2.4.5. Assembly and adjustment of the engine

To save time and not to damage an engine detail, collect the engine according to the established sequence. Before assembly carefully check each detail as it is described in the subsection "Check of Technical Condition and Repair of Knots of the Engine". Before assembly clean all details kerosene and dry up compressed air.
At each assembly replace laying.
For providing the corresponding inhaling use a dynamometer key.

Installation of a bent shaft, oil and vacuum pumps

Fig. 105. Removal and installation of hydropushers: 1 – adaptation L


Put the block on the stand and insert hydraulic pushers, using the special tool 1 (see fig. 105).
Before assembly oil external surfaces of pushers pure.

Fig. 153. Installation of a bent shaft: 1 – gear wheel of a bent shaft; 2 – adaptation G


Establish a bent shaft together with the leading gear wheel of 1 (fig. 153) by means of the special tool 2.

Fig. 154. Installation of support of a bent shaft


Establish support (fig. 154) of the central radical bearings, paying attention to that jet valves under pistons were turned towards a forward part of the engine. Tighten bolts of support of bearings the moment (4,5±5%) of kgf · m.

Fig. 155. Installation of adapters: 1, 2 – adapters


Openings of adapters (fig. 155) have to coincide with oil channels of support of the central radical bearings and the trunk oil main. Moment of an inhaling of adapters of 5,5 kgfs · m.

Fig. 156. Drive of units: 1 – gear wheel of a bent shaft; 2 – gear wheel of the vacuum pump; 3 – gear wheel of the fuel pump; 4 – camshaft gear wheel; 5 – gear wheel of the oil pump; And, In, With – tags


Install the vacuum pump assembled, having combined tags And (fig. 156) on gear wheels of the pump and a bent shaft, tighten bolts the moment of 2,8 kgfs · m.
Install the oil pump and tighten bolts the moment of 2,8 kgfs · m.

Fig. 157. Installation of a back support of the radical bearing of a bent shaft


Establish a back support of the radical bearing of a bent shaft (fig. 157) together with a persistent washer so that openings for an oil supply coincided.

Installation of the camshaft
Having combined tags In and With (see fig. 156) on gear wheels, install the camshaft and tighten bolts the moment of 2,8 kgfs · m.
Grease the surfaces of basic necks of the camshaft with engine oil.

Installation of a flywheel

Fig. 158. Installation of a case of a flywheel


Establish a case of a flywheel (fig. 158) and fix it on the block of cylinders, having tightened bolts the moment of 4,8 kgfs · m; tighten nuts of fastening of a support of the back radical bearing to a flywheel case the moment of 2,8 kgfs · m.
Wipe a persistent flange and an epiploon of a support of the back radical bearing.
Oil an epiploon and establish it in a support. Establish a persistent flange on a support of the back radical bearing, clear and check bolts, especially their working surfaces.
Grease flywheel bolts according to tab. 8, remove surplus of oil.
Attach a flywheel to a bent shaft and insert bolts, tightening them in pairs cross the moment of 2 kgfs · m.
Double-check the moments of an inhaling of bolts by means of the dynamometer key established on 2 kgfs · m. Turn each bolt for 60 °, in pairs cross. Then tighten bolts the moment of 13,3 kgfs · m.

Check of axial movement of a bent shaft

Fig. 159. Measurement of axial movement of a bent shaft


Measure axial movement of a bent shaft (fig. 159) by means of the indicator.

Fig. 138. Support of the back radical bearing: 1 – back radical bearing; 2 – support of the back radical bearing; 3 – the valve is jet; 4 – persistent washer; 5 – back epiploon; 6 – ring


Axial movement has to be 0,153–0,304 mm. At a deviation from the set limits use persistent washers 4 (see fig. 138) other thickness (see the table to fig. 138).

Check of a face beating of a case of a flywheel

Fig. 160. Check of a face beating of a case of a flywheel


1. Install the indicator on an end face of a bent shaft (fig. 160) so that the leg of the indicator touched a flywheel case end face.
2. Before taking readings to exclude an axial gap of a bent shaft, it is necessary to move it back.
3. Put an indicator scale on 0 and, turning a bent shaft, take readings in four points.
4. The difference between the greatest and smallest indications should not exceed 0,20 mm that is the most admissible face beating of a case of a flywheel.

