaft axis is not more than 0.050 mm over a length of 100 mm.
To ensure selective assembly in new cylinder blocks, the tappet holes are sorted into two size groups.
The size groups are marked with oil-resistant paint on the bosses under the pushers.
After processing the holes for pushers of repair sizes, they must also be sorted into size groups. Markings of size groups and repair dimensions of holes for pushers are given in table. 2.
Cylinder liners
Cylinder liners installed on one engine must be of a nominal size or bored and honed to one repair size common to all liners, indicated in the table. 3.
The ovality and taper of the final processed sleeves should not exceed 0.02 mm. Moreover, the larger base of the cone should be in the lower part of the sleeve.
Barrel shape and corsetry no more than 0.01 mm.
The surface of the sleeve must be mirror-shiny without marks or blackness, its cleanliness must correspond to class 9-a.
To ensure selective assembly of the liner-piston interface, in automobile factories liners of nominal size are sorted into five size groups.
Size groups are designated by letters of the Russian alphabet, which are printed with a rubber seal on the polished outer surface of the sleeves.
For the same purpose, sleeves processed to repair size must also be sorted into size groups.
If the ovality of the liner seating surface exceeds the permissible value of 0.025 mm, then the surface must be restored by remaining and then processed to the nominal size.
In this case, the runout of the seating surface relative to the inner surface of the sleeve should not exceed 0.08 mm, and the non-parallelism of the axes of these surfaces should not exceed 0.02 mm over a length of 100 mm.
Table 1. Size groups of liners of nominal and repair sizes and their designations
Nominal size, sleeve diameter:
- A - 92.0+0.012 mm;
- B - 92.0+0.024 mm;
- B - 92.0+0.036 mm;
- G - 92.0+0.048 mm;
- D - 92.0+0.060 mm
First repair size, sleeve diameter, increase in sleeve diameter by 0.5 mm:
- 1A - 92.5+0.012 mm;
- 1B - 92.5+0.024 mm;
- 1B - 92.5+0.036 mm;
- 1G - 92.5+0.048 mm;
- 1D - 92.5+0.060 mm
Second repair size, sleeve diameter, increase in diameter by 1.0 mm:
- 2A - 93.0+0.012 mm;
- 2B - 93.0+0.024 mm;
- 2B - 93.0+0.036 mm;
- 2G - 93.0+0.048 mm;
- 2D - 93.0+0.060 mm
Third repair size, sleeve diameter, increase in diameter by 1.5 mm:
- 3A - 93.5+0.012 mm;
- 3B - 93.5+0.012 mm;
- 3B - 93.5+0.024 mm;
- 3G - 93.5+0.036 mm;
- 3D - 93.5+0.048 mm
Table 2. Size groups of holes for pushers of nominal and repair sizes
Nominal size:
- - group (I), marking color yellow, hole diameter 25.0 +0.011 mm;
- - group (II), marking color blue, hole diameter 25.0 +0.023 mm;
First repair size:
- - group (I), marking color white, hole diameter 25.1 +0.011 mm;
- - group (II), marking color green, hole diameter 25.1 +0.023 mm;
Second repair size:
- - group (I), marking color black, hole diameter 25.2 +0.011 mm;
- - group (II), marking color red, hole diameter 25.2 +0.023 mm;
Table 3. Nominal and repair dimensions of holes in camshaft bushings
Nominal size, hole diameter in the bushing - 50.0+0.05 mm;
First repair size, increase in diameter by 0.25 mm, hole diameter in the bushing - 49.75+0.05 mm;
Second repair size, increase in diameter by 0.5 mm, hole diameter in the bushing - 49.5+0.05 mm
Pistons and piston pins
Table 4. Size groups of pistons of nominal and repair sizes and their designations
Nominal size, piston diameter:
- A - 92.0-0.012 mm;
- B - 92.0+0.012 mm;
- B - 92.0+0.024 mm;
- G - 92.0+0.036 mm;
- D - 92.0+0.048 mm
First repair size, increase in diameter by 0.5 mm, piston diameter:
- 1A - 92.5-0.012 mm;
- 1B - 92.5+0.012 mm;
- 1B - 92.5+0.024 mm;
- 1G - 92.5+0.036 mm;
- 1D - 92.5+0.048 mm
Second repair size, diameter increase by 1.0 mm, piston diameter:
- 2A - 93.0-0.012 mm;
- 2B - 93.0+0.012 mm;
- 2B - 93.0+0.024 mm;
- 2G - 93.0+0.036 mm;
- 2D - 93.0+0.048 mm
Third repair size, increase in diameter by 1.0 mm, piston diameter:
- 3A - 93.5-0.012 mm;
- 3B - 93.5+0.012 mm;
- 3B - 93.5+0.024 mm;
- 3G - 93.5+0.036 mm;
- 3D - 93.5+0.048 mm
For car repair production, pistons are produced in nominal and three repair sizes.
