Audi 80/90/Coupe

since 1986-1991 of release

Repair and car operation



Audi 80/90/Coupe
+ 1.2. Car identification
- 2. Engines, carburetors
   2.1.2. Removal and engine installation (5-cylinder models)
   2.1.3. Dismantling and assembly of engines
   2.1.4. Head of the block of cylinders, gazoraspredeleniye mechanism
   + 2.2. Engine electric equipment
   + 2.3. Carburetors
3. Greasing system
+ 4. Cooling system
+ 5. Fuel system
+ 6. Exhaust system
+ 7. Ignition system
+ 8. Transmission
+ 9. Suspension brackets, wheels
+ 10. Brake system
+ 11. Steering
+ 12. Body, salon
+ 13. Central air
+ 14. Electric equipment


dfe5d7b3



2.1.3. Dismantling and assembly of engines

GENERAL INFORMATION

Crankshaft and block of cylinders


Prevention

Tighten only a dinamometrichesky key. Use of a key of "graggers" can lead to breakages.


The block of cylinders in collecting (4-cylinder models)

1. Bolts
2. Loose leaves 1, 2, 4 and 5th radical bearing
are established in covers 1, 2 and the 5th radical bearings without an oil flute, and in a cover of the 4th bearing with a myaslyany flute
3. Laying
is subject to obligatory replacement
4. Forward holder of an epiploon
5. Epiploon
6. 20 N of m.
7. Ring laying
at damage replace
8. 25 N of m.
9. Epiploon
take an epiploon from the case a stripper 10-203
before installation slightly grease working and external edges of an epiploon
10. Epiploon case
11. Intermediate shaft
at first remove the ignition distributor
12. Loose leaves 1, 2, 4 and 5th radical bearing
are established in a bed of the block of cylinders with an oil flute
13. Loose leaf of the 3rd radical bearing
the persistent bearing is established in a bed of the block of cylinders with an oil flute (the repair bearing has an assembly fillet)
14. A persistent half ring from the block of cylinders
15. Loose leaf of the 3rd radical bearing
16. The directing bearing
put greasing on the basis of a molybdenum disulfide
17. Crankshaft
18. Persistent half ring
watch correctness of installation
19, 20. Covers of radical bearings
pay attention to asymmetry of a bed of the loose leaf and fixing inflow

Sizes of the crankshaft (engine of 1,6 liters)

 
Diameter of shatunny necks (mm)
Standard size
45,96-45,98
First repair size
45,71-45,73
Second repair size
45,46-45,48
Third repair size
45,21-45,23

Sizes of the crankshaft (engine of 1,8 liters)

 
Diameter of radical necks (mm)
Diameter of shatunny necks (mm)
Standard size
53,96-53,98
47,76-47,78
First repair size
53,71-53,73
47,51-47,53
Second repair size
53,46-53,48
47,26-47,28
Third repair size
53,21-53,23
47,01-47,03

Sizes of the crankshaft (engine of 2,0 liters)

 
Diameter of radical necks (mm)
Diameter of shatunny necks (mm)
Standard size
54,022-54,042
47,822-47,842
First repair size
53,772-53,792
47,572-47,592
Second repair size
53,522-53,542
47,322-47,342
Third repair size
53,272-53,292
47,072-47,092

Three repair sizes of bearings with a step in 0,25 mm.

Belt of a drive of a cam-shaft, installation


Prevention

It is not allowed to turn the crankshaft and a cam-shaft at the removed gear belt as damages of pistons by heads of valves are possible.

Crankshaft installation in situation VMT is not allowed.


