Mitsubishi Galant

1990-2001 of release

Repair and car operation



Mitsubishi Galant
+ Identification numbers of the car
+ Controls
+ Options and routine maintenance
- The engine
   + Removal/installation of the power unit, dismantle of components
   - Regenerative repair of the engine
      The general information
      Check компрессионного pressure in engine cylinders
      Check of oil pressure
      Alternative variants of schemes of regenerative repair of the engine
      Good advice on carrying out of regenerative repair of the engine
      Preparation for major repairs performance
      Order of dismantling of the engine by its preparation for major repairs
      Regenerative repair of a head of cylinders
      Regenerative repair of the block of cylinders
      Trial start and обкатка the engine after major repairs
+ Cooling and heating systems
+ The power supply system and release
+ Engine electric equipment
+ Control systems of the engine
+ Manual transmission
+ Coupling and трансмиссионная a line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment





Regenerative repair of the block of cylinders

The general information

During carrying out of regenerative repair of the block of cylinders replacement of pistons with piston rings, radical and шатунных bearings of a cranked shaft, components of drive ГРМ and the oil pump is usually made. On engines OHV the camshaft and pushers of valves is subject to replacement also.

It is in case of need made проточка cylinders/replacements of sleeves. Mirrors of cylinders should отхонингованы without fail.

The cranked shaft usually also is subject проточке with the subsequent selection of repair loose leaves of bearings.

Removal of step deterioration in the top part of cylinders

 PERFORMANCE ORDER

1. Whereas during the running cycle pistons do not reach the top cut of the cylinder, in the end of their course on a mirror of cylinders the step which presence stirs to extraction of shatunno-piston assemblages is formed and can be the reason of damage of new pistons at their installation in the engine.
2. Some types of the vertical drills applied to removal of step deterioration of cylinders are issued, all of them are among concerning inexpensive tools.
3. Turn a cranked shaft so that the piston of the corresponding cylinder has fallen to the bottom position.
4. Cover the bottom of the piston with a rags protective layer
5. Prepare a vertical drill and, adhering to instructions of manufacturers of the tool, process the top part of the cylinder, having removed with it step deterioration.

Try not to be overzealous and not to damage a mirror of cylinders in its working part!

6. Take a vertical drill, rags and the sawdust formed as a result of processing.
7. Operating in a similar manner, remove step deterioration from mirrors of all cylinders.


Dismantling and cleaning

 PERFORMANCE ORDER

1. Establish the engine on the assembly stand or a strong workbench. Alternatively lay the unit on a garage floor on pair wooden blocks (a surface interfaced to transmission downwards). Engine position should provide an easy approach to fixture of covers of the bottom heads of rods and possibility проворачивания a cranked shaft. All provided by a design of the unit of a cover should be removed from the engine.
2. Remove from the engine components of drive ГРМ and a head of cylinders. Remove the pallet картера and маслозаборный knot. In case of need remove a drive of the oil pump, balancing and auxiliary shaft.
3. Remove traces of step deterioration in the top part of cylinders (see above).
4. Turn the engine so that direct access to a cranked shaft has opened. With the help чертилки or кернера mark rods according to their accessory the to cylinders. Similarly mark also covers of radical bearings.
5. Again turn the engine, - this time the first cylinders upwards. Turn a cranked shaft so that the piston of the first cylinder has appeared in the bottom part of the course. Release fixture and remove a cover of the bottom head of a rod of the first cylinder (track that the loose leaf шатунного the bearing remained in a cover).

6. Pull on fixing hairpins pieces of a fuel hose, having provided with that protection of a neck of a shaft and a mirror of cylinders against damage to extraction process шатунной assemblages.

7. The wooden handle of a hammer push a rod upwards approximately on 25 mm and take from bed in its bottom head the top loose leaf of the bearing.

8. Continue to tap cautiously assemblage upwards until from the cylinder piston rings will not be liberated.

In case of resistance occurrence immediately stop percussion of assemblage and make sure of completeness of removal of traces of step deterioration in the top part of a mirror of the cylinder!


9. Manually definitively take shatunno-piston assemblage from the block. Enclose bearing loose leaves in bed, establish into place a cover of the bottom head of a rod, slightly having tightened fixture.
10. Operating in a similar manner, take from the block the remained shatunno-piston assemblages.

At service of V-shaped engines assemblages from of the same kind cylinders at first are taken, then the engine turns over upwards the second row and the remained assemblages are taken.

12. At the given stage the cranked shaft should appear the only thing remaining in the block a component. In stages in regular intervals ослабьте fixture also remove covers of radical bearings (with the loose leaves enclosed in them).
13. Cautiously take from the beds in the block a cranked shaft.
14. Make careful cleaning of all removed components. If be not going to start immediately engine assemblage, lay the block in a pure polyethylene package.