To ensure selection by liners, the pistons are sorted into five size groups, which are designated by letters of the Russian alphabet.
The designation of the size group is stamped on the piston crown.
Size groups of pistons of nominal and repair sizes, as well as their designations are given in table. 4.
The pistons are sorted into four size groups based on the diameter of the hole for the piston pin.
The groups are marked with oil-resistant paint on the outer surface of the piston bosses.
The size groups of the piston pin holes and their markings are given in Table 5.
The piston skirt is oval and tapered.
The major axis of the oval is located in a plane perpendicular to the piston pin axis, and the taper of the skirt in the same plane should be 0.013-0.038 mm.
The largest diameter of the cone should be at the bottom of the skirt.
When overhauling engines, only piston pins of nominal size are used, which are sorted into four size groups.
Size groups of piston pins of nominal size and their markings are given in table. 6.
Piston rings
Piston rings are produced in nominal and three repair sizes, given in table. 7.
Of the three rings installed on one piston, two (the second compression and oil scraper rings) must be covered with half, and the upper compression ring must be covered with chrome.
When checking in a ring gauge of the appropriate size, clearance between the piston ring and the gauge is not allowed.
The elasticity of compression rings, compressed with a steel tape to a gap at the joint of 0.3 ∕0.5 mm, should be 1.75 - 2.50 kgG, and oil scraper rings - 1.5 - 2.2 kgG.
Connecting rods
The connecting rod and connecting rod cover should not be disassembled during disassembly, inspection and sorting, since they are not interchangeable.
It is possible to restore the hole of the lower head of the connecting rod by leaving it, followed by processing to the nominal size.
Before machining the lower head, the connecting rod bolt nuts must be tightened with a torque wrench. Tightening torque - 6.8 - 7.5 kgm.
The bushings pressed into the upper head of the connecting rods must be bored to the nominal size.
Before boring m sleeves should be ironed with a brooch.
The cleanliness of the machined surfaces in the bushing and lower head of the connecting rod must correspond to class 8-b.
After boring, the ovality and taper of the upper connecting rod head should not exceed 0.005 mm, and the lower one - 0.008 mm.
The non-parallelism of the axes of the holes of the upper and lower heads of the connecting rod is no more than 0.03 mm over a length of 100 mm, the axes of the holes of the upper and lower heads of the connecting rod must lie in the same plane, the deviation is no more than 0.04 mm over a length of 100 mm.
Table 5. Marking of piston pin hole size groups
- First group, color white, hole diameter - 25.0-0.0025;
- Second group, green color, hole diameter - 25.0-0.0050;
- Third group, yellow color, hole diameter - 25.0-0.0050;
- Fourth group, red color, hole diameter - 25.0-0.0075;
Table 6. Marking of size groups of piston pins of nominal size
- First group, white color, piston pin diameter - 25.0-0.0025;
- Second group, color green, piston pin diameter - 25.0-0.0050;
- Third group, yellow color, piston pin diameter - 25.0-0.0050;
- Fourth group, red color, piston pin diameter - 25.0-0.0075 ∕-0.0100
Table 7. Nominal and repair sizes of piston rings
- Nominal diameter of piston rings - 92.00 mm;
- First repair size, increase in diameter by 0.5 mm, piston ring diameter - 92.50 mm;
- Second repair size, diameter increase by 1.0 mm, piston ring diameter - 93.00 mm;
- Third repair size, increase in diameter by 1.5 mm, piston ring diameter - 93.50 mm
Table 8. Marking of the size groups of the hole in the bushing of the upper head of the connecting rod
- First group, marking color white, hole diameter - 25.0+0.0070 +0.0045 mm;
- Second group, marking color green, hole diameter - 25.0+0.0045 mm;
- Third group, marking color yellow, hole diameter - 25.0+0.0020 -0.0005 mm;
- Fourth group, marking color red, hole diameter - 25.0-0.0005 -0.0030 mm
The perpendicularity of the end surfaces of the lower head relative to the axis of the hole is no more than 0.05 mm.
For connecting rods supplied for engine assembly, the distance between the axes of the lower and upper heads should be 155.95 - 156.05 mm.
To enable selective assembly of the connecting rod with the piston pin, the connecting rods must be sorted into groups according to the size of the hole in the upper head.
Each group of connecting rods is marked with oil-resistant paint of a certain color. The markings of the connecting rods are given in table. 8.