Gear belt of a drive in collecting (4-cylinder models)

1. 45 N of m.
2. Top cover of a gear belt
3. 20 N of m.
4. 10 N of m.
5. Uspokoitel
6. Klinoremenny transfer
7. Klinoremenny transfer
8. Remote laying
9. Pulley
10. 20 N of m.
11. Klinoremenny transfer
12. Pulley
13. 20 N of m.
14. Bottom cover of a gear belt
15. 10 N of m.
16. Remote plug
17. Bolt of a leading gear wheel
tighten with the moment of 90 N of m and tighten on 1/4 turns
доворот it is possible to execute in stages replace a bolt
at an inhaling or an otvorachivaniye of a bolt stop a gear wheel the adaptation 3099
before installation slightly oil a bolt for the engine
18. Leading gear wheel of a gear belt
19. Intermediate gear wheel of a gear belt
when clothing a belt watch the provision of an adjusting label
20. 80 N of m.
21. 20 N of m.
22. Back cover of a gear belt (bottom)
23. 10 N of m.
24. Back cover of a gear belt (bottom)
25. Gear belt of a drive of a cam-shaft
26. Roller of a natyazhitel

PERFORMANCE ORDER
1) combine a label on a conducted gear wheel of a cam-shaft with a label on a head of the block of cylinders
2) combine a label on a crankshaft pulley (or on an uspokoitel) with a label on an intermediate gear wheel (it is specified by an arrow) (VMT of the first cylinder)
3) dress a belt on a gear wheel of the crankshaft and an intermediate gear wheel
4) fix a pulley and an uspokoitel on the crankshaft four bolts
5) remember their situation
6) dress a belt on a conducted gear wheel of a cam-shaft
7) adjust a belt tension a roller of a natyazhitel, rotating the last in the direction specified by an arrow
8) 45 N of m.
9) in the middle between a conducted gear wheel of a cam-shaft and an intermediate gear wheel the belt should be overwound on 90 °
10) tighten a nut of a natyazhitel
11) turn the crankshaft twice and again check a belt tension
12) remove a pulley of the crankshaft and an uspokoitel
13) establish the bottom cover of a belt of a drive of a cam-shaft
14) establish the top cover of a belt of a drive of a cam-shaft, a pulley of klinoremenny transfer, an uspokoitel and klinoremenny transfer
15) check installation of the moment of ignition, if necessary adjust

Prevention

At replacement of the engine, a head of the block of cylinders, laying of a head of the block, an engine and heater radiator, repeatedly to fill in the merged cooling liquid it is forbidden.

Laying and consolidations is subject to obligatory replacement.

At detection in oil of metal shaving from wear of details of the engine, carefully clear oil channels, replace a maslookhladitel and the oil filter.

Blocks of cylinders of an incomplete complete set are delivered with the established directing bearing of the crankshaft. At engine installation on model with automatic transmission directing bearing remove.

Mutual substitution of worn-out loose leaves is not allowed.


Head of the block of cylinders assembled

1. Cover of a head of the block
2. Consolidation of a cover of a head of the block (forward)
3. A conducted gear wheel of a cam-shaft at installation of a belt watch the correct provision of a gear wheel
4. Head of the block of cylinders
5. 25 N of m.
6. Laying of a head of the block of cylinders the party with marking of "OBEN" should be turned towards a block head
7. Arm of a natyazhitel of the generator
8. Consolidation of a cover of a head of the block (back)
9. Cam-shaft cover
10. Intensifying laying
11. Bolts of fastening of a head of the block
12. 10 N of m.
13. Stopper of a maslozalivny mouth

Engine case assembled

1. 20 N of m
2. Arm of fastening of the generator
3. The pump of cooling liquid
4. A bolt with a molotoobrazny head
5. Oil pallet
6. Laying of the oil pallet
7. 20 N of m.
8. Laying
9. Laying
before assembly grease with structure
AMV 1881 100 02
10. Oil filter
turn on by means of a special key
before installation familiarize with the instruction
on the filter case
11. 25 Nanometers.
12. Maslookhladitel
13. Sensor of emergency pressure of oil of 25 Nanometers.
14. 20 N of m.
15. Sensor of emergency pressure of oil
16. Flange of the case of the oil filter
17. Inlet branch pipe of a shirt of cooling of the block of cylinders
18. 20 N of m
19. Sealing ring
20. 25 N of m.
21. Plate of fastening of the distributor
22. Ignition distributor

