Stand- for disassembly and assembly of the engine.
bracket - for mounting the engine on the stand.
Key- for fastening the nuts of the intake and exhaust manifolds. The tightening torque of the nuts is 25 Nm. Unscrewing the nuts is shown in the figure.
Retainer- to keep the flywheel from turning. When loosening or tightening the crankshaft ratchet, clutch mounting bolts or flywheel, it is necessary to install a retainer in the hole of the block to secure the flywheel from turning.
Key- for unscrewing and wrapping the central bolt of the crankshaft and turning the crankshaft of the engine when adjusting the valves.
Puller- to remove the front bearing of the input shaft of the gearbox.
Keys- for unscrewing and wrapping studs.
With a key (A) hairpin (1) clamped in the hub (2) eccentric (3). in key (B) hairpin (1) clamped in the nut (2) bolt (3). The diameter and thread pitch of the key must match the stud.
bushing kit - for installing pistons complete with piston rings and connecting rods in the cylinders of the engine block. When installing the pistons, a sleeve is selected that matches the size of the piston. The surfaces of the cylinders and pistons must be lubricated with engine oil before installation.
mandrels- for pressing the plugs of the crankshaft and cylinder block. The dismantling of the plugs is carried out with a core and is performed during the overhaul of the engine in order to qualitatively clean the cylinder block cooling jacket from scale and the oil channels of the cylinder block, crankshaft and camshaft from resinous deposits on their walls. After pressing the plugs of the oil channels, it is necessary to caulk them with a core at several points.
Ring Gauges - to set the caliper to zero when measuring the wear of the engine cylinders.
Nutrometer - to measure the wear of the engine block cylinders. The cylinder diameter is measured in four zones. Two measurements are made in each belt - in the longitudinal and transverse directions of the engine. In the belt area (1) Cylinders practically do not wear out. Therefore, by the difference in measurements in the first and other zones, one can judge the amount of cylinder wear.
A, B. Measurement direction
boring machine- for boring the cylinders of the engine block to the repair size, honing machine - for the final processing of cylinders. Honing is performed first with a set of medium-grained abrasive stones, then fine-grained ones. To achieve the best cleanliness of the working surface of the cylinder, it is adjusted with a fine-grained abrasive paper wound on a honing head. Piston mandrel and support - for pressing out the piston pin. The piston pin is pressed out on a press using a mandrel 2 (A) and supports (4) with a cylindrical recess in which the piston is placed, or with the help of support 2 (B). Before pressing out the pin, the piston rings are removed.
Piston ring sharpener
It is checked with a set of feelers when rings are installed in a gauge having a hole diameter that is equal to the nominal diameter of the ring, with a tolerance of±0,003 mm.
If the gap is insufficient, it is necessary to cut the butt surfaces of the rings on the fixture, and if the gap is increased, replace the rings.
calibrated plastic wire - to check the gap between the liners and the necks of the crankshaft of the engine. The clearance between the liners and the crankshaft journal can be checked by calculation (measuring details). However, it is more convenient to use a calibrated plastic wire to check the gap. In this case, it is necessary to carefully clean the working surfaces of the liners and the corresponding crankshaft journal. Then put a piece of plastic wire on its surface. Install a connecting rod with a cap or a main bearing cap on the crankshaft journal (depending on the type of checked neck) and tighten nuts or bolts. Remove the cover and, by flattening the wire, determine the gap size on the scale printed on the package.
If the gap is within tolerance or less than the limit (0.1 mm for connecting rod and 0.15 mm for main journals), these earbuds can be used again.
With a gap greater than the limit, it is necessary to replace the liners on these necks with new ones. If the crankshaft journals are worn, then it is necessary to grind them to the repair size and, accordingly, replace the liners with repair ones (increased thickness).
A thermostatically controlled electric furnace for heating the upper heads of the connecting rods is necessary to ensure an interference fit in the pin-rod connection. For better heating, the connecting rods are placed with their upper heads inside the furnace. If the connecting rod is placed in a cold oven, the temperature of the oven is adjusted to 240°C. The connecting rods are removed when the temperature reaches this value. If the connecting rods are placed in an oven heated to 240°C, then they are kept at this temperature for 15 minutes.
Devices for pressing the piston pin into the piston and connecting rod
The finger must be prepared in advance for assembly on the fixture. To do this, put on a roller (1) piston pin tool (2) and guide (3), by fixing it with a screw (4).
Tighten the screw loosely to avoid jamming when the piston pin expands from contact with the heated connecting rod. Remove the heated connecting rod from the oven and clamp it in a vise as quickly as possible. Put the piston on it and with the tool push the piston pin into the piston hole and into the upper head of the connecting rod so. so that the shoulder of the tool is in contact with the piston. In this case, the piston should be pressed by the boss against the upper head of the connecting rod in the direction of the pressing shown by the arrow.
Device for checking the strength of the piston pin with a torque wrench
To do this, clamp the base of the fixture in a vice and lower the bracket (8) indicator.
Install the assembled piston with connecting rod on the fixture and insert the threaded rod into the pin hole (3) all the way to his head (2) at the end of the finger. Screw a nut onto the opposite end of the rod (5) so that it is in contact with the support, and possible gaps have been selected. Set stop (6) into the groove of the rod, excluding its rotation. Raise bracket (8) to a horizontal position, secure it with the handle (7) and set the indicator (9), pin (1) which to rest on the head (2) rod. Set the indicator to zero.
With torque wrench (2) attach to nut (1) moment 13 Nm, which corresponds to an axial load of 2 kN. Lower the dynamometer. In this case, the indicator needle should return to zero. In the event that the pin has moved in the connecting rod head, it is necessary to replace the connecting rod.
The device for checking the parallelism of the axes of the piston pin and the lower head of the connecting rod
Connecting rod head (without inserts) must be installed on the fixture and centered with retractable knives (2). Set the caliber on the bottom of the piston (4) and with a set of probes, at a distance of 125 mm from the corner or the upper end of the gauge, determine the gap between the vertical plate of the fixture and the vertical plane of the gauge. The place of measurement depends on whether the gauge of the vertical plate touches the corner or the upper end. A gap of no more than 0.4 mm is allowed. With a larger gap, the connecting rod must be replaced.
Grinding machine and fixture for grinding main and connecting rod journals of the crankshaft
With flange (1) and split sleeve (2) the crankshaft is mounted on a grinding machine. Depending on the wear of the crankshaft journals, they are ground to the required size.
1 flange
2 Split sleeve.
Prisms for checking the geometric parameters of the crankshaft
To do this, it is necessary to install the crankshaft on two prisms and use the indicator to check the runout and misalignment of its necks.
Milling cutter and cutter arbor for processing crankshaft plug sockets
After grinding and subsequent finishing of the journals of the crankshaft of the engine, it is necessary to remove the plugs of the oil channels and process the sockets of the plugs with a cutter (2), put on a mandrel (1). Thoroughly wash the crankshaft and its passages with gasoline and blow with compressed air.
Mandrel for pressing new plugs
After pressing in, the plugs should be minted with a core at several points.
Device for measuring the axial clearance of the crankshaft on an engine installed on a car
Axial movement of the crankshaft is created by depressing and releasing the clutch pedal. The value of the axial clearance is determined by the movement of the front end of the crankshaft. The maximum allowable gap must not exceed 0.35 mm.
Drift for installing the rear oil seal holder (with stuffing box) on the crankshaft
To do this, lubricate the oil seal with engine oil and, avoiding distortion, press it into the holder.
Mounting board - to perform repair work on the cylinder head removed from the engine.
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