Check of a radial beating of an opening of a case of a flywheel

Fig. 161. Check of a radial beating of an opening of a case of a flywheel


1. Install the indicator on an end face of a bent shaft (fig. 161), at the same time the leg of the indicator has to touch a flywheel case in a point 1.
2. In each point of measurement move a bent shaft so that to eliminate radial gaps of a bent shaft in radical bearings. Put instrument readings on 0 and, turning a bent shaft, take readings in four points.
3. The difference between the greatest and smallest indication should not exceed 0,20 mm that is the most admissible radial beating of an opening of a case of a flywheel.

Check of a face beating of a flywheel

Fig. 162. Check of a face beating of a flywheel


1. Install the indicator on a case of a flywheel (fig. 162), at the same time the leg of the indicator has to touch a back end face of a flywheel.
2. Before taking all readings, move a bent shaft so that its axial gap was always chosen in one party (forward or back). Put instrument readings on 0 and, turning a flywheel, take readings through everyone 90 °.
3. The difference between the greatest and smallest indications should not exceed 0,10 mm that is the most admissible face beating of a flywheel.

Installation of sleeves of cylinders

Fig. 163. Installation of sleeves of cylinders: 1 – sleeve; 2, 3, 4 – sealing rings; 5 – a nest under a fillet; 6 – the lower aligning corbel;
7 – adaptation E


1. Install sleeves (fig. 163) in the block of cylinders and turn them approximately on 45 ° in both parties.

Fig. 164. Installation of sleeves of cylinders


2. Measure depth In (fig. 164) on which the sleeve is drowned in the block of cylinders, using special adaptation with the indicator 7 (see fig. 163). Depth In has to be 0,11–0,23 mm.
3. According to the received result of measurement, choose laying under a cylinder sleeve flange for receiving the necessary vystupaniye of a sleeve. Vystupany I sleeves has to be within 0,01–0,06 mm.

Note
After 50 business hours of the engine change of the size I determined to a sleeve vypressovka to minus 0,03 mm is admissible (the sleeve is drowned in relation to the block of cylinders).

4. Take out a sleeve, establish laying under a flange and sealing rings 2, 3, 4 on a sleeve 1.
5. Apply Molyguard LMP/180/2 or Polymer 400 sealant on the lower aligning corbel of the 6th block of cylinders.
6. Apply LOCTITE AVX sealant (special) 986 (or 586) on a fillet of a sleeve and a nest 5 under a fillet in the block of cylinders.
7. Install a sleeve in the block of cylinders. At the same time you watch that the sealing ring 2 was correctly inserted into the nest.

Fig. 165. Draft of sleeves of cylinders


8. Besiege sleeves of cylinders (fig. 165). For this purpose tighten bolts of fastening of a head the moment of 5 kgfs · m, using clips of 1 head of the block of cylinders and the plug of suitable diameter and height.
9. Clear the top surface of the block of cylinders of the sealant remains.
10. Check the size I (see fig. 163).
11. If installation of a head of the block of cylinders is postponed, it is necessary to keep load of sleeves during 12 h.
12. Between installation of sleeves and launch of the engine there have to pass not less than 6 h.

Note
At assembly of the new engine it is possible to use sleeves of two standard sizes (category A and B). In spare parts sleeves only are delivered to category A.

Installation of pistons and rods
Rods are delivered in a set on four pieces of one weight (as much as possible a tolerance of 18 g).

Fig. 128. Assembly of rods


Note
From a big head of a rod four brands are put: two on the rod and two on a cover of a big head of a rod. Two brands from deepening specify weight group on the mass of a rod in a head of the piston (see fig. 128).


Fig. 166. Installation of piston rings: 1 – top compression ring; 2 – lower compression ring; 3 – oil scraper ring


Install rings on pistons by means of the suitable tool and develop them so that position of locks corresponded to fig. 166.
Install pistons with rods according to the numbering made at dismantle.
Install pistons with rods so that deepenings in heads of pistons were turned towards the camshaft.

Fig. 167. Installation of the piston


To insert the piston into a sleeve (fig. 167), use the device for compression of piston rings.
Establish covers of the lower heads of rods, having provided coincidence of numbers on a body and a cover of a rod.
Tighten rod bolts.