Flywheel assembled

1. Tighten with the moment of 30 N of m and
tighten on 1/4 turn (on 90 °)
Tighten a dinamometrichesky key
with the strelochny indicator. At
tightening key "graggers"
breakage is possible, to tighten on 90 °
it is possible in two stages on 45 °
replace bolts
carving of new bolts grease with the structure fixing from an otvorachivaniye
2. 10 N of m.
3. Holder of a back epiploon
4. Laying
5. Intermediate plate
6. Back epiploon
remove the adaptation 1O-221
before installation do not grease, as on an epiploon from ремкомплекта greasing already is available
establish by means of the adaptation which is a part ремкомплекта
7. Flywheel
8. Frictional disk of coupling
at installation it is aligned by an opravka 3176
9. An inhaling on a diagonal with the moment of 25 N of m.
10. Press coupling disk

Crankshaft / flywheel assembled

1. 65 N of m.
2. Cover of radical bearings
the cover of the 1st bearing settles down with сторны a crankshaft pulley
pay attention to the displaced arrangement of a bed under the loose leaf of the bearing and inflow of bolts of fastening
3. Tube of a maslopriyemnik
4. 10 N of m.
5. Lock plate
is subject to obligatory replacement
6. Laying
is subject to obligatory replacement
7. 10 N of m.
8. Persistent half rings of covers of radical bearings
pay attention to orientation of rings
at installation
9. Top loose leaves of radical bearings
establish together with persistent half rings
10. Bottom loose leaves 1, 2, 3 and 5 radical bearings
are not interchangeable
11. Persistent half rings of the block of cylinders
12. Crankshaft
13. The directing bearing
14. Tighten with the moment of 350 N of m and
tighten on 1/4 turns (90о)
15. Flywheel
before removal put the oriyentatsionny
labels in relation to the crankshaft
16. Lock rings
17. Epiploon
выпрессовывайте with the help
adaptations 320 3
before installation slightly grease working and external edges
establish by means of opravka from a set 2080 And
press against the stop an opravka from a set 2080 And
18. 10 N of m.
19. 10 N of m.
20. Oil pump
at installation watch the correct landing to the crankshaft
21. Laying
is subject to obligatory replacement
22. Laying
is subject to obligatory replacement
23. Holder of a back epiploon
24. Epiploon
remove by means of the adaptation 2086
at installation do not grease, as from ремкомплекта greasing is put on an epiploon in advance
establish by means of the adaptation which is a part ремкомплекта
remove the adaptation and press an opravka 2003/1 against the stop
25. 20 N of m.

Flywheel, installation

the facet on a washer 1 should be turned towards the plane of installation of a disk of coupling

if necessary establish adjusting laying 2


tighten bolts with the moment of 30 N of m and tighten on 1/4 turns (on 90 °)
Prevention

Inhaling make a dinamometrichesky key with the strelochny indicator. At a tightening a key - "graggers" breakage is possible.


replace bolts. Carvings of new bolts are in advance greased with the structure fixing from an otvorachivaniye

Size and = 30,5–32,1 mm

Drawing of an adjusting label of a corner of an advancing of ignition

The size and = 14 mm (it is measured on an arch).

Prevention

At replacement of the flywheel / leader of a disk of coupling it is necessary to put an adjusting label of a corner of an advancing of ignition. On a new flywheel there is only VMT label (0 degrees).


Flywheel / hydrotransformer removal / installation

 

Extraction of the directing bearing
 

Installation of the directing bearing by means of a shock stripper of VW 207 or 3176

the bearing facet with marking should be turned aside from the engine

Depth of landing


Size and = 1,5 mm

Forward epiploon of the crankshaft from a gear belt

Vypressovka and press fitting

PERFORMANCE ORDER
1) remove a gear belt
2) remove a gear wheel of a gear belt (turn on bolts by means of a key 3099)

3) turn out an internal cartridge of a stripper of an epiploon 2085 on two turns from external (the internal boss should act approximately on 3,0 mm), and fix the screw with a nakatka

4) for the correct orientation of a stripper, screw a cylindrical bolt from the adaptation 3083 in the crankshaft against the stop
5) grease a carving head of a stripper of an epiploon, establish a stripper and with the maximum effort push into an epiploon
6) unscrew the screw with a nakatka, and rotate an internal cartridge of a stripper to an epiploon exit
7) clamp a stripper in a vice and get an epiploon flat-nose pliers
8) slightly grease working and external edges of a new epiploon
9) dress on a shaft directing plug from the adaptation 3083 and push an epiploon on directing plug
10) press an epiploon against the stop
11) measure a gap in a joint of piston rings; insert a ring into the cylinder so that the plane of a ring settled down at an angle 90 ° to a cylinder axis, on distance of 15 mm from the bottom edge of the cylinder

Gap in a joint: 

 – new kompressionny rings – 0,30–0,45 mm;
 – new maslosjemny rings – 0,25–0,45 mm;
 – a limiting gap – 1,0 mm.

