- Through apertures in a camshaft gear wheel to attach two bolts with spring washers a persistent flange to the block;

- To establish on a neck of the forward end of a cranked shaft маслоотражатель the convex party to a gear wheel;

Fig. 4.67. Запрессовка cuffs in a cover of distributive gear wheels оправкой

- To check up suitability of a cuff, запрессованной in a cover of distributive gear wheels, to the further work. If the cuff has the worn out working edges or poorly covers a nave of a pulley of the cranked shaft, inserted into a cuff, to replace its new. Запрессовку cuffs in a cover are recommended to be made with the help оправки, as is shown in fig. 4.67;

- To put on hairpins of a lining a cover of distributive gear wheels;

Fig. 4.68. A centering of a cover of distributive gear wheels with the help оправки

— To centre a cover on the forward end of a cranked shaft with the help оправки (fig. 4.68) and to wrap all nuts and bolts of fastening of a cover. If is not present aligning оправки cover installation can be made on a nave of a pulley of a cranked shaft. A nave it is necessary напрессовать on a cranked shaft so that its end entered on depth of 5 mm into a cover aperture. After that to fix a cover nuts, maintaining an identical backlash on a circle between a nave and a cover aperture. Backlash alignment to make easy blows of a wooden or rubber hammer on a cover. After that definitively to fix a cover;

Fig. 4.69. Напрессовка naves of a pulley of a cranked shaft

- To remove aligning оправку and напрессовать a nave of a pulley with a pulley-dempferom of a cranked shaft (fig. 4.69);

- To insert in шпоночный a groove a rubber stopper and запрессовать шпонку;

- To wrap in a sock of a cranked shaft a coupling bolt, preliminary having put on it a gear washer. Turning for a coupling bolt a cranked shaft, to check up, whether touches a pulley-dempfer a cover of distributive gear wheels;

- To establish the oil pump in gathering with маслоприемником;

- To establish a drive of the oil pump and the gauge of the distributor of ignition in a following order:

Fig. 4.6. Definition of the top dead point

• turning a cranked shaft, to combine the third label on a disk демпфера with an edge-index on a cover of distributive gear wheels (see

Fig. 4.70. Position of cams of a camshaft of the first cylinder at installation of a drive of the oil pump and the ignition gauge-distributor: 1 — an inlet cam; 2 — a final cam

Fig. 4.6). The cams of a camshaft putting in action valves of the first cylinder, should be thus directed by tops in the opposite party from pushers (towards oil картера) and are symmetrized (fig. 4.70);

Fig. 4.71. Check of an axial backlash between a gear wheel and the case of a drive of the oil pump and the ignition gauge-distributor

• to check up an axial backlash between the case of a drive and a gear wheel with the help щупа (fig. 4.71). The backlash should be within 0,15—0,40 mm;

• to put on hairpins of fastening of a drive a lining;

Fig. 4.72. Groove position on the plug of the platen of a drive of the oil pump and the ignition gauge-distributor: And — before drive installation on the block; In — after drive installation on the block

• to turn the drive platen in the position shown on fig. 4.72 And, and to put a drive in a block nest. At drive introduction in a nest it is necessary to turn slightly the platen of the oil pump that the end of the platen of a drive has entered into an aperture of a shaft of the pump. The drive should be inserted without considerable efforts. In correctly established drive the cut in the platen plug should be directed in parallel an axis of the engine and is displaced from the engine, as is shown in fig. 4.72 In;

• to fix a drive;

- To check up backlash presence in camshaft and drive gear wheels;

- To grease joints of the bottom flange of the block of cylinders with a cover of distributive gear wheels and the holder of stuffing by glue-hermetic «Elastosil 137-83» or paste УН-25;

- To establish on the bottom flange of the block of cylinders a lining oil картера;

- To establish oil картер on hairpins and to fix its nuts with washers, in regular intervals tightening nuts;

- To establish and tighten bolts the bottom part картера couplings;

- To clear chambers of combustion and channels of a head of cylinders of a deposit and adjournment, to wipe and blow compressed air;

- To grind in valves, using притирочную the paste made of one part of micropowder М-20 and two parts of oil И-20А.