Check of a condition of components

 PERFORMANCE ORDER

1. During check of a condition of components of the block of the engine some special tools be required. Into number of such tools enter:

Two or three micrometers for measurement of diameters of pistons and necks of a cranked shaft;
Циферблатный a measuring instrument плунжерного type;
the Machine tool for an estimation of degree of deformation of rods.
2. At absence near at hand necessary toolkit it is necessary to charge performance of check of a condition of components to experts of car-care centre.
3. Attentively examine the block on presence in it of cracks and other mechanical damages. Ways of revealing of latent defects are described in Section Regenerative repair of a head of the cylinders, devoted to check of a condition of a head of cylinders. Will charge most correctly performance of check of a condition of moulding of the block to experts of car-care centre.


The engine block

Check of centering of beds of radical bearings

 PERFORMANCE ORDER

1. Check up beds of radical bearings in the block and covers on presence of traces of an overheat, задиров and agnails and other mechanical damages. In case of need give the block in проточку, or make its replacement. Easy defects can be removed by means of a file with a small tooth.
2. Check up centering of beds of bearings in the block by means of a planeness measuring instrument, having laid last along an axis of a lining of a cranked shaft, - in case of revealing люфта or backlashes the block also should be pierced. Corresponding расточке till the repair size should be subjected and covers of radical bearings. After проточки the engine should be completed by new loose leaves of the corresponding repair size.


Check of planeness of an interfaced surface of the block

 PERFORMANCE ORDER

1. Interfaced to a head of cylinders the surface of the block named also декой, should be smoothed carefully out with full removal from it all traces of a material of an old lining, coal and pitch adjournment. Check is made by means of a measuring instrument of planeness and щупа лезвийного type. At first degree неплоскостности lengthways ДП the block, then, - along its both diagonals is estimated.
2. If the size неплоскостности exceeds 0.076 mm at length of 15.2 mm (or 0.152 mm for full length of an interfaced surface), the block of cylinders is subject проточке.


Cylinders

 PERFORMANCE ORDER

1. Usually working backlash of planting of pistons in cylinders makes 0.0381 0.0635 mm.

2. Estimate an external condition of mirrors of cylinders and make their measurement. Measurements are made by means of telescopic нутромера and a micrometer in three sections and two взаимоперпендикулярных planes. The analysis of results of measurements will allow to define volume of forthcoming regenerative works. Ovality and конусность cylinders should not fall outside the limits admissible ranges. The taken measurements will allow to define further size of backlashes of planting of pistons in cylinders.

3. The top part of cylinders is worn usually out a little bit more strongly, than bottom, that leads to formation конусности. If the size конусности exceeds 0.305 mm, the cylinder is subject проточки.
4. Besides, usually walls of cylinders usually wear out on persistent surfaces of pistons, i.e. in a plane, a perpendicular axis of a cranked shaft more strongly. Such deterioration leads to formation of ovality of cylinders which also should not leave for admissible limits (see Specifications).


Cranked shaft

 PERFORMANCE ORDER

1. Wash out a cranked shaft solvent, then carefully dry, whenever possible having taken advantage of compressed air. Do not forget to clean a rigid brush oil apertures. Then wash out their solvent.

At use of compressed air put on goggles!

2. Check up radical and шатунные necks of a cranked shaft on presence задиров, cavities, cracks and signs of non-uniform deterioration. Examine all surface of a shaft on presence of cracks and other damages. For revealing of the latent cracks it is necessary to resort to магнитопорошковой дефектоскопии, - give a shaft to a car-care centre workshop.
3. Spend on necks edge of a copper coin, - if on a surface there are copper traces, hence, its roughness exceeds admissible and it is necessary to give a shaft in проточку.
4. A grinding stone, надфилем or a scraper remove agnails from edges of oil apertures.
5. Check up the remained surfaces of a shaft on presence of cracks and other mechanical damages. The razed cracks come to light in the course of carrying out of special check in the conditions of a car repair shop.
6. By a micrometer measure diameters radical and шатунных shaft necks. Measurement of diameter of each neck make in several points on length and perimetre that will allow to estimate its size конусности and ovality which should not fall outside the limits admissible ranges (see Specifications). It is necessary to estimate also size of palpation of a cranked shaft, - be required pair of V-shaped blocks and measuring instrument DTI. In the absence of necessary stock address for the help to experts of car-care centre.
7. In case deterioration/konusnost/ovality of necks exceeds admissible size, or mechanical damages of surfaces take place, it is necessary to give a cranked shaft in проточку. After проточки a shaft it is necessary to pick up new loose leaves radical and-or шатунных bearings of the corresponding repair size.
8. Check up a condition сальниковых necks on both pins of a cranked shaft. Presence of the developed flutes, agnails or задиров will lead to an exit of new epiploons out of operation in the near future. In some cases of a pin can be restored by проточки and напрессовки on them of special thin-walled plugs. If such regenerative repair is not obviously possible, replace a shaft.
9. Check up a condition of loose leaves radical and шатунных bearings.