The piston in collecting (4-cylinder models)

 
1. Piston rings
place joints at an angle 120о
"top" label on a ring is turned aside
piston bottoms
establish at the pressed-out rings in special pincers
2. Piston finger
establish and выпрессовывайте with
help of the VW adaptation of 222 A
3. Lock ring of a piston finger
4. Bolt of a cover of a rod
5. Block of cylinders
6. Shatunny loose leaf
it is not interchangeable
ledges should coincide completely with dredging in a shatunny cover the limiting
axial люфт 0,37 mm
check a radial gap by means of a calibration plastic wire a limiting gap of 0,12 mm
7. Oil nozzle
8. 10 N of m.
establish on AMV 1888 100.02 greasing
9. Tighten with the moment of 30 N of m and tighten strictly on 1/4 turns (on 90 °)
grease contact surfaces
10. Rod cover
Labels "And" – cylinder number
labels "In" should be turned towards a driving belt
11. Rod
replacement of only all set is allowed
12. Piston
put labels of installation of the piston and
cylinder numbers
the arrow on the piston is turned towards a gear belt

Check of a gap of piston rings in a piston flute
gap of new rings – 0,02–0,05 mm

limiting gap – 0,15 mm


Check of the sizes of the piston

measure diameter at distance about 10,0 mm from bottom edge of a skirt of the piston, at an angle 90 ° to a piston axis

the nominal admission – no more than 0,04 mm


Check of diameter of the cylinder

execute measurements by a nutromer on a range of 50-100 mm in three places, in the directions A (cross-section) and In (longitudinal)

maximum deviation from nominal diameter – 0,08 mm


Prevention

It is not allowed to carry out measurement when the block of cylinders is fixed at the stand by the VW 540 adaptation as distortions of results owing to deformations are possible.


Piston identification
Size and = 4,6 mm

Size b = 19,3 mm


Diameters of the piston and cylinder channel (liter engine 1,6 and 1,8)

SIZE
PISTON
CYLINDER
The standard
80,98 mm
81,01 mm
The 1st repair
81,23 mm
81,26 mm
The 2nd repair
81,48 mm
81,51 mm

Diameters of the piston and cylinder channel (engine of 2,0 liters)
SIZE
PISTON
CYLINDER
The standard
82,48 mm
82,51 mm
The 1st repair
82,73 mm
82,76 mm
The 2nd repair
82,98 mm
83,01 mm

Gear belt in collecting (5-cylinder models)

1. 350 N of m.
2. Ремнь generator drive
3. Uspokoitel
4. 10 N of m.
5. Bottom cover of a belt of a drive of a cam-shaft
6. 10 N of m.
7. Top cover of a belt of a drive of a cam-shaft
8. Gear belt of a drive of a cam-shaft
9. 80 H.м.
10. A conducted gear wheel of a cam-shaft
at installation of a belt of a drive watch the correct orientation of a conducted gear wheel
11. Remote plugs
12. Cover of a driving belt (back)
13. 10 N of m.
14. 20 N of m.
15. 20 N of m.
16. Leading gear wheel of a cam-shaft
17. The pump of cooling liquid
turn of the case of the pump regulates a tension of a gear belt
18. Sealing ring
is subject to obligatory replacement

Prevention

At replacement of the engine, a head of the block of cylinders, laying of a head of the block, an engine and heater radiator, repeatedly to fill in the merged cooling liquid it is forbidden.

Consolidations and laying always replace new.


