Before disassembly, thoroughly clean the engine of dirt and oil
Disassemble and assemble the engine on a turntable using tool kits, for example, models 2216-B and 2216-M GARO, as well as special tools and accessories
In case of an individual engine repair method, install parts suitable for further work in their original places where they have run in.
To ensure this, when removing pistons, piston rings, connecting rods, piston pins, liners, valves, rods, rocker arms and pushers, mark them in any way that does not cause damage (punching, writing, paint, attaching tags, etc.).
For any type of repair, it is impossible to dismantle the connecting rod caps with connecting rods, rearrange the clutch housing and main bearing caps from one engine to another, or interchange the middle main bearing caps in one block, since these parts are machined 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, attach the indicator stand 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 resinous deposits.
Remove carbon deposits from pistons, intake valves and combustion chambers mechanically or chemically.
The chemical method of removing carbon deposits consists in 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 composition of the solution (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 composition of the solution (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 the parts, rinse with hot (80-90°C) water and blow with compressed air. Do not wash parts made of aluminum and zinc alloys in solutions containing alkali (NaOH).
When assembling the engine, observe the following:
- 1. Wipe and blow the parts with compressed air, and lubricate all friction surfaces with engine oil.
- 2. Threaded parts (studs, plugs, fittings), if they were screwed out or replaced during the repair process, install on the red lead.
- 3. Install permanent connections (for example, a cylinder block plug) on nitro varnish.
- 4. Tighten bolts and nuts with a torque wrench, tightening torque, Nm (kgf m):
Cylinder head stud nuts.....71.6–76.5(7.3–7.8)
Connecting rod bolt nuts.....66.7–73.5 (6.8–7.5)
Crankshaft main bearing cap nuts.....122.6–133.4 (12.5–13.6)
Nuts for bolts securing the flywheel to the crankshaft ..... 74.5–81.4 (7.6–8.3)