Connecting rods
1. Check up an axial backlash between the piston and a rod. Using a feeler gauge, measure the end play by moving the connecting rod forward/back. If the axial clearance of the connecting rod exceeds the standard value, it is necessary to replace it with a new one. If, after installing a new connecting rod, the axial clearance exceeds the standard value, the crankshaft assembly must be replaced.
Note: Standard clearance: 0.05 - 0.31 mm.
2. Measure the clearance in the connecting rod bearings.
Put alignment marks on the connecting rod and connecting rod cap for proper installation.
Loosen the two connecting rod cap bolts.
Remove the connecting rod cap together with the lower bearing shell.
Clean and wash the bearing and connecting rod journal of the crankshaft.
Place a special plastic gauge on the crankpin along the axis of the crankshaft.
Install the connecting rod cover and tighten the mounting bolts to a torque of 27.5 - 31.4 Nm.
Attention. Do not turn the crankshaft.
Remove the two mounting bolts and remove the connecting rod cover.
Measure the thickness of the plastic gauge (scale attached to the kit).
Note: Standard clearance in: bearings: 0.024 -0.052 mm.
If the plastic gauge is too wide or too thin after removal, remove the top bushing and install a new one. Then repeat the bearing clearance measurement. It is necessary to select the insert according to the color of the marking (see table below).
Attention. Do not insert a washer or scratch the surface of the clearance adjustment bushing.
If the bearing clearance is still too large or too small, install the next bushing and repeat the measurement.
Note: If it is not possible to adjust the clearance in the bearings by selecting liners, it is necessary to replace the crankshaft assembly and repeat the adjustment.
Attention. If the identification mark is not visible on the insert due to soot, it must be washed in a solvent. Do not clean the insert with a scraper or wire brush.
3. The location of the connecting rod identification mark is shown below.
Connecting rod dimensions
4. Location of the crankshaft identification mark.
Crankshaft Dimensions
5. Location of identification marks on the connecting rod bearing shell
Insert dimensions
Insert selection
6. Check the technical condition of the connecting rods:
During reinstallation, make sure that the numbers of the cylinders that were marked on the connecting rod and the cover during disassembly match. When installing a new connecting rod, make sure that the grooves to hold the bearing in place are on the same side.
If the connecting rod bearing surfaces at either end are damaged, replace the connecting rod. In addition, replacement of the connecting rod is required in case of wear of the steps or severe roughness of the surface of the inner diameter of the small head.
Using a special tool, check the connecting rod for deflection and twisting. If the measured value is close to the repair limit, restore the proper condition of the connecting rod using a press. Any severely bent or deformed connecting rod must be replaced.
Note:
- Permissible deflection of the connecting rod: no more than 0.05 mm / 100 mm.
- Permissible twisting of the connecting rod: no more than 0.1 mm / 100 mm.
Crankshaft
1. Measure the clearance in the crankshaft bearings. For this:
Turn away bolts of fastening and remove covers of radical support together with loose leaves of bearings.
Clean all main bearings and bearing shells.
Lay a special plastic gauge on each crankshaft main journal.
Install all main bearing covers and tighten the mounting bolts to 49.0 Nm.
Attention. Do not turn the crankshaft.
Remove the cover and bearing again, measure the thickness of the plastic gauge (scale attached to the kit).
Note: Standard value: 0.026 - 0.044 mm.
If the measurement value is too large or small, remove the upper and lower bearing shells, install new ones, select the bearing according to the color of the mark, recheck the clearance.
Attention. Do not grind or scratch bearings or caps to adjust clearance.
If the gauge shows that the clearance is still not standard, install a larger or smaller bearing and check the clearance again.
Note: If it is not possible to adjust the clearance in the bearings by selecting liners, it is necessary to replace the crankshaft assembly and repeat the adjustment.
Attention. If the identification mark is not visible on the insert due to soot, it must be washed in a solvent. Do not clean the insert with a scraper or wire brush.
2. The location of the marks characterizing the inner diameter of the main bearings of the crankshaft.
Cylinder block
3. The location of the marks on the crankshaft.
Note: Read the order of the labels according to the arrow in the figure below.