Before the grinding in beginning it is necessary to check up, whether is not present коробления a plate of the valve and a valve and saddle burn-out. In the presence of these defects to restore tightness of the valve one grinding in it is impossible and follows at first прошлифовать a saddle, and the damaged valve to replace new. If the backlash between the valve and the plug exceeds 0,25 mm tightness also cannot be restored. In this case it is necessary to replace the valve and the plug new.

Fig. 4.73. Выпрессовка directing plugs of valves

Valves (in spare parts) are issued the standard size, and directing plugs — with the internal diameter reduced by 0,38 mm (for their expansion under the definitive size after запрессовки in a head of cylinders). Выпрессовка the worn out directing plug it is made with the help оправки (fig. 4.73). Saddles of valves leave milling твердосплавным a vertical drill.

Repair saddles have external diameter on 0,25 mm more than standard, therefore nests for saddles are chiseled till next sizes: for a saddle of the inlet valve — 49,25+0,025 mm, for final — 42,25+0,025 mm. Saddles of valves and directing plugs before assemblage should be cooled in carbon dioxide (dry ice), and a head of cylinders to heat up to temperature 160—175 ° S.Sedla and plugs at assemblage should be inserted into head nests freely or with easy effort.

Fig. 4.74. Facets of saddles of valves: width of a facet

Запрессовка new plugs of inlet and final valves it is made to выступания over a head on 20 mm. After запрессовки to develop an aperture of the plug till the diameter of 9+0,022 mm, and facets of saddles прошлифовать, aligning on an aperture in the plug. At polishing it is necessary to provide концентричность facets on a saddle of the valve with an aperture in the plug within 0,05 mm. Facets grind at an angle 45 °. External diameter (fig. 4.74) facets at a saddle for the inlet valve should be 46,8 mm, and at final — 38,8 mm. The width of a facet «b» should be at a saddle of the inlet valve of 1,8-2,3 mm, at final — 2,3—2,5 mm. The width of a facet is provided расшлифовкой apertures of a saddle of the inlet valve at an angle 30 °, as is shown in fig. 4.74 And, and the final valve — at an angle 15 ° (fig. 4.74 B). The facet should be identical on all perimetre.

After polishing of saddles and grinding in of valves all gas channels carefully to clear and blow compressed air that does not remain to an abrasive dust;

- Cores of valves to cover with a thin layer коллоидного the graphite dissolved in oil, applied to the engine, or to oil;

- On directing plugs of valves напрессовать маслосъемные caps to insert valves into plugs according to the made labels and to collect them with springs. To be convinced that crackers have entered into a ring flute of valves;

Fig. 4.34. Sequence of an inhaling of nuts of fastening of a head of cylinders

- To rub with a graphite powder from both parties a lining of a head of cylinders and to put on it hairpins. To establish a head and to fix its nuts with washers. To tighten nuts динамометрическим a key the moment 83—90 Н·м (8,3—9,0 кгс·м), observing an order specified in fig. 4.34;

- To clean a wire and to blow compressed air of an aperture in коромыслах, in an axis коромысел and adjusting screws, in the fourth basic rack of an axis коромысел and oil channels in a head of cylinders. To check up reliability of landing of plugs коромысел. In case of weak landing in an operating time the plug can be displaced and block an aperture for greasing of a bar of a pusher of the valve. It is necessary to replace such plugs;

- To make подсборку axes коромысел. Before statement of everyone коромысла to grease its plug with engine oil;

- To insert pushers into nests according to labels on them. Pushers and apertures in the block preliminary to grease with engine oil;

- To insert bars in gathering with tips into apertures in a head of cylinders;

- To establish подсобранную an axis коромысел on hairpins and to fix nuts with washers. Adjusting bolts the spherical part should lay down on sphere of the top tip of a bar;

