Assembling diesel engine D-245
Installing cylinder liners
Cylinder liners and seating surfaces of the cylinder block under the liners should be wiped with a cloth and blown with compressed air.
Install the cylinder liners into the diesel block. The protrusion of the cylinder liner flanges above the block plane when the liner is pressed with a force of 9±0.1 kN should be 0.05-0.11 mm.
For details on installing liners, see the article - "Cylinder liners D-245 installation"
Laying the crankshaft
Before assembly, each crankshaft must be checked using a magnetic or ultrasonic flaw detector for the absence of micro and macrocracks, as well as for compliance of the selected set of main bearing shells with the size of the main journals.
Look at the article in detail - "Crankshaft D-245 installation"
Installing the connecting rod and piston group
Check that the size group of the pistons set matches the size group of the cylinder liners.
Pistons of one set on a diesel engine must be of the same size group, corresponding to the size group of cylinder liners.
The gasket of the distribution board must not have visible damage.
Nuts and other mechanical damage to the treated surfaces of the distribution board are not allowed.
Look at the article in detail - Gas distribution mechanism ZIL-5301
Installing the cylinder head and valve mechanism
We look at installing the cylinder head in the article - Cylinder head installation D-245
Installation of injection pump, injectors, high and low pressure pipes
The injection pump mating plate must be clean; nicks and other damage to the slab are not allowed. The fuel pump gasket must not show any visible damage.
When installing the fuel pump, you must align the marks of the fuel pump drive gear and the splined flange.
The splined flange of the fuel pump gear must fit freely, without jamming, onto the splines of the fuel pump shaft bushing.
The fuel pump gear flange bolts must be tightened to a torque of 18-25 Nm.
Diesel engines must be equipped with injectors of the same group.
The sealing gaskets on the side adjacent to the injectors must be lubricated with grease. The injector mounting bolts must be tightened to a torque of 20-25 Nm.
High pressure pipes must be secured at a distance of 10-15 mm from the union nuts with clamps with gaskets.
Low pressure fuel pipes should be purged with compressed air before installation on a diesel engine.
You can see the article in detail - Installation of fuel injection pump and ZIL-5301 injectors
Installing the oil pump and power steering pump housing
Before installing the oil pump, you need to check the ease of rotation of the gears.
The oil pump guide pins must fit snugly into the holes in the first main bearing cap.
You must place lock washers under the oil pump mounting bolts.
The lateral clearance between the teeth of the oil pump drive gears should be within 0.1-0.65 mm.
The bolts securing the outlet pipe to the oil pump and cylinder block must be tightened to a torque of 15-25 Nm.
The power steering pump housing must be washed and blown with compressed air before installation.
The lateral clearance between the teeth of the hydraulic pump drive gears should be within 0.08-0.2 mm.
The drive housing of the hydraulic pump after installation on a diesel engine must be closed with a cover with a gasket.
The oil pump received for diesel engine assembly must be run-in and tested.
Look at the article in detail - Installation of the oil pump and power steering pump housing D-245
Installing the oil receiver
Before installation, the oil receiver must withstand a hydraulic test with diesel fuel or an air test under pressure of 0.1 ± 0.02 MPa.
Leaks, drips or air infiltration at the junction of the pipe and the flange are not allowed.
Sagging and irregularities after welding must be smoothed out.
Installing the oil sump
Seals must be installed in the grooves of the oil sump support before assembly.
Before installing the oil pan, trim the protruding ends of the gasket between the distribution cover and the plane of the block.
The plane of contact of the oil sump to the block is necessary before installing the gasket o lubricate in three places with UZOM paste GOST 13489-79.
Nags and dents more than 0.1 mm wide on the machined surfaces of the oil sump are not allowed.
Installing the back sheet, cuff housing and crankshaft flywheel
The back sheet should fit tightly on the pins pressed into the cylinder block.
The rear sheet and the interface with the crankcase, as well as the surface of the flywheel and crankshaft flange, must be wiped with a clean cloth.
Paronite gaskets of the back sheet and cuff body must be lubricated with UZOM paste on both sides before installation on the pins.
The mating surfaces of the flywheel and crankshaft flange must not have nicks, burrs or other damage.
The flywheel mounting bolts should be tightened evenly in several steps. The final tightening of the flywheel mounting bolts should be carried out with a torque of 180-200 Nm.
Installing the diesel engine support and crankshaft pulley
The crankshaft pulley should be wiped with a clean cloth. There should be no nicks or burrs on the seating and working surfaces of the crankshaft support and pulley.
The crankshaft pulley mounting bolt must be tightened with a torque of 240-280 Nm.
Installing a centrifugal oil filter (centrifuge)
The mating surfaces of the unit and the centrifuge must not have nicks or other damage.
Mating surfaces must be wiped with a clean cloth before installing the centrifuge.
There should be no tears or irregularities on the centrifuge gasket. The centrifuge mounting bolts must be tightened as far as possible, after installing the sealing gaskets.
Installing the Fluid Pump Assembly and Thermostat
The liquid pump roller should rotate smoothly by hand without jamming the impeller. The liquid pump gasket must not have tears or delaminations.
Before installation on the liquid pump, the gasket must be lubricated on both sides with UZOM paste.
There should be no mechanical damage on the interface between the thermostat housing and the cylinder head.
Before installing the thermostat housing, the mating surface with the cylinder head must be wiped with a clean cloth.
Before installation, the thermostat housing gasket must be lubricated on both sides with UZOM paste.
Before installation on a diesel engine, the liquid pump must be tested on the OR 18003-07 stand.
Installing the alternator, fan and fluid pump drive belt
The grooves of the generator and liquid pump pulleys must be located in the plane of the grooves of the crankshaft pulley with a permissible deviation of ±1.5 mm.
On the mating surfaces of the liquid pump pulley and the fan crosspiece, nicks and burrs are not allowed.
For the procedure for installing the generator and tensioning the belt drive, see the article - Generator ZIL- 5301 dismantling and disassembly
Installing the starter
The mating surfaces of the starter and back sheet must not have nicks or burrs.
Wipe the mating surfaces of the starter and back sheet with a clean cloth. No gap is allowed between the starter surface and the back sheet.
Installing the compressor
The locating pins pressed into the distribution cover must be a tight fit.
The compressor gasket must be smooth, without tears or delamination.
Pre-tightening of the oil line fitting bolt and compressor mounting should be done by no more than 3 threads.