| 1. Cнимите from a rod of the first cylinder a bearing cover (being guided on the labels put at dismantling). Remove old loose leaves of the shatunny bearing and wipe landing surfaces of loose leaves in a core of a rod and in a cover a pure fabric not leaving pile. These surfaces should be always absolutely pure. |
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2. Wipe a back surface of the top shatunny loose leaf and lay it in a place in a rod. Be convinced that the ledge on the loose leaf came into sample in a rod and lubricant openings coincided. |
| 3. At installation of the loose leaf is inadmissible to use a hammer, it is necessary to observe extreme care not to damage a working surface of the loose leaf. At this stage greasing of the loose leaf is not required. |
| 4. Wipe a back surface of the bottom loose leaf and enclose it in a rod cover. Be again convinced that the ledge on the loose leaf coincides with sample on a rod cover, the loose leaf do not grease. It is very important, that interfaced surfaces of the loose leaf and a rod in the course of assembly were absolutely pure, without oil traces. |
| 5. Place joints of piston rings according to fig. Arrangement of joints of piston rings for engines of 1,3 l, fig. Arrangement of joints of piston rings for l engines 1,6 and 1,8. |
| 6. Put on bolts of covers of rods pieces of rubber hoses that will protect a cylinder surface from damage. |
| 7. Grease pistons and rings with pure oil for the engine, dress on the piston an opravka for an obzhatiya of rings. The length of a site of a skirt of the piston acting from the adaptation should be about 6,0 mm to provide the correct entrance of the piston in the cylinder. Rings should be aflush with a piston surface. |
| 8. Turn a cranked shaft to the bottom dead point in the first cylinder, oil cylinder walls for the engine. |
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9. Turn the piston with a rod so that labels (1) on a rod and (2) on the bottom of the piston were turned towards a forward part of the engine, carefully enter the piston with a rod into the first cylinder against the stop adaptations for an obzhatiya of rings in the block of cylinders. |
| 10. Slightly knock on the upper edge of an opravka to provide uniform contact to the plane of the block of cylinders on all circle. |
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11. Carefully knock with the wooden handle of a hammer on the piston bottom, directing a rod on the corresponding neck of a cranked shaft. Piston rings can jump out of an opravka directly ahead of entry into the cylinder therefore, the opravka always should nestle on the block of cylinders. |
| 12. Carry out this operation carefully, immediately stop a piston vtalkivaniye at feeling of any resistance at an entrance in the cylinder. Define the reason of jamming of the piston and eliminate it then continue piston installation in the cylinder. |
Prevention
It is not allowed to make effort at piston installation in the cylinder, irrespective of the reason caused resistance to piston occurrence. Otherwise it is possible to break rings or the piston.
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| 13. After piston installation in the cylinder it is necessary to measure a gap between shatunny bearings and a shaft neck, and only after that to finalize a rod cover. |
| Check of gaps in shatunny bearings |
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14. Prepare a piece of the calibration plastic wire, which length a little less than a width of the shatunny bearing, and put it on a shatunny neck (it is specified by an arrow) first cylinder parallel to a crankshaft axis. |
| 15. Clear a surface of a cover of the rod, adjacent to the loose leaf, remove hoses from bolts of fastening of covers and establish a cover. Be convinced that labels of mutual orientation on a cover and on a rod are on the one hand. Be convinced that the forward label on a cover is directed towards a gear belt. |
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16. Slightly grease internal surfaces of nuts, wrap nuts and tighten them with the set moment. Tighten nuts a face head with the picked-up external diameter that will allow to avoid the wrong indication of the moment of an inhaling in case of a head zadevaniye for a cover of the shatunny bearing. |
| 17. If the head starts to touch a cover, raise a head so that to provide its free turn. Crankshaft rotation at an inhaling of nuts is not allowed. |
Prevention
On l engines 1,6 and 1,8 after an inhaling of nuts tighten them on 90 °.
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| 18. Unscrew nuts and carefully remove covers, without having damaged plastic calibre. |
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19. Compare thickness of the crushed calibration wire to value put on on packing of calibre and define size of a lubricant gap (a scale проградуирована in millimeters and in inches). Compare the received value to the standard. |
| 20. If the gap does not correspond established, the wrong selection of shatunny bearings (in this case pick up loose leaves of bearings) can be the reason. Before coming to a determination about need of replacement of loose leaves be convinced that at measurement of a gap there were no pollution or oil between bearings and surfaces of rods and shatunny covers. Check also diameter of shatunny necks. If the width of the crushed calibration wire on the ends strongly differs, the radical neck of the crankshaft has a konusnost (see subsection 3.1.2.13). |
| Final installation of rods |
| 21. Carefully remove the remains of a calibration material from shatunny necks of the crankshaft and / or with in surfaces of shatunny bearings. Do not allow damage of surfaces of shatunny bearings, scratch out a forefinger or plastic edge. |
| 22. Be convinced of full purity of working surfaces of shatunny bearings, put on bearing loose leaves a thin homogeneous layer of konsistentny greasing with a molybdenum or oil disulfide for engine assembly. For access to a surface of the top shatunny loose leaf it is necessary to push the piston into the cylinder, previously having dressed on cover bolts pieces of hoses. |
| 23. Draw a rod to a neck of a cranked shaft, remove hoses from bolts of covers, establish covers and tighten nuts with the moment specified in subsection 3.1.2.1. |
| 24. Repeat the described procedure for pistons and rods of other cylinders. In the course of assembly watch purity of interfaced surfaces of a rod and external surfaces of shatunny loose leaves. Watch that each piston assembled with a rod corresponded to this cylinder. At piston installation dredging or an arrow should be turned into the cylinder towards a forward part of the engine. Grease the cylinder with fresh oil. After measurement of a gap grease working surfaces of shatunny bearings. |
| 25. After final installation of pistons with rods, check freedom of rotation of the crankshaft, having turned it on some turns by hand. |
| 26. At the last stage of assembly it is necessary to check axial люфт a rod. Procedure of check is described in subsection 3.1.2.9. |
| 27. Compare size axial люфта to value specified вподразделе 3.1.2.1. If axial люфт corresponded to norm before engine dismantling, and in the course of repair the former crankshaft and rods are established, after repair axial люфт also should be within norm. If new rods and the crankshaft are established, люфт can not correspond to norm. In this case it is necessary to remove and hand over rods in a car-care center workshop for polishing. |