Specifications of the cylinder head Cylinder head without combustion chambers, cast aluminum alloy. When casting, the heads are marked with a part number. Seats and valve guides are pressed into...
Specifications of the cylinder block The cylinder block is sleeveless, cast iron. In the lower part of the cylinder block, there are five supports for the crankshaft main bearing shells. The main...
Technical characteristics of the crank mechanism Crankshaft Crankshaft steel, forged. The shaft is five-bearing. The upper main bearing shells have oil grooves. Axial fixation of the crankshaft is carried out...
Specifications of the lubrication system The engines have a pressure lubrication system. Under vacuum, oil is sucked in from the oil sump through a mesh filter: oil receiver by a gear oil pump and fed...
Specifications of the cooling system The engine uses a liquid cooling system with forced circulation. The cooling system includes an engine water jacket, a radiator, an expansion tank, a...
Technical characteristics of carburetor engines Fuel pump The diaphragm-type mechanical fuel pump is driven by the countershaft eccentric. Brand: Pierburg. Fuel supply pressure at crankshaft speed 2000 rpm,...
Specifications of the non-contact ignition system Since model year 1980, YP, YZ engines, as well as EP, DT, DS and DZ engines have been equipped with a contactless ignition system that includes a distributor...
Design of hydraulic pushers The hydraulic pusher consists of two main moving parts: the pusher itself 2 (see picture), which simultaneously serves as a plunger during operation, and...
The principle of operation of hydraulic pushers Starting valve lift At the moment the camshaft cam hits the valve stem, the check valve closes the chamber and the pressure in it increases. An increase in...
Checking the technical condition of hydraulic pushers The design of the hydraulic pusher is non-separable and cannot be repaired. Start the engine and let it run until the cooling fan is turned on for the first...
Carburetor engines Fuel pump The fuel pump is fastened with two nuts through a heat-insulating gasket and an o-ring. Pump body and cover are one-piece, i.e. the pump cannot be...
Carburetor Zenith 2B2 Features of the device and calibration data of carburetors are given in the subsection « Design and specifications ». The principle of operation of the...
Checking and adjusting the Zenith 2B2 carburetor Checking the fuel level in the float chambers Remove the carburetor cover and turn it over. Measure the distance between the plane of the carburetor cover and...
Checking and adjusting the Pierburg 2B5 carburetor Adjusting the fuel level in the float chambers Remove the carburetor cover and turn it over. Measure the distance between the plane of the carburetor cover and...
Warm engine idle adjustment Engine idle adjustment Engine idle adjustment is made on a warm engine (oil temperature not less than 60°C), with the choke fully open, with the ignition...
Checking and adjusting the Keihin 26-30 DC carburetor Air damper starting gap adjustment Fully pull out the choke control handle; at the same time, the air damper control lever should be at the stop. Press the...
Checking and adjusting the Pierburg 2E2 carburetor Checking the fuel level in the float chamber The position of the float in the float chamber is not adjustable. If a malfunction is detected, check the...
Engines with K-Jetronic fuel injection system Features of the device and the principle of operation of the system «K-Jetronic» Components of the fuel injection system «K-Jetronic»: 1 - mixture regulator...
Checking and adjusting the K-Jetronic system Throttle valve adjustment Note. The throttle valve opening is set at the factory and cannot be changed during operation. However, if the stop screw is...
Vehicles with YZ engine with contact ignition system Adjusting the engine idling speed Connect the tachometer according to the instruction manual. Turn on high beam headlights. Start the engine and bring the...
Vehicles with DZ engine Connect the tachometer according to the instruction manual. Warm up the engine to operating temperature. Pinch the hose going to the idle control valve move....
Checking the performance of the fuel pump Disconnect the drain hose from the supply pressure regulator on the fuel dispenser and lower its end and beaker. Disconnect the high voltage wire from the...