- To establish backlashes between end faces of cores of valves and nouses коромысел. A backlash between коромыслами both the first and eighth valves — 0,35—0,40 mm, a backlash between the others коромыслами and valves — 0,40—0,45 mm. Adjustment to make, as it is specified in subsection «Feature of maintenance service of the engine»;

Fig. 4.35. Sequence of an inhaling of bolts of fastening of a cover коромысел

- To put a lining and a cover коромысел and to fix their bolts with washers, observing an order specified in fig. 4.35;

- To grease and put on a forward cover of a transmission муфту coupling deenergizings in gathering with the bearing;

- To establish and fix a transmission;

- To establish a plug of deenergizing of coupling;

- To establish details and the units of the engine named in subsection «engine Dismantling», observing return sequence.

Dismantling, repair and assemblage of separate knots and engine units

The pump of a cooling liquid.

Pump dismantling is necessary for carrying out in a following order:

- To turn away bolts of fastening of a cover of the pump and to uncover;

Fig. 4.75. Removal крыльчатки the water pump of a cooling liquid

- To remove a stripper крыльчатку (fig. 4.75);

Fig. 4.76. Removal of a nave of a pulley of the pump of a cooling liquid

- To remove a stripper a nave (fig. 4.76);

- To turn out a bearing clamp;

Fig. 4.77. Выпрессовка the bearing with the platen of the pump of a cooling liquid

- выпрессовать from the case the bearing in gathering with the platen (fig. 4.77);

- выпрессовать from the case an epiploon.

Pump assemblage to spend in the following sequence:

Fig. 4.78. Запрессовка an epiploon

- With the help оправки to establish an epiploon, without supposing a warp, in the pump case (fig. 4.78);

Fig. 4.79. Запрессовка the bearing with the platen of the pump of a cooling liquid in the case

- запрессовать the bearing with the platen in gathering in the case so that the nest under a clamp has coincided with an aperture in the pump case (fig. 4.79);

- To wrap a clamp of the bearing and закернить that did not occur самоотворачивание a clamp;

Fig. 4.80. Напрессовка naves of a pulley of the pump of a cooling liquid on a shaft

- напрессовать on the platen of the bearing a nave of a pulley of the pump, having sustained the size (117,5±0,2) mm (fig. 4.80);

Fig. 4.81. Напрессовка крыльчатки the pump of a cooling liquid

- напрессовать крыльчатку on the bearing platen заподлицо with the pump case. To act крыльчатка because of a case plane should no more, than on 0,2 mm (fig. 4.81);

- To establish on the case a lining and to tighten bolts a cover.

At напрессовке naves and крыльчатки it is necessary to unload the case, a clamp and the bearing of the pump from efforts запрессовки, i.e. The emphasis at напрессовке should be on a platen end face.

Before assemblage to clear and wash out pump details, to remove adjournment with крыльчатки cases and covers. To check up size of axial moving of an external holder of the bearing concerning the platen which should not exceed 0,13 mm at loading 50 Н (5 кгс).

The pump bearing is filled by greasing on manufacturer and at repair of the pump of greasing does not demand.

The oil pump.

Pump dismantling to spend in a following order:

- To turn away four bolts, to remove a reception branch pipe with a grid, a branch pipe lining, a pump cover, a cover lining;

- To take out from the case a conducted gear wheel and the platen with a leading gear wheel in gathering. The leading gear wheel (as the spare part) arrives in gathering with the platen that appreciably facilitates pump repair;

- To take out a spring and плунжер редукционного the valve from the pump case, preliminary having removed шплинт;

- To wash out details and to blow compressed air.