Crankshaft
Table 9. Nominal and repair dimensions of the main and connecting rod journals of the crankshaft
- Nominal size, diameter of main journals - 70.00-0.013 mm, diameter of connecting rod journals - 60.00-0.013 mm;
- First repair, diameter reduction by 0.25 mm, main journal diameter - 69.75-0.020 mm, connecting rod journal diameter - 59.75-0.013 mm;
- Second repair, diameter reduction by 0.50 mm, main journal diameter - 69.50-0.020 mm, connecting rod journal diameter - 59.50-0.013 mm;
- Third repair, diameter reduction by 0.75 mm, main journal diameter - 69.25-0.020 mm, connecting rod journal diameter - 59.25-0.013 mm;
- Fourth repair, diameter reduction by 1.00 mm, main journal diameter - 69.00-0.020 mm, connecting rod journal diameter - 59.00-0.013 mm;
- Fifth repair, diameter reduction by 1.25 mm, main journal diameter - 68.75-0.020 mm, connecting rod journal diameter - 58.75-0.013 mm;
- Sixth repair, diameter reduction by 1.50 mm, main journal diameter - 68.50-0.020 mm, connecting rod journal diameter - 58.50-0.013 mm;
For crankshafts coming for assembly, oil channels and dirt traps must be thoroughly cleaned of sludge.
Conrod and main journals must be nominal or one of the repair sizes indicated in table. 9.
When grinding crankpins, the crank radius must be maintained at nominal.
For necks of the same name, different repair sizes are not allowed.
Ovality and taper of the crankshaft journals should not exceed 0.01 mm.
The surface cleanliness of the necks must correspond to class 9.
The length of the anterior molar neck should be in the range of 30.45–30.90 mm. The length of the connecting rod journal is 52.0–52.2 mm.
The radii of the connecting rod journal fillets should be within 1.2-2.0 mm, the main ones - 1.2-2.5 mm.
When rotating a shaft installed in prisms on the outer main journals, the runout should not exceed:
- - for medium journals - 0.02 mm;
- - for the journal for the timing gear - 0.03 mm;
- - > fan pulley hub - 0.04 mm;
- - > > rear oil seal - 0.04mm;
- - flange end - 0.04 mm.
Axis non-parallelism connecting rod and main journals - no more than 0.012 mm along the length of each journal.
Main and connecting rod bearings
Table 10. Nominal and repair dimensions of main and connecting rod bearing shells
- Nominal size, thickness of main bearings - 2.250 -0.013 mm, thickness of connecting rod bearings - 1.750 -0.013 mm;
- First repair size, reduction in the inner diameter of the liner - 0.25 mm, thickness of the main bearings - 2.375 -0.013 mm, thickness of the connecting rod bearings - 1.875 -0.015 mm;
- Second repair size, reduction in the inner diameter of the liner - 0.50 mm, thickness of the main bearings - 2.500 -0.013 mm, thickness of the connecting rod bearings - 2.000 -0.015 mm;
- Third repair size, reduction in the inner diameter of the liner - 0.75 mm, thickness of the main bearings - 2.625 -0.013 mm, thickness of the connecting rod bearings - 2.125 -0.015 mm;
- The fourth repair size, reduction in the inner diameter of the liner - 1.00 mm, thickness of the main bearings - 2.750 -0.013 mm, thickness of the connecting rod bearings - 2.250 -0.015 mm;
- Fifth repair size, reduction in the inner diameter of the liner - 1.25 mm, thickness of the main bearings - 2.875 -0.013 mm, thickness of the connecting rod bearings - 2.375 -0.015 mm;
- Sixth repair size, reduction in the inner diameter of the liner - 1.50 mm, thickness of the main bearings - 3.000 -0.013 mm, thickness of the connecting rod bearings - 2.500 -0.015 mm;
Thin-walled crankshaft bearing shells must be completely interchangeable and provide, without selection, the fits in the bearing matings necessary for normal engine operation.
The presence of cracks and chipping of the antifriction layer from the steel tape at the connecting rod and main bearings is not allowed.
Kinks and scratches on the working surface are not allowed.
On the back side of the liner, scratches with a depth of no more than 0.1 mm and no more than three are allowed.
Sharp edges and burrs at the joints of the liner must be cleaned.
Kinks, scratches and corrosion on the joint planes of the liners are not allowed. Cleaning the joints to remove these defects is not allowed.
The locking protrusion of the liner must not be damaged.
Repair of liners by refilling the antifriction layer is not allowed.
The nominal and repair dimensions of the liners are given in table. 10.
Flywheel
The working surface of the flywheel must be smooth, its cleanliness after processing must correspond to class 9.