Pressure test To check the pressure, use a VW 1318 manometer with a fitting and a cock that measures both the flow pressure and the inlet pressure. Connect the pressure...
Checking injection nozzles Unscrew the injector from its socket and screw in the spare injector instead. Lower the nozzle into the beaker. Start the engine, let it run at about 2000 rpm,...
Checking the starter injector and thermal time switch Disconnect the block from the starting injector and connect a test lamp to it. Disconnect the high voltage wire from the ignition coil. Turn on starter. On a...
Pilot pressure regulator test Warm up the engine (oil temperature 50-70°С). Disconnect the block from the control pressure regulator and connect a voltmeter to the block. Turn on the...
Idle air control valve check Note. The check is carried out on a warm engine. Disconnect the idle air control valve connector and connect a voltmeter to the connector terminals (see fig.)....
Checking the auxiliary air valve On a cold engine (when the coolant temperature is less than 30°С) Disconnect the block from the auxiliary air supply valve. Disconnect the hose going to the...
K-Jetronic Fuel Injection Circuit Circuit open: 1 - ignition switch; 2 - electromagnetic starting nozzle; 3 - thermal time relay; 4 - relay for turning on the fuel pump; 5 - fuel electric pump;...
Adjustment of gaps between breaker contacts Remove the distributor cap and rotor. Make sure that the contact surfaces are not uneven, strictly parallel and adjacent to each other over the entire surface....
Checking the contactless ignition switch Disconnect the wires from the digital idle stabilizer move (if it is installed) and connect them together. Disconnect the central high voltage wire from the...
Removing the cylinder head Disconnect the wire from the negative battery terminal. Place a container under the engine to collect the coolant and drain the coolant from the cooling system...
Installing the cylinder head Note. Replace the gaskets every time the cylinder head is removed. Install a new cylinder head gasket «oben» («top») towards the plane of the head. Insert...
Disassembly and repair of the cylinder head When disassembling the cylinder head, put marks on the removed parts in order to put them in their original places during assembly. Remove the bearing caps No....
Cylinder head assembly Install the valve spring support washers with pliers 10-218 and insert the valves into the guide bushings, after lightly lubricating the valve stems with...
Removal and installation of carburetor engines Withdrawal Place the engine on a lift and remove the hood. Disconnect the wire from the negative battery terminal. Set the heater control knob to position...
Engine disassembly Note When disassembling, apply the queens on the parts that are suitable for further use, so that during assembly, install them in their original places in the...
Engine Assembly Checking cylinder diameters Accurately measure cylinder diameters. Measurements to be made with a caliper in three belts as in the transverse direction «A»,...
Engine Assembly Lay liners with a groove on the inner surface in the seats of the main bearings (see photo). Lubricate the crankshaft journals with engine oil and place the...
Oil filter replacement Drive the oil filter housing onto the threads using a band or clamp tool. Remove tool and unscrew filter. Lubricate the filter gasket with engine oil. Screw on...
Removal and installation of the oil pump Removing the oil pump The oil pump can be removed directly on the vehicle. Drain the oil from the engine crankcase. Remove oil sump. Loosen the bolts securing...
Checking the oil pressure in the lubrication system Disconnect the wires from the oil pressure sensor, remove the sensor and screw in the control pressure gauge hose fitting instead. Start the engine and let it...
Coolant replacement Place a container under the engine to collect the coolant. Set the heater control knob to the extreme right position. Shine the cap from the radiator 1 or the...
Removal and installation of the water pump Drain the liquid from the cooling system. Disconnect the wire from the negative battery terminal. Remove generator. Disconnect hoses from water pump. Loosen...
Disassembly and assembly of the water pump Remove the pump drive pulley. Loosen the bolts of the pump cover and remove it complete with the bushing, shaft and impeller, disconnect the cover from the...
Alternator Drive Belt Tension Adjustment Loosen the mounting bolts of the bracket and tension bar of the generator. Move the generator away from the cylinder block and tighten the bolt securing the...