Shatunno-piston assemblages

 PERFORMANCE ORDER

1. Preliminary shatunno-piston assemblages should be carefully cleared. Rings are necessary for removing from pistons.

 Piston rings are subject to replacement without fail.

2. By means of the special adaptation remove rings from pistons, - try not to damage a wall of the last casually.
3. Scratch out from the bottoms of pistons traces of coal adjournment. After removal of the basic layer of adjournment smooth out a surface manually a wire brush or a piece of a fine-grained emery paper.

 At all do not use for зачистки made of a soft material and pistons easily subject to erosion wire nozzles to an electrodrill!

4. By means of the special adaptation clean flutes under installation of rings on pistons. It is alternatively possible to take advantage for this purpose of a fragment of an old piston ring, however be careful, - do not scratch a bottom and walls of a flute and do not cut fingers.
5. Having removed the basic adjournment, wash out шатунные assemblages by solvent and carefully dry them, whenever possible with application of compressed air.

 At using the compressed air do not forget to put on goggles! Check up passableness масловозвратных apertures in back walls of flutes under installation of piston rings, and also oil apertures in the bottom heads of rods.

6. If walls of pistons and a mirror of cylinders are not damaged and excessively are not worn out, and the engine block was not pierced and not replaced, necessity for replacement of pistons also disappears. Normal deterioration of pistons is shown in the form of vertical traces of development on a persistent surface and a small weak point of planting top компрессионного rings in the flute. Do not forget, that replacement of piston rings is made without fail, without dependence from their condition.
7. Attentively examine each of pistons on presence of cracks in a skirt, round ledges under installation of piston fingers and around an arrangement of rings.
8. Check up persistent surfaces of a skirt of the piston on presence of scratches, the bottom - on presence of through apertures and прогаров on edge. Presence of scratches on a skirt can be regarded as a sign of long overheats of the engine, or too early ignition of an air-fuel mix, - check up serviceability of functioning of system of cooling. Прогары along the edges of the bottom are the detonation certificate. In any case, the reason of the revealed infringement should be eliminated in order to avoid relapses. As the possible reasons of formation of the listed defects leaks of soaked up air, wrong configuration of an air-fuel mix, infringement of installation of a corner of an advancing of ignition, wrong functioning of systems of ignition and EGR can act also.
9. Dot corrosion of pistons in the form of cavities speaks about hit in chambers of combustion and-or картер the engine of a cooling liquid. Besides, take care, that the reason of internal leaks has been eliminated.

10. Estimate size of a lateral backlash of planting of piston rings in the flutes for what enclose a new ring outside in the flute on the piston and щупом лезвийного type measure a remaining backlash. Repeat measurement in two-three points on flute perimetre. Watch to mixing компрессионные a ring (the top differs from the second). If the backlash size exceeds admissible value (Specifications see), pistons are subject to replacement.

11. Define a landing backlash of pistons in the cylinders, subtract from diameters of cylinders (see above) diameters of corresponding pistons. Measurement of diameter of the piston is made on a persistent surface under a corner 90 to an axis of a piston finger and on the set removal from the bottom. If the landing backlash of the piston in the cylinder exceeds admissible value (Specifications see), it is necessary to give the block in проточку with a selection of new pistons and piston rings of repair diameter.

12. Having tried повращать components in opposite directions, estimate density of planting of pistons on rods. Presence a little appreciable люфта speaks about excessive deterioration of a joint. For situation correction it is necessary to deliver shatunno-piston assemblages in a car-care centre workshop where necessary regenerative repair and replacement of fingers will be made.
13. Performance of procedure of removal of pistons from rods (in case of occurrence of such necessity) also should be entrusted to experts of car-care centre. In parallel, rods can be checked up on presence of signs of a bend, twisting and other deformations with application of the special diagnostic equipment.

Needlessly it is not necessary to remove pistons from rods.

14. Check up rods on presence of cracks and other mechanical damages. Temporarily remove covers of the bottom heads, take loose leaves of old bearings, wipe beds in covers and heads and check up them on presence of agnails, задиров and roughnesses. Having finished check, enclose loose leaves into place, establish covers on the bottom heads of rods, and by hand tighten fixing bolts.

If the engine is under repair for the purpose of elimination of knock of fingers, replace шатунные assemblages.


Bearings

Condition check

 PERFORMANCE ORDER

1. In spite of the fact that bearings of a cranked shaft in the course of engine major repairs are subject to replacement without fail, old loose leaves should be kept for the purpose of attentive studying of their condition which results can give a lot of helpful information on the general condition of the engine. On an illustration examples of typical defects of loose leaves of bearings are resulted.