Head of the block of cylinders in collecting (5-cylinder models)

1. Intensifying porkladka
2. Stopper of a maslozalivny mouth
3. Consolidation of a cover of a head of the block
4. Segment shponka
5. Head of the block of cylinders
6. Laying of a head of the block of cylinders
7. Consolidation of a cover of a head of the block
8. Bolts of fastening of a head of the block
9. Cover of a head of the block
10. 10 N of m.
The oil pallet in collecting (5-cylinder models)

1. Oil фипьтр
turn on a special key familiarize with the instruction on the case
2. Block of cylinders
3. Laying
4. Lock plate
is subject to obligatory replacement
5. 10 N of m.
6. Oil pallet
7. Maslopriyemnik
8. 40 N of m.
9. Uplotnitepnoye ring
is subject to obligatory replacement
10. 25 N of m.

11. Bottom cover of a case of coupling
12. 20 N of m.
13. 10 N of m.
14. 25 N of m.
turn with adaptation 10-201 use
tighten in stages on a diagonal
15. Press coupling disk
before removal put an oriyentatsionny label
16. A conducted disk of coupling
it is aligned by means of an opravka 3176

Uspokoitel, removal and installation

PERFORMANCE ORDER
1) put on carving and bolt surfaces anticorrosive structure of AVM 188 001 02
2) dress on the crankshaft with the established uspokoitel a belt and a gear wheel

3) stop an uspokoitel the adaptation 2084 and tighten a bolt of an uspokoitel with the moment of 350 N of m, using the extension piece 2079 and a face key


Gear belt, installation

Prevention

At installation of an uspokoitel the gear belt should not be clamped (or is crumpled) between a gear wheel of the oil pump and a conducted gear wheel of a cam-shaft.


PERFORMANCE ORDER
1) installation of the moment of opening of valves
2) combine a label on a cam-shaft gear wheel with edge of laying of a head of the block of cylinders (it is specified by an arrow)
3) turn the crankshaft in VMT;
after installation of the engine combine VMT "About" label with the cast arrow on a coupling case (it is specified by an arrow in drawing)
4) on the removed engine combine dredging on a pulley with a label on the case of the oil pump (it is specified by an arrow)

5) unscrew bolts of fastening of the pump of cooling liquid (are specified by shooters);
establish a drive belt;
adjust a belt tension pump turn in the direction counter-clockwise (it is specified by an arrow);
tighten bolts of fastening of the pump


Check of a tension of a belt

The tension of a belt is considered adjusted if the belt can be overwound on 90 ° big and index fingers in the middle between a conducted gear wheel of a cam-shaft and the pump of cooling liquid.

repeatedly check a belt tension

establish a belt cover

establish the power steering pump

establish klinoremenny transfer of the generator


Prevention

At measurement axial люфта the provorachivaniye of the crankshaft is not allowed.


Removal and crankshaft installation

PERFORMANCE ORDER
1) for removal: put a label of provision of a flywheel concerning the crankshaft
2) for installation: tighten fastening bolts with the moment of 350 N of m and tighten on 1/4 turns (90 °)
3) to tighten on 90 ° it is possible in two stages on 45 °
4) replace bolts; carvings of new bolts are in advance greased with the structure fixing from an otvorachivaniye

Vypressovka of the directing bearing

the needle directing bearing выпрессовывайте a stripper

The crankshaft – the sizes

Axial люфт:

 – the new crankshaft – 0,07–0,23 mm

 – the limiting – 0,25 mm

 – the radial gap – is checked by the calibrated plastic wire

 – the new crankshaft – 0,018–0,058 mm

 – the limiting – 0,16 mm

Shatunnye bearings – check

Axial люфт:

 – new bearings – 0,05–0,31 mm

 – the limiting – 0,4 mm

Radial gap:

 – new bearings – 0,010–0,056 mm

 – the limiting – 0,12 mm

The radial gap is checked by the calibrated plastic wire.
Classification by diameter
Diameter of radical necks
Diameter of shatunny necks
The standard
57,958-57,978
47,758-47,778
The 1st repair
57,708-57,728
47,508-47,528
The 2nd repair
57,458-57,478
47,258-47,278
The 3rd repair
57,208-57,228
47,008-47,028