Crankshaft Dimensions (indigenous necks)
4. Location of identification marks on the main bearing bushing.
Main Bearings Dimensions
Selection of liners of main bearings
5. Check the axial clearance of the crankshaft:
Using a dial gauge, measure the crankshaft end play by moving it forward/back with a screwdriver.
Note:
- Standard axial clearance: 0.07 - 0.25 mm.
- Maximum permissible value: 0.30 mm.
If the axial clearance exceeds the allowable limit, the thrust bearings must be replaced.
Note: Thrust bearing thickness: 1.925 - 1.965 mm.
Using a micrometer, measure the outside diameter of the crankshaft main and connecting rod journals. Measure in two mutually perpendicular planes, as shown in the figure.
Note:
- The diameter of the main journals of the crankshaft: 60.000 -60.018 mm.
- Diameter of connecting rod journals of the crankshaft: 48.000 - 48.018 mm.
Cylinder block
1. Remove any remaining sealant from the cylinder head connector surface using a scraper.
2. Using a soft brush and solvent, clean the cylinder block.
3. Using a special ruler and a set of probes, measure the flatness of the contact surface of the cylinder block with the head.
Note: Standard non-flatness value: less than 0.05mm.
4. Visually check the cylinder mirror for deep scratches and burrs. If defects are found, replace the cylinder block assembly.
5. Using a bore gauge, measure the inside diameter of the cylinders in two perpendicular planes at three locations.
Note:
- Place of measurements (from the top of the cylinder block): 10 mm (A); 80mm (IN); 150 mm (WITH).
- Standard internal diameter: 84.000 - 84.030 mm.
6. Check the cylinder size code on the bottom of the cylinder block.
7. Check the piston size code on its bottom (indicated in the figure).
8. Pick up the piston in relation to internal diameter of the block of cylinders. The clearance between piston and cylinder should be 0.075 -0.095 mm.
Pistons and piston rings
1. Clean piston rings.
Using a special scraper, remove carbon deposits from the surface of the rings.
Using a special tool or a broken ring, clean out the ring grooves in the piston.
Using solvent and a brush, rinse and clean the piston.
Note: Do not use a metal bristle brush when cleaning.
2. Using a micrometer, measure the outer diameter of the piston in the plane of the transverse axis of the piston pin and at a distance of 10 mm from its upper surface, as shown in the figure.
Note: Standard piston diameter: 83.915-83.945 mm.
3. The difference between the outer diameter of the piston and the inner diameter of the cylinder is the gap.
Note: Standard value: 0.075 - 0.095 mm.
4. Measure the side clearance of the piston rings:
Using a feeler gauge, measure the gap between the new piston rings and the piston cutout. If the piston ring clearance exceeds the allowable value, the piston assembly must be replaced.
Note: Standard side clearance: 0.102 - 0.146 mm (compression №1), 0.070-0.110 mm (compression №2) and 0.030 -0.070 mm (oil scraper).
5. Check up a backlash in locks of piston rings. For this:
Install the piston ring in the cylinder. Then, move the ring inside the cylinder using the piston as shown. Measure the gap in the lock using a set of feeler gauges. If the gap in the lock exceeds the allowable limit, it is necessary to replace the ring with a new one. If the gap in the lock is too large, it is necessary to measure the inner diameter of the cylinder. If the cylinder diameter exceeds the allowable limits, it is necessary to replace the cylinder block assembly.
Note: The standard value of the gap in the lock of the ring: 0.18 - 0.33 mm (compression №1), 0.35 - 0.50 mm (compression №2), 0.25 - 0.50 mm (oil scraper).
Piston pins
1. Using a micrometer, measure the outside diameter of the piston pin.
Note: Standard value: 33.991-33.997 mm.
2. Measure the clearance between the piston pin and the bore in the piston.
Note: Standard clearance: 0.007 - 0.019 mm.
3. Measure the difference between the outside diameter of the piston pin and the inside diameter of the connecting rod bushing.
Note: Standard value: 0.023 - 0.041 mm.