2. The exit of bearings out of operation can occur owing to a lack of greasing, hit of particles of a dirt, overloads of the engine and corrosion development. Without dependence from character of defects, the reason of damage of loose leaves should be eliminated in the course of performance of major repairs of the engine in order to avoid relapse.
3. For survey take loose leaves of bearings from the beds in the engine block / the bottom heads of rods and radical/shatunnyh covers and spread out them as installation on a pure working surface. Organisation of placing of loose leaves will allow to adhere character of the revealed defects to a condition of corresponding necks of a shaft.
4. The dirt and extraneous particles get to the engine various ways. They can be left in the block in the course of unit assemblage, or get through filters or ventilation system картера. All particles getting to impellent oil, finally, sooner or later, appear in bearings. Often the metal sawdust formed in the course of normal operation of internal components of the engine takes root into a soft material of loose leaves. The probability of presence at bearings of traces of an abrasive is great, in particular, when the due attention has not been paid to cleaning of the block after end of regenerative repair of the engine. Without dependence from a way which extraneous particles get to the engine, as a result they with high degree of probability appear introduced in a soft surface of loose leaves of bearings of a cranked shaft and easily come to light at visual survey of the last. Large particles usually are not late in loose leaves, but leave on their surface and a surface of necks of a shaft appreciable traces in the form of scratches, cavities and задиров. The best guarantee from such troubles is the responsible relation to cleaning of components after end of major repairs of the engine and carefulness of observance of cleanliness at assemblage. Frequent regular change of impellent oil also allows to prolong service life of bearings essentially.
5. Oil starvation can be a consequence of several various, but often interconnected phenomena. So, the engine overheat conducts to разжижению engine oil and to its replacement from working backlashes of bearings. The lack of greasing of bearings can speak in excessive size of working backlashes, and also usual leaks (internal or external). Often meeting reason of replacement of oil from backlashes of bearings is constant excess of turns of the engine. Passableness infringement маслотоков (usually connected with wrong combination of apertures at installation of components) also conducts to reduction of giving of greasing to bearings. Typical result of oil starvation is the full or local wipe/vyshcherblivanie of a blanket of loose leaves from a metal substrate. Thus the working temperature can rise to such level, that the substrate as a result of an overheat gets a bluish shade.
6. Essential influence on service life of bearings is rendered also peculiar to the owner of the car by a driving manner. Movement with small speed on the raised transfer leads to considerable overloads of the bearings, accompanied replacement of an oil film from their working backlashes. Such overloads lead to increase of plasticity of loose leaves and occurrence of cracks in a blanket (fatigue deformation). Thus the superficial material starts to crumble and separate from a steel substrate. Car operation in a city cycle (on short distances) conducts frequent trips to development of corrosion of bearings because the insufficient warming up of the engine involves loss of a condensate and allocation of chemically aggressive gases. The given products accumulate in impellent oil, forming slags and acids. At hit of such oil in bearings aggressive substances promote development of corrosion of loose leaves.
7. Wrong installation of loose leaves in the course of engine assemblage also can be the reason of their fast destruction. Too hard planting does not provide the demanded size of a working backlash of bearings that leads to their oil starvation. Result of hit under loose leaves (in the course of their installation) extraneous particles is formation of eminences, the blanket with which is quickly wiped.
8. Balancing and auxiliary shaft can be equipped by the ring bearings which performance of replacement it is necessary to charge to experts of car-care centre.


Хонингование mirrors of cylinders

 PERFORMANCE ORDER

1. Before engine assemblage it is without fail spent хонингование mirrors of cylinders for the purpose of achievement of correct planting to them of the piston rings, providing due tightness of chambers of combustion.

At absence near at hand necessary tools or unwillingness independently to carry out хонингование, work for quite moderate payment can be charged experts of a workshop of car-care centre.

2. Before to start to хонингованию, establish to the place of a cover of radical bearings / the connecting bridge (without loose leaves) and tighten fixing bolts with demanded effort.
3. Two types хонов for processing of mirrors of cylinders are issued: хон type “bottle ершик” and, more traditional, superficial хон in the form of a nozzle with подпружиненными grinding stones. Both tools provide necessary quality of processing of mirrors of cylinders though use of the first is more preferable to not skilled mechanic. Enough of the rags, special хонинговочного or simply liquid lubricating oil, and also an electrodrill as a drive for хонинговочных nozzles Is required also. Operate in a following order:
a) Clamp хон in an electrodrill cartridge, reduce подпружиненные grinding stones/rods ершика nozzles and fill last in the cylinder.

