| 1. Remove a bearing cover from a rod of the first cylinder (being guided on the tags put when dismantling). Remove old inserts of the conrod bearing and wipe landing surfaces of inserts in a core of a rod and in a cover with the pure fabric which is not leaving pile. These surfaces have to be always absolutely pure. |
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2. Wipe a back surface of the top connecting rod and lay it in the place in a rod. Make sure that the ledge on an insert came into selection in a rod and lubricant openings coincided. |
| 3. At installation of an insert it is inadmissible to use the hammer, it is necessary to observe extreme care not to damage a working surface of an insert. At this stage lubricant of an insert is not required. |
| 4. Wipe a back surface of the lower insert and enclose it in a rod cover. Be again convinced that the ledge on an insert coincides with selection on a rod cover, do not grease an insert. It is very important that the interfaced surfaces of an insert and a rod in the course of assembly were absolutely pure, without oil traces. |
| 5. Place joints of piston rings according to rice. Arrangement of joints of piston rings for engines of 1,3 l, rice. Arrangement of joints of piston rings for l engines 1,6 and 1,8. |
| 6. Put on pieces of rubber hoses bolts of covers of rods that will protect the surface of the cylinder from damage. |
| 7. Oil pistons and rings pure for the engine, dress on the piston a mandrel for sinking of rings. Length of the speaker from adaptation of the site of a skirt of the piston has to be about 6,0 mm to provide the correct entrance of the piston to the cylinder. Rings have to be aflush with the surface of the piston. |
| 8. Turn a bent shaft to the lower dead point in the first cylinder, oil cylinder walls for the engine. |
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9. Turn the piston with a rod so that tags (1) on a rod and (2) on the bottom of the piston were turned towards a forward part of the engine, carefully enter the piston with a rod into the first cylinder against the stop of the device for sinking of rings in the block of cylinders. |
| 10. Slightly knock on the upper edge of a mandrel to provide uniform contact with the plane of the block of cylinders on all circle. |
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11. Carefully knock with the wooden handle of the hammer on the piston bottom, directing a rod to the corresponding neck of a bent shaft. Piston rings can jump out of a mandrel just before entry into the cylinder therefore, the mandrel always has to nestle on the block of cylinders. |
| 12. Carry out this operation carefully, immediately stop pushing-in of the piston at feeling of any resistance at an entrance to the cylinder. Define the reason of jamming of the piston and eliminate it then continue installation of the piston in the cylinder. |
Prevention
It is not allowed to make effort at installation of the piston in the cylinder, irrespective of the reason which caused resistance to occurrence of the piston. Otherwise it is possible to break rings or the piston.
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| 13. After installation of the piston in the cylinder it is necessary to measure a gap between conrod bearings and a neck of a shaft, and only after that to finalize a rod cover. |
| Check of gaps in conrod bearings |
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14. Prepare a piece of a calibration plastic wire which length is a little less than width of the conrod bearing, and put it on a conrod neck (it is specified by an arrow) the first cylinder parallel to a crankshaft axis. |
| 15. Clear the rod cover surface adjacent to an insert, remove hoses from bolts of fastening of covers and establish a cover. Make sure that tags of mutual orientation on a cover and on a rod are on the one hand. Make sure that the forward tag on a cover is directed towards a gear belt. |
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16. Slightly grease internal surfaces of nuts, wrap nuts and tighten them with the set moment. Tighten nuts a face head with the picked-up outer diameter that will allow to avoid the wrong indication of the moment of an inhaling in case of a head zadevaniye for a cover of the conrod bearing. |
| 17. If the head begins to touch a cover, then raise a head so that to provide its free turn. Rotation of the crankshaft at an inhaling of nuts is not allowed. |
Prevention
On l engines 1,6 and 1,8 after an inhaling of nuts tighten them on 90 °.
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| 18. Turn off nuts and carefully uncover, without having damaged plastic caliber. |
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19. Compare thickness of the crushed calibration wire to the value caused on on packing of caliber and determine the size of a lubricant gap (the scale is graduated in millimeters and in inches). Compare the received value to standard. |
| 20. If the gap does not correspond established, then the wrong selection of conrod bearings can be the cause (in this case pick up inserts of bearings). Before coming to the decision on need of replacement of inserts be convinced that at measurement of a gap there were no pollution or oil between bearings and surfaces of rods and conrod covers. Check also diameter of conrod necks. If width of the crushed calibration wire on the ends strongly differs, then the radical neck of the crankshaft has conicity (see subsection 3.1.2.13). |
| Final installation of rods |
| 21. Carefully remove the remains of calibration material from conrod necks of the crankshaft and / or with in the surfaces of conrod bearings. Do not allow damage of surfaces of conrod bearings, scratch out a forefinger or the edge of plastic. |
| 22. Be convinced of full purity of working surfaces of conrod bearings, apply on bearing inserts a thin uniform layer of jellied lubricant with a disulfide of molybdenum or oil for assembly of the engine. For access to a surface of the top connecting rod it is necessary to push the piston into the cylinder, previously having dressed pieces of hoses on cover bolts. |
| 23. Attract a rod to a neck of a bent shaft, remove hoses from bolts of covers, establish covers and tighten nuts with the moment specified in subsection 3.1.2.1. |
| 24. Repeat the described procedure for pistons and rods of other cylinders. In the course of assembly you watch purity of the interfaced surfaces of a rod and external surfaces of connecting rods. You watch that each piston assembled with a rod corresponded to this cylinder. At installation of the piston dredging or an arrow have to be turned into the cylinder towards a forward part of the engine. Oil the cylinder fresh. After measurement of a gap grease the working surfaces of conrod bearings. |
| 25. After final installation of pistons with rods, check freedom of rotation of the crankshaft, having turned it on several turns by hand. |
| 26. At the last stage of assembly it is necessary to check an axial side play of a rod. The procedure of check is described in subsection 3.1.2.9. |
| 27. Compare the size of an axial side play to the value specified to a vpodrazdela 3.1.2.1. If the axial side play met standard before dismantling of the engine, and in the course of repair the former crankshaft and rods are installed, then after repair the axial side play also has to be within norm. If new rods and the crankshaft are established, then the side play can not meet standard. In this case rods should be removed and handed over in a workshop of car service for grinding. |
