Withdrawal
1. Remove the toothed belt, cylinder head cover, flywheel, cylinder head and oil pan.
2. Remove the rear cover from the cylinder block and the crankshaft rear O-ring.
3. Turn away nuts and remove covers of rods.
4. Turn out bolts, remove covers of radical bearings of a cranked shaft and get a cranked shaft.
5. Remove a gear rotor of the gauge of an angle of rotation of a cranked shaft.
Attention! Mark the crankshaft main bearing caps in order to install them in their places and in the same position.
Examination
1. Check the crankshaft main and connecting rod bearing journals for wear and wear. Check crankshaft oil holes for blockage.
2. With a micrometer, measure the diameters of the crankshaft journals in two diametrically opposite directions. In the presence of development or ovality, regrind the crankshaft. Regrinding the crankshaft journals only to the next repair size.
- The diameter of the crankshaft journals, 50 mm
- The diameter of the connecting rod journals of the crankshaft, 45 mm
- Ovality and taper of crankshaft journals, no more than 0.005 mm
Inserts of main and connecting rod bearings
Check the connecting rod and main bearings for localized corrosion, flaking, melting, wear, or other damage. If necessary, replace the liners.
Measuring the clearance between bearing shells and crankshaft journals
1. Measure the diameter of the main and connecting rod journals of the crankshaft.
2. Measure the bore diameter of the main and connecting rod bearings.
3. Measure the thickness of the main and connecting rod bearing shells.
4. Determine the clearance between the liners and the crankshaft journals by subtracting the sum of the diameters of the main and connecting rod journals and the thickness of the liners from the diameter of the shaft bearing holes.
- Gap between liners and connecting rod journals, 0.018–0.036 mm
- The gap between the liners and the main journals No. 1,2,4, 5 of the crankshaft, 0.018–0.036 mm
- The gap between the liners and the main neck No. 3 of the crankshaft, 0.028–0.046 mm
Oil seal rings
Check the front and rear oil seals for damage or wear on the sealing lips. If there are any defects, replace the O-ring.
Crank angle sensor rotor
1. Remove the crank angle sensor rotor.
2. Check the crank angle sensor rotor for damage, cracks and wear and replace if necessary.
3. Check the clearance between the crank angle sensor rotor and the crank angle sensor.
Gap between crank angle sensor rotor and crank angle sensor: 0.5 - 1.1 mm
Note.
- 1. Measure the installation depth of the sensor, i.e. the distance from the top of the rotor teeth of the crank angle sensor to the surface of the cylinder block mating with the plane of the gearbox.
- 2. Calculate the difference between the length of the crank angle sensor and the distance obtained.
- 3. The length of the sensor is equal to the distance between the end of the sensor and the inner point of the contact surface.
Selection of main bearing shells
1. Check the hole size code for the crankshaft main bearing shell in the cylinder block.
Note.
- Write down the letter code for the hole size for the crankshaft main bearing shell in the cylinder block.
- The reading order is from left to right, with the first code corresponding to the size of the front hole in the cylinder block.
2. Check the crankshaft main bearing journal size code.
Note.
- Write down the letter code for the size of the crankshaft main bearing journal located on the crankshaft counterweight.
- The reading order is from left to right, with the first code corresponding to the size of the crankshaft front main journal.
Diameters of crankshaft journals
3. According to the table, select the thickness of the main bearing shells.
Installation
1. Install the upper main bearing shells to the engine block. When reinstalling the earbuds, install them in the same places they were before removal.
2. Before installing the crankshaft, apply a thin film of clean engine oil to all sliding surfaces. Install the crankshaft onto the main bearing shells in the cylinder block.
3. Install the remaining main bearing shells into the crankshaft main bearing caps. Install the crankshaft main bearing caps as marked, with the arrow on each cap pointing towards the crankshaft pulley. In a certain sequence, in 2 or 3 stages, tighten the crankshaft main bearing cap bolts in the following order: center, No. 2, No. 4, front and rear.
Torque:
- Bolts of fastening of covers of radical bearings: 55–60 Nm
- Connecting rod cap bolts: 32–35 Nm
4. Turn the crankshaft and check that it rotates easily and smoothly. Using a feeler gauge inserted between the thrust shoulder of the central bearing and the crankshaft, check the end play of the crankshaft.
Axial play of the crankshaft: 0.005–0.175 mm
5. Lubricate the outside of the new rear O-ring with engine oil. Using the special tool 09231-22000, install the o-ring until it stops in the rear cover slot.
6. Install the back cover of the unit and tighten the bolts.
7. Install the connecting rod caps.
8. Install the flywheel, front cover, oil pan and toothed belt.