Do not forget to put on goggles or an obverse guard!

b) Plentifully moisten a mirror of the processed cylinder oil, include a drill and start to make a nozzle back and forth motions in the cylinder. Speed of vertical moving хона should provide drawing on a surface of a mirror of the cylinder of a mesh pattern with a corner of crossing of the parties ячеи nearby 60 . Do not regret some oil and try not to remove from a surface of walls of the cylinder of more material, than it is really necessary for achievement of demanded result.

Manufacturers of piston rings can make own demands to a corner of crossing of the parties ячеи a mesh pattern, - attentively familiarise with the instruction on packing ремнабора.

c) do not take хон from the cylinder to a full stop of a drill! Continue to make back and forth motions by a nozzle until it will not stop to rotate. After a drill stop compress grinding stones and take хон from the cylinder. At using хоном type “bottle ершик” wait a full stop of a drill, then take a nozzle, continuing manually to rotate a cartridge in a normal direction.
d) Wipe rags a mirror of the cylinder and pass to хонингованию the following.

4. On termination of processing, take advantage надфилем for removal of facets from upper edges of cylinders, - the given processing is made so that there were no difficulties with refuelling in cylinders of pistons with the rings put on them. Observe extreme care, - do not scratch надфилем a cylinder mirror.
5. In summary all block should be washed carefully out a warm solution of soap water.

It is possible to consider cylinders washed out when after carrying out on a mirror the white rags moistened with oil on it does not remain a grey touch. Do not forget to clean a cylindrical brush all oil apertures and channels, then wash out the block a water stream under a pressure.

6. After washing carefully dry the block and oil the pierced surfaces for their protection against corrosion. Prior to the beginning of engine assemblage turn the block in a pure polyethylene package.


Assemblage

 PERFORMANCE ORDER

1. First of all it is necessary to prepare a workplace, special attention having given to cleanliness of surfaces and presence of sufficient free space. Take care of the place equipment under warehousing of components subject to installation. All established details also should be very carefully cleaned and dried up.
2. Fix the block of cylinders on the assembly block and once again carefully wash out its solution of soap water, special attention giving to procleaning маслотоков and water galleries. Dry the block, whenever possible with application of compressed air, then spray its anticorrosive solution of type Wd-40j. Wipe mirrors of cylinders pure неворсящейся rags.
3. Establish into place выжимные stoppers and заглушки oil galleries.
4. Not less carefully clean a cranked shaft and start its installation on the engine (see more low).


Engine assembly order

 PERFORMANCE ORDER

1. Before to start engine assemblage, make sure available all necessary details, materials and tools which number the following concerns:

a) the Standard set of the metalwork tool;
b) the Dinamometrichesky key with a drive on 1/2-дюйма;
c) the Tool for putting on of piston rings;
d) the Tool for обжимания piston rings;
e) Short pieces of a fuel hose for putting on on hairpins of covers шатунных bearings;
f) Measuring set Plastigage;
g) the Set щупов лезвийного type;
h) the File with a small tooth;
i) Fresh impellent oil;
j) Assembly impellent, or молибденсодержащая greasing;
k) Прокладочный hermetic;
l) Hermetic for fixing of carving connections.
2. With a view of economy of time and minimisation of volume of arising problems make engine assemblage in a following order:

Four-cylinder engines

a) Piston rings;
b) the Cranked shaft and radical bearings;
c) Shatunno-piston assemblages;
d) the Back epiploon of a cranked shaft;
e) Balancing assemblage of the engine;
f) the Head of cylinders with pushers of valves;
g) Camshafts;
h) Balancing shaft with asterisks;
i) Газораспределительная a chain;
j) the Oil pump;
k) Маслозаборник with the mesh filter;
l) the Pallet картера;
m) the Inlet pipeline and a final collector;
n) the Cover of a head of cylinders;
o) the Flywheel/privodnoj a disk.

Engines V6

a) Piston rings;
b) the Cranked shaft and radical bearings;
c) Shatunno-piston assemblages;
d) the Back epiploon of a cranked shaft with the holder;
e) the Oil pump;
f) the Pallet картера;
g) Heads of cylinders;
h) Camshafts and pushers of valves;
i) Газораспределительный a belt with cogwheels;
j) Covers of drive ГРМ;
k) Covers of heads of cylinders;
l) the Inlet pipeline and final collectors;
m) the Flywheel/privodnoj a disk.


Installation of piston rings

 PERFORMANCE ORDER

1. Before installation of new piston rings it is necessary to check up backlashes in their locks. It is meant, that lateral backlashes of planting of rings in flutes of pistons are checked already up and correspond to the accepted norms (see above).
2. Spread out shatunno-piston assemblages with complete sets of rings on a working surface of a workbench. Since this moment each complete set of rings will be rigidly adhered"to the piston. Now it is possible to start measurement of backlashes in locks of rings.