Note
At assembly of the new engine pistons of two standard sizes can be used. In spare parts pistons only of one standard size are delivered.

Selection of laying of heads of cylinders
Install the first piston in VMT
by means of devices K and E (see the appendix 4).

Fig. 168. Selection of laying of heads of cylinders


The indicator (see fig. 168) measure distance from the piston bottom to the top plane of the block of cylinders on the left side. Pick up laying of heads of suitable thickness for the table.

Received
size,
mm
Thickness
laying,
m
Gap between the bottom of the piston and the plane of heads of the block of cylinders, mm
0,53-0,62
1,41
0,79-0,88
0,63-0,72
1,51
0,79-0,88
0,73-0,82
1,61
0,79-0,88

Fig. 169. Designation of laying of heads of cylinders


Designation of laying (fig. 169), mm:
  without groove of X       1,41;
  two grooves of X       1,51;
  one groove of X       1,61.

Installation of heads of cylinders
1. Carefully clear the surface of the block of cylinders.
2. Establish laying and heads of cylinders, be convinced of a dense prileganiye of heads to laying.
3. Cover a carving of bolts and flanges of their heads with structure of "Molyguard LMP 180 + Molycote" or SAE 30 oil with 20% additive of the additive Rothen.
4. Acquire bolts And yes

Fig. 170. Installation of heads of cylinders

In (fig. 170) manually, having convinced that they are centered correctly.
5. Temporarily establish an inlet collector and double-check density of a prileganiye of heads to laying.
6. Tighten bolts of heads of cylinders in the following sequence:
– M14 bolts the moment of 3,1 kgfs · m in the following order: 3–2–1–10–9–8– 7–6–5–4;
– tighten bolts of M14 on 70 ° in the following order: 1–2–3–4–5–6–7–8– 9–10;
– tighten bolts of M14 on 70 ° in the following order: 1–2–3–4–5–6–7–8– 9–10;
– bolts And (M12) tighten the moment of 3,1 kgfs · m;
– tighten bolts And (M12) on 85 °;
– bolts of B (M12) tighten the moment of 3,1 kgfs · m;
– tighten bolts of B (M12) on 85 °.
7. Establish racks of axes of yokes in the following order:
– install the piston of the first cylinder in VMT, combining tags on a pulley of a bent shaft and a forward cover of driving gear wheels;
– establish racks of axes of yokes of the second and third cylinders and tighten nuts the moment of 2,7 kgfs · m;
– turn a bent shaft on 90 ° clockwise, establish racks of axes of yokes of the first and fourth cylinders and tighten nuts the moment of 2,7 kgfs · m.
8. Launch the engine and let's it work 20 min. with the minimum frequency of rotation without loading.
9. Kill the engine and let's cool down not less than three hours.
10. Serially completely weaken and repeatedly tighten each bolt of M14 the moment of 3,1 kgfs · m with a double dovorachivaniye on 65 ° in the following order: 1–2–3–4–5–6–7–8–9–10.
11. Check an inhaling of bolts And yes During the moment of 9,2 kgfs · m.
12. Remove an inlet collector.

Note
The admission at the time of an inhaling of ±5%. The admission on an angle of rotation ±5 °.

Check of phases of gas distribution
Carry out check in the following order:
– rotate a bent shaft until the piston of the first cylinder does not reach compression step VMT;
– install the indicator on the inlet valve;
– slowly rotate a bent shaft clockwise;
– when the arrow of the indicator begins to move, check a corner of the beginning of opening of the inlet valve by means of adaptation S (see the appendix 4);
– move the indicator on the final valve and continue to rotate a bent shaft until the arrow of the indicator does not stop that corresponds to the moment of the end of closing of the final valve.
Other cylinders do not need check as the camshaft is designed with extremely narrow size of a deviation.

Fig. 171. Chart of phases of gas distribution


If the measured sizes do not correspond to the chart (fig. 171), then the gear wheel of the vacuum pump and a gear wheel of the camshaft are established incorrectly (see fig. 156).

Installation of the fuel pump of high pressure and gear wheel of its drive
Install the fuel pump with laying and a spline. Temporarily tighten nuts of fastening of the pump.
Establish a gear wheel, having combined tags With (see fig. 156).