The flywheel must be statically balanced. The amount of permissible imbalance should not exceed 35 gcm.
When balancing, drill a hole with a diameter of 11 mm at a radius of 156 mm to a depth of 18 mm.
The maximum runout of the working surface should not exceed 0.1 mm.
The dimensions of the holes for the flywheel mounting bolts should not exceed 12.30 mm.
Camshaft
The camshaft bearing journals must be nominal or one of the repair sizes given in table. 11.
Ovality and taper of the support journals - no more than 0.010 mm, Mutual runout of the support journals and the journal for the gear - no more than 0.020 mm.
Runout of the cylindrical part of the cams relative to the journals is no more than 0.05 mm.
The surface finish of the support journals must correspond to class 9-b.
When installing the shaft on the outer support journals, the runout of the intermediate journals should not exceed 0.05 mm.
Pushers
The outer diameter of the pushers must be nominal or one of the repair sizes given in table. 12.
Ovality, taper and cutting of the outer surface of the pusher - no more than 0.007 mm.
Hardness of the outer spherical surface RC—60.
Cracks, scratches, rough spots and burns are not allowed on the surface of the pusher.
Cylinder head
The cylinder head arriving for assembly must be thoroughly washed, the cooling jacket must be cleaned of scale and dirt, the oil channels must be cleared of sludge, and the exhaust channels must be cleared of carbon deposits.
Valve guides pressed into the block head must be of nominal or one of the repair sizes and marked with paint.
The dimensions of the bushings and their markings are indicated in the table. 13.
The distance from the upper end of the guide sleeve to the plane of the head should be 24 mm.
Intake and exhaust valve seats must be ground at 45° to the axis of the guide bushings.
The width of the working chamfer of the seat should be 1.5 ± 2.0 mm.
The runout of the conical surfaces of all valve seats relative to the axes of the valve guide holes is no more than 0.025 mm.
Valve guides pressed into the cylinder head along the outer diameter can be of nominal size or repair size (increased by 0.25 mm).
Intake and exhaust valves
The diameters of the valve stems must be nominal or one from the repair dimensions given in table. 14.
The working chamfer of the valve head must be ground at an angle of 45° to the axis of the stem.
The cleanliness of the working surface of the chamfer after grinding must correspond to class 8.
Runout of the working surface of the chamfer relative to the valve stem is no more than 0.03 mm.
Intake pipe
At the inlet pipe entering the assembly, the cooling jacket must be cleaned of dirt and scale, and the inlet channels must be free of carbon deposits.
The surfaces of the connector with the cylinder heads must be flat - deviation within 0.1 mm no more.
The pipe must be tested with water under pressure of 3 - 4 kg/cm 2.
Table 11. Nominal and repair dimensions of the camshaft journals
- Nominal size, diameter of support journals - 50.00-0.017 mm;
- First repair, diameter reduction by 0.25 mm, diameter of support journals - 49.75-0.017 mm;
- Second repair, diameter reduction by 0.50 mm, diameter of support journals - 49.50-0.017 mm
Table 12. Nominal and repair dimensions of the pusher
Nominal size:
- - First group, marking color yellow, pusher diameter - 25.0 -0.015 mm;
- - Second group, marking color blue, pusher diameter - 25.0-0.008 mm
First repair, increasing the diameter of the pusher by 0.10 mm:
- - First group, marking color is white, pusher diameter - 25.1 -0.015 mm;
- - Second group, marking color green, pusher diameter - 25.1-0.008 mm
Second repair, increasing the diameter of the pusher by 0.20 mm
- - First group, marking color black, pusher diameter - 25.2-0.015 mm;
- - Second group, marking color red, pusher diameter - 25.2-0.008 mm
Table 13. Nominal and repair dimensions of the valve guide
- Nominal size, marking - yellow, inner diameter of valve guide - 9.00 +0.022 mm;
- First repair, reduction in diameter by 0.20 mm, marking - white, internal diameter of the valve guide - 8.80+0.022 mm;
- Second repair, increase in diameter by 0.20 mm, marking - green, internal diameter of the valve guide - 9.20+0.022 mm;
Table 14. Nominal and repair dimensions of valve stems
- Nominal size, marking - yellow, inlet rod diameter - 9.0 -0.050 mm, outlet rod diameter - 9.0-0.075 mm;
- First repair, diameter reduction by 0.20 mm, marking - white, inlet rod diameter - 8.8-0.050 mm, outlet rod diameter - 8.8-0.075 mm;
- Second repair, increase in diameter by 0.20 mm, marking - green, inlet rod diameter - 9.2-0.050 mm, outlet rod diameter - 9.2-0.075 mm