The procedure for disassembling the cylinder block
- 1. Oil dipstick
- 2. Oil dipstick tube
- 3. Crankshaft position sensor mounting screw
- 4. Crankshaft position sensor
- 5. Oil filter
- 6. Oil filter connector
- 7. Intake manifold support bracket 8 Clamp
- 9. Branch pipe of the crankcase ventilation system
- 10. Collar
- 11. Screw
- 12. Gasket
- 13. Knock sensor mounting screw
- 14. Knock sensor
- 15. Crankshaft pulley screw
- 16. Washer
- 17. Crankshaft pulley
- 18. Cover screw
- 19. Upper front timing cover
- 20. Gasket of the upper front cover of the timing drive
- 21. Timing belt
- 22. Screw fastening the timing belt tensioner
- 23. Timing belt tensioner
- 24. Timing gear drive pulley
- 25. Idler pulley
- 26. Screw securing the rear cover of the timing drive
- 27. Rear timing belt cover
- 28. Coolant pump mounting screw
- 29. Coolant pump
- 30. Coolant pump gasket
- 31. Oil pump mounting screws
- 32. Oil pump seal
- 33. Oil pump front cover
- 34. Screw for fastening the pressure reducing valve
- 35. Oil seal
- 36. Pressure reducing valve spring
- 37. Reducing valve piston
- 38. Oil pump gear
- 39. Oil pump gear
- 40. Screw of fastening of a back cover of the oil pump
- 41. Rear cover of the oil pump
- 42. Oil pump gasket
- 43. Screw
- 44. Threaded ring
- 45. The screw of fastening of the pallet of an oil crankcase
- 46. Oil pan
- 47. Screw
- 48. Oil scraper tube
- 49. Gasket
- 50. The screw of fastening of a cover of the radical bearing
- 51. Main bearing cap
- 52. Set of liners of main bearings
- 53. Bolt for connecting rod bearing cap
- 54. Connecting rod bearing shells
- 55. Crankshaft
- 56. Flywheel screw (ITUC)
- 57. Flywheel (ITUC)
- 58. Flywheel screw (AKP)
- 59. Flywheel (AKP)
- 60. Crankshaft sealing ring
- 61. Connecting rod
- 62. Piston rings
- 63. Piston pin
- 64. Piston
- 65. Cylinder block
Preparatory work
- remove the cylinder head;
- remove the timing drive elements;
- remove the oil pan, oil filter and oil pump.
Notes on removing the crankshaft
Before removing the main bearing caps, disconnect the connecting rods from the crankshaft and push the pistons through the top of the cylinder block.
Notes on removing main bearing caps
When removing the main bearing caps, mark their positions. When assembling, they must be installed in their original places.
Notes on disassembling the connecting rod and piston group
When disassembling the connecting rod and piston group, mark the positions of the connecting rods and connecting rod bearing caps. When assembling, they must be installed in their original places.
Checking the degree of wear of the elements of the cylinder block
Checking the crankshaft
Control parameters:
- shaft journal diameter: 55 mm;
- shaft journal diameter: 43 mm;
- maximum taper of the main journal: 0.005 mm;
- maximum taper of the connecting rod journal: 0.005 mm;
- maximum deviation from the round shape of the main neck: 0.004 mm;
- maximum deviation from the round shape of the connecting rod journal: 0.004 mm;
- main bearing clearance: 0.026-0.042 mm;
- connecting rod bearing clearance: 0.019-0.070 mm;
- runout of the end of the crankshaft: 0.1 mm;
- connecting rod side clearance: 0.070-0.242 mm.
Checking the piston pins
Control parameters:
- finger diameter: 18mm;
- finger offset: 0.5-0.7 mm.
Checking piston rings
Control parameters:
- clearance at the junction of the upper compression ring: 0.15-0.3 mm;
- gap at the joint of the 2nd compression ring: 0.3-0.5 mm;
- axial clearance in the groove of the upper compression ring: 0.05-0.09 mm;
- axial clearance in the groove of the 2nd compression ring: 0.05-0.09 mm.
Piston check
Control parameters:
- piston diameter: 78.97 mm
- clearance between piston and cylinder wall: 0.03 mm.
Cylinder check
Control parameters:
- cylinder diameter: 79.0 mm
- maximum deviation from round shape: 0.0065 mm;
- maximum taper: 0.07 mm.
Assembly
Assembly is carried out in the reverse order of disassembly.
Tightening torques
System element | Torque |
Screw of fastening of a cover of the radical bearing | 50 Nm + 45° |
Connecting rod bearing cap screw | 25Nm + 30°+ 15° |
Oil pump mounting screw | 10 Nm |
Screw of fastening of a reception tube of the oil pump | 10 Nm |
Screw of fastening of the pallet of an oil crankcase | 10 Nm |
Screw of fastening of a back cover of a drive of GRM | 10 Nm |
Piston ring installation notes
When installing, distribute the piston ring gaps as shown in the figure.
1. The joint of the radial expander of the composite oil scraper ring.
2. Gap of the second compression ring.
3. Joint of the axial expander of the composite oil scraper ring.
4. Clearances of the first compression ring and the rings of the composite oil scraper ring.