Gap measurement in a joint of piston rings

insert a ring into the cylinder so that the plane of a ring settled down at an angle 90 ° to a cylinder axis, at distance of 15 mm from the bottom edge of the cylinder

Gap in a joint:

 – new kompressionny rings – 0,20–0,40 mm

 – new maslosjemny rings – 0,25–0,50 mm

 – a limiting gap of worn-out rings – 1,0 mm

Check of a gap of piston rings in a piston flute

gap of new kompressionny rings – 0,02–0,07 mm

new maslosjemny rings – 0,02–0,06 mm

limiting gap of worn-out rings – 0,15 mm


Piston / rod assembled


1. Piston finger
at dense landing heat up
the piston to temperature 60 ° With
establish and выпрессовывайте
by means of the VW 207C adaptation
2. Stolornoye ring of a piston finger
3. Bolt of a cover of a rod
4. Shatunny loose leaf
pay attention to correctness of installation
it is not interchangeable
ledges should correspond completely to dredging in
to shatunny cover
5. Block of cylinders
check of internal diameter of cylinders
6. An oil nozzle for
piston coolings
7. 10 N of m.
establish on greasing
AMV 188 100.02
8. Tighten with the moment of 30 N of m and tighten on
1/4 turns (on 90 °)
grease contact surfaces
for measurement of a radial gap of bearings, tighten with the moment of 30 N of m.
9. Rod
replacement of only all set is allowed
in a place "And" number labels are put
labels "In" должнеы to be turned towards a driving belt
10. Lock ring of a piston finger
11. Piston
put labels of position of the piston in the cylinder and cylinder numbers
the arrow on the piston is turned towards a driving belt
piston identification
12. Piston rings
place joints at an angle 120 °
gap check in joints of rings илпюстрируется check of height of a ring
"top" label on a ring is turned towards the piston bottom

Check of diameter of the piston


measure diameter at distance about 10 mm from bottom edge of a skirt of the piston, at an angle 90 ° to a piston axis

the nominal admission – no more than 0,04 mm


Check of diameter of the cylinder

carry out measurements by a nutromer on a range of 50-100 mm in three places, in the directions A (cross-section) and In (longitudinal)

maximum deviation from nominal diameter of 0,08 mm

Identification sizes of the piston
Size and = 4,4 mm

Size b = 22,2 mm


Prevention

The size "a" is measured in a place of the greatest zaglubleniye.


Diameters of the cylinder and piston

Classification by the size
Diameter of the piston
Diameter of the cylinder
The standard
82,48 mm
82,51 mm
The 1st repair
82,73 mm
82,76 mm
The 2nd repair
82,98 mm
83,01 mm

Arrangement of components of a gear belt (Compartment model)

1. Moment of an inhaling of 10 N of m.
2. Cover of a gear belt (top)
3. Gear belt of a drive of a cam-shaft
4. Plugs
5. Moment of an inhaling of 65 N of m.
tighten and turn on VW 544 key
6. Leading gear wheel of a cam-shaft
7. Cover of a gear belt (internal)
8. Moment of an inhaling of 350 N of m.
tighten and turn on special keys 2079 and 2084
9. Moment of an inhaling of 20 N of m.
10. Uspokoitel
11. Moment of an inhaling of 10 N of m.
12. Cover of a gear belt (bottom)
13. Leading gear wheel of a gear belt
14. Roller of a natyazhitel
moment of an inhaling of 10 N of m.
15. Moment of an inhaling of a bolt of 20 N of m.
16. The pump of cooling liquid
17. Ring laying
at repair of engines of earlier release it is recommended to clear a surface of a prileganiye of laying, and ring laying to replace

Prevention

Epiploons, laying and consolidations are subject to obligatory replacement.