Pump assemblage to spend in a following order:

- To insert into the case the platen in gathering with a leading gear wheel and to check up ease of its rotation;

— To put in the case a conducted gear wheel and to check up ease of rotation of both gear wheels;

- To put on the case a lining from a cardboard in the thickness of 0,3 mm. Application of a varnish, a paint and others герметизирующих substances at lining installation, and also installation of thicker lining is not supposed, as it conducts to the pressure decrease, developed by the pump;

- To put a cover, паронитовую a lining, a reception branch pipe with a grid and to tighten to the case bolts with spring washers. If on a cover plane there is a considerable development from gear wheels it is necessary прошлифовать it before removal of traces of development;

- To insert плунжер and a spring редукционного the valve into an aperture in the case and to fix шплинтом with a washer;

- To check up the pressure developed by the pump. Pressure is checked at certain resistance on an exit. For this purpose on special installation the jet in diameter joins a target branch pipe of the pump of 1,5 mm and length 5 mm. The pump with a reception branch pipe and a grid should be in the tank which has been filled in with a mix, consisting of 90 % of kerosene and 10 % of oil М-8В or М-53/10Г1. Mix level in a tank should be on 20—30 mm below a plane of a socket of the case and a cover of the oil pump. The pump is resulted in rotation from the electromotor. At frequency of rotation of a shaft of the pump of 250 mines^{-1 the} pressure developed by the pump, should be not less than 100 кПа (1 kgs/sm ²), and at 725 mines^-1 — from 360 to 500 кПа (from 3,6 to 5 kgs/sm ²). At smaller pressure of oil reduction of a thickness of a lining between the case and a cover is supposed. A drive of the oil pump and the ignition gauge-distributor. In spare parts the drive in gathering and separately шестигранный the platen of a drive of the oil pump arrives. Therefore to assort a drive follows only at deterioration шестигранного the platen or insignificant deterioration of the case (a backlash between the case and a gear wheel — 0,5 1,0 mm). At deterioration of a gear wheel, the platen of a drive or considerable deterioration of the case a drive to replace.

Fig. 4.82. Removal of a gear wheel of a drive of the oil pump and the gauge-distributor

Fig. 4.83. Напрессовка gear wheels on the platen

Drive dismantling to carry out in a following order:

- выпрессовать a pin of a gear wheel of a drive with the help a small beard and to remove шестигранный the platen of a drive of the oil pump;

- To press a gear wheel. For this purpose to establish the drive case the top end face on a support with an aperture, than the platen easy access to gathering with the persistent plug is provided. Effort выпрессовки to apply on the platen end through оправку 012,5 mm (fig. 4.80).

Drive assemblage to carry out in a following order:

- To insert into the case the platen in gathering with the plug, having greased with its engine oil;

- If necessary to put on the platen a persistent washer. The thickness of a washer should be picked up so that after напрессовки gear wheels between a washer and a gear wheel there was a backlash of 0,15-0,40 mm;

- напрессовать a gear wheel on the platen before aperture coincidence under a pin in a gear wheel and the platen (fig. 4.81);

— To insert in шестигранное an aperture the platen of a drive of the oil pump;

- запрессовать in an aperture a pin in diameter of 3,5-0,08 mm and length 22 mm, расклепав it from both parties;

- To check up a hand platen rotation, a backlash between the case and a gear wheel (between a persistent washer and a gear wheel) and radial moving of the free end шестигранного the platen of a drive of the oil pump. Radial moving should be not less than 1 mm in any direction.

Power supply system repair

Fuel tank.

Fig. 4.23. A bulk mouth of a fuel tank: 1 — a hose of a bulk pipe; 2 — a collar; 3 — an arm; 4 — a stopper of a bulk pipe; 5 and 6 — linings; 7 — an arm of fastening of a tank to a frame

In case of infringement of tightness of its fuel tank it is necessary to remove from the car. For this purpose it is necessary to weaken nuts of fastening of a plate of a loop лючка a bulk pipe and to take out an arm 3 (fig. 4.23 see), to remove лючок a body floor (over a fuel tank) and to disconnect fuel hoses from топливозаборника, to remove the wires going to the gauge of the index of level of fuel and to isolate them, to disconnect from arms coupling tapes (preliminary having put under a tank an emphasis) and to remove a tank.