3. Fill top (№ 1) компрессионное a ring in the first cylinder of the engine and level it perpendicularly, having pushed downwards the piston bottom. The ring should appear around the bottom border of a working course of rings in the cylinder.

4. Define backlash size in the ring lock with the help щупа лезвийного type the Edge () щупа should slip hardly in the lock. Compare result of measurement to requirements of Specifications. If the backlash size leaves in this or that party for limits of an admissible range before to undertake any actions on situation correction (see more low), once again make sure, that have not mixed a ring.

5. If the backlash is too small, it is possible to expand it by расточки with a file with a small tooth (preliminary familiarise with instructions to the complete set, - not all rings are supposed to be processed a file) Clamp a rectangular file in a vice, then put on a ring the lock a file so that the end of the last has appeared in a circle. Slowly pull a ring on itself, removing surplus of metal from its end faces in the lock. Having reached the file end, remove a ring, again check up a backlash, in case of need repeat procedure.

At all do not push a ring from itself on a file as thus lock edges will converge, and the risk of destruction of metal is great.

6. The excessive size of a backlash is not криминалом if does not exceed value of 0.51 mm. Once again make sure, that the got complete sets of rings meet under the characteristics to requirements of the engine of your car.
7. Repeat procedure for the remained rings (the second компрессионного and маслосъемного) the piston of the first cylinder, then for rings of all other pistons. Remember that now each complete set of rings "is unequivocally adhered" to the piston on which it should be established.
8. Having checked up and having modified properly backlashes in locks of rings, it is possible to start their putting on on the pistons.
9. The first on the piston puts on маслосъемное (bottom) ring. Маслосъемное the ring consists of three separate sections. At first fill in the bottom flute of the piston a spring dilator. If the dilator is equipped противоротационным by a uvula, track, that last has got to reciprocal drilling in a piston flute. Now establish in a flute the bottom working section of a ring. In order to avoid casual damage of working sections маслосъемного rings do not use for their installation any tool, - simply get in a flute under/over a dilator at first one end of section, densely press its finger and, moving on ring perimetre, fill the rest. In last turn the top working section of a ring is established.

10. Having planted in the bottom flute of the piston all three components маслосъемного rings, check up rotation freedom (slidings in a flute) the top and bottom working sections.
11. The following establishes the second (bottom) компрессионное a ring. The ring should be established by marks upwards (to the piston bottom).

Strictly follow instructions of manufacturers of rings which are usually printed on complete set packing. Do not mix the second компрессионное a ring with the first (top) - they have various cross-section section.


12. Having taken advantage of a special dilator and having tracked that the ring has been turned by marks upwards, plant it in an average flute on the piston. Try not to plant the lock of a ring more than it is really necessary for its unobstructed putting on on the piston.

13. Operating in a similar manner, establish the first (top) компрессионное a ring (marks upwards). Try not to mix the top ring with the second.
14. Serially complete with rings all remained pistons.


Installation of a cranked shaft

 PERFORMANCE ORDER

1. Installation of a cranked shaft is the procedure first step actually engine assemblages. It is meant, that at the given stage the block of the engine and actually a shaft already are properly cleaned, checked up and subjected necessary regenerative repair.
2. Turn the engine upside down.
3. Give fixing bolts, remove covers of radical bearings/assemblages of covers. Spread out covers on a workbench as installation on the engine.
4. If yet have not done it, take from the beds in the block and covers old loose leaves of radical bearings. Wipe beds pure неворсящейся rags - they should be irreproachably pure.


Check of working backlashes of radical bearings

 PERFORMANCE ORDER

Try not to touch surfaces of new loose leaves with naked hands in order to avoid undesirable contact of bearings to traces of oil always present on fingers and chemically aggressive substances.

1. Wipe backs of new loose leaves of radical bearings and enclose equipped with an oil flute половинки in the beds in the block. Remained половинки loose leaves enclose in corresponding covers of bearings. Track, that uvulas of loose leaves have entered into reciprocal landing grooves in beds of the block and covers. Oil apertures in the block also should appear in the correct image are combined with apertures in loose leaves.

In no event make attempts to begin to knock the loose leaf resistant to installation in the bed a hammer. Grease with nothing bearings at the given stage!

2. Wipe surfaces of bearings in the block and radical necks of a cranked shaft pure неворсящейся rags. Check up passableness of oil apertures of a shaft, in case of need clean them. Any containing in маслотоках extraneous particles, eventually, inevitably get to bearings.
3. Carefully wiped cranked shaft accurately lay in radical bearings of the block.
4. Before to establish a shaft definitively, it is necessary to check up sizes of working backlashes in its radical bearings.