Arrangement of components (Compartment model)

1. Stopper of a maslozalivny mouth
2. Cover of the mechanism of a gazoraspredeleniye
3. Bolt of a head of the block
4. Head of the block of cylinders
5. 65 N of m.
6. A conducted gear wheel of a cam-shaft
at installation of a gear belt watch correctness of provision of a gear wheel
7. Laying of a head of cylinders
8. Laying of a cover of the gas-distributing mechanism
9. Laying
10. A soaking-up collector

Engine components in collecting (Compartment model)

1. Moment of an inhaling of 10 N of m.
2. Tube of a maslopriyemnik
at first fastens to the oil pump
3. Lock plate
is subject to obligatory replacement
4. Laying
5. Moment of an inhaling of 65 N of m.
6. Covers of radical bearings
N1 cover, is from a crankshaft pulley
dredging under radical bearings at installation should settle down one after another and to be turned towards a pulley
pay attention to the displaced arrangement of beds under radical loose leaves
7. Loose leaves 1, 2, 3, 5 and 6th radical bearings
in covers of bearings the lubricant flute is absent
this flute is available in beds of loose leaves of the block of cylinders
mutual replacement of the fulfilled loose leaves is not allowed
assembly ledges on loose leaves should coincide with dredging in covers of bearings
8. The directing bearing
9. A persistent half ring of the loose leaves established in covers
these half rings differ an arrangement of landing tooth
10. Loose leaf of the 4th radical bearing
in covers of bearings the lubricant flute is absent
this flute is available in beds of loose leaves of the block of cylinders
11. A persistent half ring of the loose leaves established in the block of cylinders
these half rings differ an arrangement of landing tooth
12. Crankshaft
13. Tighten with the moment of 30 N of m and tighten on 1/4 turns
to tighten on 1/4 turns, it is possible in two stages on 45 °
replace bolts
carvings of new bolts are in advance greased with the structure fixing from an otvorachivaniye
14. Flywheel
at removal and installation press in a flywheel the reperny probe of installation of the moment of ignition
press the adaptation 10-201
15. Back epiploon of the crankshaft
16. Holder of an epiploon of the crankshaft
17. Oil pump
at installation be convinced that the shaft of the pump entered into gearing with the crankshaft
18. Forward epiploon of the crankshaft
19. Moment of an inhaling of 10 N of m.
20. Lock rings

Prevention

Epiploons, laying and consolidations are subject to obligatory replacement.

At measurement axial люфта to turn the crankshaft it is forbidden.


Diameters of necks

Classification by the size
Diameter of radical necks
Diameter of shatunny necks
The standard
57,958-57,978
47,758-47,778
The 1st repair
57,708-57,728
47,508-47,528
The 2nd repair
57,458-57,478
47,258-47,278
The 3rd repair
57,208-57,228
47,008-47,028

Piston / rod in collecting (Compartment model)

1. Piston rings
2. Piston
3. Rod
it is processed together with a cover of the shatunny bearing
it is not interchangeable
4. Cover of the shatunny bearing
it is processed together with a rod
it is not interchangeable
5. Tighten with the moment of 30 N of m and tighten on 1/4 turns (90 °)
before an inhaling grease contact surfaces
6. Lock ring
7. Piston finger
at dense landing heat up the piston to 60 ° With
establish by means of a prisposbleniye 2070
8. Bolt of a cover of a rod
9. Block of cylinders
10. Shatunny loose leaf
11. An oil nozzle for piston cooling
12. Moment of an inhaling of 10 N of m.
before a wraparound grease with fixing structure of AMV 188 001 02
13. Pay attention to an arrangement of labels at assembly

Removal lock ring of a piston finger

hook and take out a ring as is shown in drawing

Check of the sizes of pistons


diameter of the piston is measured at distance about 12 mm from bottom edge of a skirt of the piston, at an angle 90 ° to a piston axis

the nominal admission – no more than 0,04 mm


Diameters of the cylinder and piston


Classification by diameter
Diameter of the piston
Internal diameter of the cylinder
The standard
80,98
81,01
The 1st repair
81,23
81,26
The 2nd repair
81,48
81,51

Check of internal diameter of the cylinder

Measurement places:

1–in 10 mm from the upper edge of the cylinder

2–in the middle of the cylinder

3–in 10 mm from bottom edge of the cylinder

measurements are carried out by a nutromer on a range of 50-100 mm in places 1, 2 and 3

repeat measurements in the same places, but in the direction perpendicular to the previous

maximum deviation from nominal diameter – 0,08 mm