Fig. 172. Installation of a cover of driving gear wheels


Install the piston of the first cylinder in compression step VMT. Turn · a nut of fastening of a gear wheel also establish to m by the moment of 8,8 kgfs on sealant (see tab. 8) a forward cover (fig. 172).

Installation of the fuel pump of high pressure in case of its removal without dismantle of a cover of driving gear wheels
1. At assembly check that the spline of a shaft was coaxial with a shponochny groove of a gear wheel.
2. Turn off a bolt of a stripper and install the pump with laying and a spline.
3. Acquire three nuts fixing the pump to a flange and wrap one of them, disconnect a stripper and tighten a nut, the fixing gear wheel, the moment of 8,8 kgfs · m.

Adjustment of a corner of an advancing of injection of fuel

Fig. 173. Installation of the indicator: 1 – adaptation K


1. Turn out the central stopper from the back party of the pump and install adaptation K (fig. 173).

Fig. 107. Tags for installation of the piston of the 1st cylinder in VMT: 1 – a tag on a pulley; 2 – a tag on a cover


2. Take readings of the indicator at the time of the termination of a deviation his shooters at turns of a bent shaft to the left and to the right on a small corner from situation 20-25 ° to compression step VMT in the first cylinder. Establish an arrow of the indicator on 0 ° by turn of a scale and rotate a bent shaft clockwise until the tag 1 (see fig. 107) on a pulley does not coincide with a tag 2 on a forward cover. If indications of the indicator exceed the limit of 0,68-0,72 mm, adjust a fuel supply advancing corner position of the pump, slightly turning its case before obtaining indications of the indicator of 0,68-0,72 mm to the left and to the right.
3. For bigger confidence repeat all measurements after tightening of nuts of fastening of the pump.
Establish a pulley of a bent shaft with a spline, holding a bent shaft for a flywheel. Tighten a nut after drawing structure of LOCTITE 510 on a carving of a bent shaft.
Turn the engine at the stand, establish a maslozabornik, without having damaged a sealing ring. Insert the valve of pressure of oil and be convinced that it freely moves in a nest.
Apply sealant on the lower flange of the block of cylinders. Establish an oil case and tighten its bolts the moment of 1,3 kgfs · m.

Fig. 174. Collector of the cooling system


Establish laying between a collector of the cooling system and heads of cylinders (fig. 174). Establish a collector and tighten bolts the moment of 1,2 kgfs · m.
Put laying of inlet and final collectors on heads of cylinders. Establish an inlet collector on hairpins and tighten nuts
moment of 3,3 kgfs · m. Repeat this operation for a final collector. Connect the proofreader's hose on pressurization of the fuel pump of high pressure to an inlet collector.

Fig. 175. Laying of a turbocompressor


Connect a turbocompressor to a final collector, having established metal laying (fig. 175). Tighten nuts the moment of 3,3 kgfs · m.

Fig. 102. Turbocompressor: 1 – tubes of a supply and removal of oil; 2 – turbocompressor


Connect pipelines of giving and discharge of oil to a turbocompressor (see fig. 102), previously having filled cases of bearings with oil to provide normal intake of lubricant within the first seconds of operation of the engine.

Fig. 176. Liquid and oil heat exchanger and oil filter: 1 – oil filter;
2 – union; 3 – liquid and oil heat exchanger; 4 – laying


Install the liquid and oil heat exchanger (fig. 176) with laying on the block of cylinders and fix it by the union the moment of an inhaling of 6,1 kgfs · m.
Establish an oil filter with laying, having tightened the moment no more than 1 kgf · m. Before installation oil laying by pure engine.

Fig. 177. Tubes of high pressure and pump: 1 tubes; 2 – pump of high pressure


Connect tubes of high pressure to the fuel pump and nozzles (fig. 177).
Establish a cover of yokes with laying. Tighten bolts the moment of 1,6 kgfs · m.

Fig. 103. Cooling system pump: 1 – pulley; 2 – bolt of fastening of a pulley; 3 – bolt of fastening of the pump; 4 – pump; 5 – laying; 6 – nut of fastening of the pump


Install the cooling system pump (see fig. 103) together with laying in a nest of the block of cylinders. Tighten bolts the moment of 2,5 kgfs · m.
Establish a pulley and tighten bolts the moment of 2,5 kgfs · m.
Install the thermostat and connect all hoses of the cooling system.