Before disassembling, thoroughly clean the engine of dirt and oil
Disassemble and assemble the engine on a rotary stand using tool kits, for example, models 2216-B and 2216-MGARO, as well as special tools and accessories
When using an individual engine repair method, install parts that are suitable for further work in the original places where they were worn in.
To ensure this, mark pistons, piston rings, connecting rods, piston pins, liners, valves, rods, rocker arms and pushers when removing them in any way that does not cause damage (punching, writing, paint, attaching tags, etc.).
For any type of repair, you should not remove the connecting rod caps from the connecting rods, move the clutch housing and main bearing caps from one engine to another, or swap the middle main bearing caps in the same block, since these parts are processed together.
When replacing the clutch housing, check the alignment of the hole used to center the gearbox with the axis of the crankshaft, as well as the perpendicularity of the rear end of the clutch housing relative to the axis of the crankshaft.
When checking, secure the indicator post to the crankshaft flange. The clutch must be removed.
The runout of the hole and the end of the crankcase should not exceed 0.08 mm.
After disassembling the engine, thoroughly degrease the parts, clean them of soot and tar deposits.
Remove carbon deposits from pistons, intake valves and combustion chambers mechanically or chemically.
The chemical method of removing carbon deposits involves keeping the parts in a bath with a solution heated to 80–95°C for 2–3 hours.
To clean aluminum parts, use the following solution composition (in g per 1 liter of water):
Soda ash (Na2CO3) - 18.5
Laundry or green soap - 10
Liquid glass (Na2SiO3) - 8.5
To clean steel parts, use the following solution composition (in g per 1 liter of water):
Caustic soda (NaOH) - 25
Soda ash (Na2CO3) - 33
Laundry or green soap - 3.5
Liquid glass (Na2SiO3) - 1.5
After cleaning, rinse the parts with hot (80–90°C) water and blow with compressed air.
Do not wash aluminum and zinc alloy parts in solutions containing alkali (NaOH).
When assembling the engine, observe the following:
- 1. Wipe and blow out the parts with compressed air, and lubricate all rubbing surfaces with engine oil.
- 2. Threaded parts (studs, plugs, fittings), if they were removed or replaced during the repair process, install on red lead.
- 3. Install permanent connections (for example, a cylinder block plug) using nitro varnish.
- 4. Tighten the bolts and nuts with a torque wrench, tightening torque, Nm (kgf m):
Cylinder head stud nuts - 71.6–76.5(7.3–7.8)
Conrod bolt nuts - .66.7–73.5 (6.8–7.5)
Nuts of the studs securing the crankshaft main bearing caps - 122.6–133.4 (12.5–13.6)
Nuts of bolts securing the flywheel to the crankshaft - 74.5–81.4 (7.6–8.3)