5. Cut the calibrated plastic wire from measuring set Plastigage pieces, in the length width of loose leaves are hardly shorter, and lay on one slice of a wire along each of radical necks of a shaft, in parallel their axis.

6. Wipe surfaces of loose leaves in covers and establish the last on the regular places. Try not to shift laid along necks of a shaft pieces of the calibrated wire. Slightly oil a carving of fixing bolts and screw them, having fixed covers.
7. In stages in regular intervals tighten bolts of fastening of covers with demanded effort.

Do not suppose проворачивания a shaft in the course of a fixture tightening!

8. Turn out bolts and cautiously remove covers of radical bearings. Combine the removed covers as their arrangement on the engine. Try not to damage the flattened out calibrated wire and do not turn a shaft. If any of covers does not give in to removal, for clearing it is accurate обстучите its hammer with soft the brisk.

9. On the width of the flattened out threads measured on a scale, put on packing of set Plastigage, define size of working backlashes of bearings. Compare results of measurements to requirements of Specifications.

10. If the backlash size leaves for admissible limits, probably, loose leaves not that standard size have been established. Before to look for new loose leaves, make sure, that under enclosed at the given stage the dirt or oil have not got. If the calibrated wire is flattened out from one end more than from another, it testifies to presence конусности necks.
11. Cautiously remove the calibrated wire from necks, having scratched out all its traces any not too strong tool (for example, edge of an old credit card). As a last resort, it is possible to take advantage of own nail, - the main thing that on a surface of necks/loose leaves does not remain scratches and задиров.


Definitive installation of a cranked shaft

 PERFORMANCE ORDER

1. Cautiously take a cranked shaft from the engine. Wipe surfaces of bearings in the block and in regular intervals grease with their thin layer молибденсодержащей or assembly impellent greasing. Do not forget to grease persistent washers also.

Try not to admit greasing hit on backs of loose leaves!

2. Make sure of absoluteness of cleanliness of necks of a cranked shaft, then grease (the same greasing or pure impellent oil) surfaces of pins contacting to epiploons.
3. Establish a back epiploon of a shaft.
4. Wipe and grease surfaces of loose leaves in the block, then lay a shaft on the regular place. Establish a cover of the back bearing, then all other, except the persistent. Tighten fixture of covers with demanded effort.
5. Establish a cover of the persistent bearing screw bolts of its fastening and tighten them manually.
6. Shift a shaft forward, having pressed it to a persistent surface of the top loose leaf of the bearing. Keeping a shaft motionlessly, wring out a cover of the persistent bearing back for the purpose of combination of persistent surfaces of both loose leaves.
7. Wringing out a shaft forward, tighten boats of fastening of a cover with demanded effort.
8. For measurement of size axial люфта a cranked shaft fix on the block циферблатный a measuring instrument, having pressed it плунжер to a face surface of a forward pin of a shaft.
9. Cautiously wring out a shaft back against the stop and, keeping it in the wrung out position, null a measuring instrument.
10. Shift a shaft forward till the end of its course and consider an instrument reading.
11. If the result of measurements falls outside the limits admissible value (Specifications see), replace loose leaves of the persistent bearing and repeat check. In case of need give a shaft for check to a car-care centre workshop.


Installation of shatunno-piston assemblages and check of size of working backlashes in шатунных bearings of a cranked shaft

Preparation

 PERFORMANCE ORDER

1. Before installation of shatunno-piston assemblages of a wall of cylinders should be carefully wiped, from their upper edges traces of step deterioration are completely removed and the facet is removed. It is meant, that the cranked shaft is already established on the regular place in the block.
2. Remove a cover of the bottom head шатунной assemblages of the first cylinder (make sure available the labels factory or put in the course of dismantle). Take from a head of a rod and its cover loose leaves of the old bearing and carefully wipe their beds pure неворсящейся rags.


Check of a working backlash шатунного the bearing

 PERFORMANCE ORDER

Try not to touch surfaces of new loose leaves with naked hands in order to avoid undesirable contact of bearings to traces of oil always present on fingers and chemically aggressive substances.


1. Wipe a back of the new top loose leaf and will put it to bed the bearing in a rod head. Track combination of oil apertures and behind that the directing uvula of the loose leaf has got to a reciprocal flute in a rod. At all застукивайте the loose leaf in bed a hammer. Grease with nothing the bearing at the given stage.

2. Wipe a back of the second loose leaf and lay it in a cover of the bottom head of a rod. Again track, that the uvula has got to a reciprocal groove. Do not apply some any greasing - extremely important that interfaced surfaces of the bearing and a rod remained absolutely pure and dry.

