Connecting rods and crankshaft
1. Check up an axial backlash of a rod. Using a feeler gauge, measure the end play by moving the connecting rod forward/back.
Note:
- Standard clearance: 0.1 - 0.25 mm.
- Maximum allowable value: 0.35 mm.
Note:
- If the axial clearance of the connecting rod exceeds the maximum permissible value, it is necessary to replace it with a new one.
- If, after installing a new connecting rod, the axial clearance exceeds the maximum permissible value, it is necessary to replace the crankshaft assembly.
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 along with the 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 cap and tighten the bolts to torque (17.7 - 21.6 Nm) + tighten by 88-92°.
Attention. Do not turn the crankshaft.
Turn away bolts of fastening and remove a cover of a rod.
Measure the thickness of the plastic gauge (scale attached to the kit).
Note: The standard clearance in bearings is 0.031-0.045 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.
- The location of the connecting rod identification mark is shown below.
Connecting rod dimensions
Location of the crankshaft identification mark.
Note: Read the order of the labels according to the arrow in the figure below.
Crankshaft Dimensions
Insert selection
3. 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 caps and torque bolts to 14.7 Nm+ (27.5-31.4 Nm) + tighten by 120-125°.
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: 0.020 - 0.038 mm.
The location of the identification marks on the connecting rod bearing shell
Insert dimensions
If the measurement value is too large or small, remove the upper bearing shell, install a new one, 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, try installing 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.
Note:
- When installing, make sure that the number marked on the connecting rod and its cap matches the cylinder number. When installing a new connecting rod, make sure that the bushing fixing tabs match the grooves on the bushing.
- Replace the connecting rod assembly if its side surface is damaged. Also, replace the connecting rod with increased wear of its working parts.
Using special equipment, measure the bend and twist of the connecting rod. Publishing house «Monolith»
Note:
- Allowable amount of bending of the connecting rod: 0.05 mm/100 mm or less.
- Allowable amount of crank twist: 0.1mm/100mm or less.
- If the allowable bending and twisting values are exceeded, the connecting rod assembly must be replaced.
- The location of the marks characterizing the inner diameter of the main bearings of the crankshaft.
Cylinder block
The location of the marks on the crankshaft
Crankshaft dimensions (indigenous necks)
Selection of liners of main bearings
Check crankshaft end play. 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:
- Thickness of thrust bearings: 1.925-1.965 mm.
- Using a micrometer, measure the outside diameter of the crankshaft main and connecting rod journals.
Location of identification marks on the main bearing bushing
Main Bearings Dimensions
Note:
- The diameter of the main journals of the crankshaft: 51.942-51.960 mm.
- The diameter of the connecting rod journals of the crankshaft: 47.954-47.972 mm.
Measure in two mutually perpendicular planes, as shown in the figure.
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 non-flatness of the cylinder head connector surface.
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:
Standard value of inner diameter:
- 2.0 l: 86.00-86.03 mm.
- 2.4 l: 88.00-88.03 mm.
Note: Measurement location (from the bottom of the cylinder block): 110.7mm/160mm/210mm.
6. Check the cylinder size code on the bottom of the cylinder block.
7. Check piston size code (A), 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 0.015 -0.035 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 14 mm from the bottom, as shown in the figure.
Note:
Standard piston diameter:
- 2.0 l: 85.975-86.005 mm.
- 2.4 l: 87.975-88.005 mm.
3. The difference between the outer diameter of the piston and the inner diameter of the cylinder is the gap.
Note: Standard value: 0.015-0.035mm.
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.
Note:
- Standard side clearance: 0.05-0.08mm (compression №1), 0.04 - 0.08 mm (compression №2) and 0.06 - 0.15 mm (oil scraper).
- Maximum allowable side clearance: 0.1 mm (compression №1), 0.1 mm (compression №2) and 0.2 mm (oil scraper).
Note: If the piston ring clearance exceeds the allowable value, the piston assembly must be replaced.
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:
- Standard gap in the ring lock: 0.15-0.30 mm (compression №1), 0.37-0.52mm (compression №2), 0.20-0.70mm (oil scraper).
- Maximum permissible values: 0.6 mm (compression №1), 0.7mm (compression №2), 0.8 mm (oil scraper).
Piston pins
1. Using a micrometer, measure the outside diameter of the piston pin.
Note: Standard value: 21.001 - 21.006 mm.
2. Measure the clearance between the piston pin and the bore in the piston.
Note. Standard clearance: 0.013-0.023.
3. Measure the difference between the outside diameter of the piston pin and the inside diameter of the connecting rod bushing.
Note: Standard value: 0.016 - 0.032 mm.