3. Arrange piston rings locks as it is shown on an illustration.

3. Plant on bolts of fastening of a cover of the bearing pieces of a fuel hose.
4. Grease the piston and piston rings with pure impellent oil. Put on the piston оправку the tool for обжимания rings. Leave a skirt of the piston acting of оправки the tool approximately on 6 mm for its free refuelling in the cylinder. Rings should be pressed out заподлицо with a forming surface of the piston.
5. Turn a cranked shaft so that the neck of the first crank has appeared in position НМТ. Grease with impellent oil a mirror of the first cylinder.
6. Having developed assemblage by marks on the piston bottom forward on the engine, accurately fill a rod in the first cylinder of the block. Enter into the cylinder a piston skirt, densely having pressed to a surface of the block a bottom edge оправки the tool for обжимания rings.
7. Обстучите an upper edge оправки for a guarantee of density of its pressing to the block on all perimetre of a bottom edge.

8. Accurately tapping on the bottom the wooden handle of a hammer, enter fill the piston in the cylinder, simultaneously directing the bottom head of a rod on a neck of a corresponding crank of a cranked shaft. Piston rings can unexpectedly jump out from under оправки the tool, therefore constantly watch pressing density to its block. Operate not hurrying up, at occurrence of the slightest resistance immediately stop застукивание the piston. Find out the reason of jamming and eliminate it.

At all do not undertake attempts to push the piston in the cylinder force, is can lead to its mechanical damage or destruction of piston rings!

9. After introduction of shatunno-piston assemblage in the engine, before definitive installation of a cover of the bottom head of a rod, it is necessary to check up a working backlash шатунного the bearing of a cranked shaft.

10. Cut off a piece of the calibrated plastic wire from measuring set Plastigage, in the length width of the loose leaf шатунного are hardly shorter than the bearing, and lay it along the first шатунной necks of a cranked shaft, in parallel an axis of last.

11. Wipe a bearing surface in a cover of the bottom head of a rod and establish a cover on a rod. Track, that the label on a cover has appeared the label on a rod is turned in the same party, as.
12. Slightly grease the bottom end faces of heads of fixing bolts with pure impellent oil, screw bolts and in three stages tighten them with demanded effort.

In order to avoid key jamming, take advantage of a thin-walled face head. At occurrence of signs of jamming of a key between a nut and a rod, slightly raise a head and continue a tightening. Do not suppose проворачивания a cranked shaft in the course of performance of all procedure.

13. Give fixture and cautiously remove a cover from a rod. Try not to damage the flattened out piece of the calibrated wire.

14. On width of the flattened out wire measured on a scale, printed on packing to set Plastigage, define size of a working backlash in the bearing. Compare result of measurement to requirements of Specifications.

15. If the size of a backlash falls outside the limits an admissible range before to look for loose leaves of other standard size, check up, whether the dirt/oil has got under backs enclosed in bed in a rod and a cover of loose leaves. Once again measure diameter of a neck of a shaft. Расплющивание from one end it is more than wire than from another speaks about presence конусности necks.
Definitive installation of shatunno-piston assemblage
16. Cautiously scratch out a nail or edge of an old credit card all traces of the calibrated wire from a neck and-or bearing surface.
17. Make sure of absoluteness of cleanliness both подшипниковых surfaces, then in regular intervals grease with their thin layer молибденсодержащей or assembly impellent greasing. For providing of access to a surface of the top loose leaf it is necessary to push a little the piston in the cylinder, - do not forget to put on bolts of a cover of a rod protective hoses in order to avoid damage of a surface of a neck of a shaft. Try not to admit выскакивания from the cylinder of piston rings.
18. Return a rod into place, cautiously having put on its bottom head on a neck of the crank, remove from bolts protective hoses, establish a cover, and in three stages tighten fixing nuts with demanded effort.

Track correctness of combination of labels on a cover of a rod and its bottom head.

19. Repeat all procedure for the remained shatunno-piston assemblages.
20. Do not lose sight of following important points:

a) Watch that on backs of loose leaves and their bed in rods and covers the dirt has not got;
b) Watch, that each assemblage was established in the cylinder (even in case of installation of new components as backlashes of piston rings were adjusted to concrete cylinders);
c) Pistons should settle down marks on the bottom forward on the engine (towards drive ГРМ);
d) do not forget to grease before installation of assemblages by impellent oil of a mirror of cylinders;
e) do not forget to grease before definitive installation of covers bearings (after check of working backlashes in the last).
21. Having finished installation of shatunno-piston assemblages, check up freedom of rotation of a cranked shaft, having turned it some times manually.
22. In summary it is necessary to check up once again axial люфт a cranked shaft (see above).
23. Compare results of measurement axial люфта to requirements of Specifications. If люфт was in norm before dismantling of the engine and the old shatunno-piston assemblages are used, no surprises should be. In case of a size exit люфта for admissible limits after replacement of rods, the last are necessary for removing from the engine and to give to a workshop of car-care centre for corresponding machining.