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Check Engine
| PERFORMANCE ORDER | | 1. Clean all the components of the engine. | | 2. Remove the engine block gasket remnants, sealant, dirt, oil, grease and other foreign material. |
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Check the cylinder head | PERFORMANCE ORDER | | 1. Inspect the cylinder head for damage, cracks, leaks, oil and coolant. If necessary, replace the cylinder head. |  | 2. The metal ruler and probe in six directions check the flatness of the cylinder head. If necessary, pereshlifuyte cylinder head. Maximum rounding: 0.1 mm | 3. If the flatness exceeds the allowable limits, replace or pereshlifuyte cylinder head.
Repair or replace cylinder head if the following defects:
- Burned-out valve seats;
- Damage to the mating surface for the installation of the intake and exhaust manifolds;
- Damage to the nests for the installation of oil sealing rings of camshafts. | | 4. Measure the height of the cylinder head from the bottom surface of the head to the surface of the installation gasket cylinder head cover. |  | 5. If the height of the cylinder head is different from the nominal values, replace the cylinder head. Height:
TED: 133,9-134,1 mm
BFD: 133,8-134,0 mm |  | 6. The metal ruler and stylus in two directions measure planeness of interfaced surfaces of collectors. Deviation from flatness of not more than 0.20 mm | | 7. If the flatness exceeds the allowable limits, replace the cylinder head. | | 8. The metal ruler and probe in six directions check the flatness of the mating surface of the cylinder. Deviation from flatness of not more than 0.20 mm |
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Check valves | PERFORMANCE ORDER | 1. Examine each valve on revealing of following defects:
- Damage or deformation of the valve stem;
- Damage to the valve plate;
- Damage or uneven wear of the valve stem end. |  | 2. If necessary, repair or replace the valve. The height of the edge of the valve:
TED: 1,2 mm
BFD: 1,0 mm |  | 3. Measure the length of each valve. The length of the valve:
The inlet valve:
TED: 10,2,92 mm
BFD: 105,29 mm
Exhaust valve:
TED: 101,42 mm
BFD: 105,39 mm |  | 4. micrometer at several places in height, measure the diameter of the valve stem. The diameter of the valve:
Intake valve: 5,970-5,985 mm
Exhaust valve: 5,965-5,980 |  | 5. Nutromer, in several places, measure the inner diameter of the valve guides. The inner diameter of the guide inlet and exhaust valves: 6,01-6,03 mm |  | 6. Calculate the gap between the guide sleeve and valve stem. For this subtract the outer diameter of the valve stem from the inner diameter of the corresponding valve guide. Gap:
The inlet valve:
TED: 0,050-0,060 mm
BFD: 0,040-0,045 mm
Exhaust valve:
TED: 0,030-0,065 mm
BFD: 0,045-0,050 mm
Limit: 0,020 mm | | 7. If the backlash exceeds the limit, replace the valve and / or valve guide. |  | 8. Measure the height of each protrusion of the valve sleeve. If necessary, replace the valve guide. The inlet valve A:
TED: 13,7-14,3 mm
BFD: 16,8-17,4 mm
Exhaust valve:
TED: 16,7-17,3 mm
BFD: 18,1-18,7 mm |
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A warning  Guide bushings intake and exhaust valves are different.
Check the valve seat
| PERFORMANCE ORDER |  | 1. Check the work surface and chamfer the valve seat for the following defects:
- roughness;
- Burn-out;
- Pitting;
- Cracks. |  | 2. Special cutting tool 45 ?� restore a working edge of the valve seat. |  | 3. Apply a specially formulated blue on a working facet of the valve and the valve and let dry composition. | | 4. Install the valve in the valve seat, push and rotate by 360 ?�. If the blue structure is not completely removed from a working facet of the valve, replace the valve. If the blue structure is not completely removed from a working facet of the valve seat, re-treat with the valve seat. |  | 5. Measure the width of a working facet of the valve. Width:
TED: 1,98-2,69 mm
BFD: 0,8-1,4 mm |  |  | | 6. Check the depth of the working surface of the valve seat by measuring it in the center of the valve face. If the valve is mounted in the valve seat is too high, process valve seat scan angle 63 ?�, is then scanned with an angle of 45 ?�. If the valve is mounted in the valve seat is too low, the valve seat treat the scan angle of 0 ?�, then scan angle of 45 ?�. | | 7. Using a special abrasive powder, grind the valve and valve seats. |  | 8. Clean the valves and valve seats of the remnants of the abrasive powder. |  | 9. Install the valve in the cylinder head and measure protrusion (Size L) of the valve stem with respect to the installation the bottom of the valve spring. |
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Check the valve spring
| PERFORMANCE ORDER | | 1. Inspect each valve spring for cracks and damage. |  | 2. Measure the length of the spring in the free state. Install the spring on a flat horizontal surface and measure the deflection of the spring from the top of the vertical plane. The length of the spring in a free state:
TED: 46,7 mm
BFD: 45,6 mm
Maximum permissible deviation from the vertical plane of the spring:
TED: 1,63 mm
BFD: 1.59 mm | Checking camshaft | | 1. Place the first and last cervical camshaft on V-shaped blocks. | | 2. Place the measuring head dial indicator to the middle neck bearing of the camshaft and install the indicator scale to 0. |  | 3. Turn the camshaft and measure its palpation. Maximum permissible camshaft runout: 0.03 mm | | 4. Check the camshaft to the absence of uneven wear, cracks or damage. |  | 5. In the two points, measure the height of each cam camshaft. The height of the cams of the inlet camshaft:
TED: 41,6949 mm
BFD: 40,888 mm
Height cams exhaust camshaft:
TED: 42,2369mm
BFD: 40,688 mm | | 6. In the two perpendicular directions, measure the diameter of each camshaft necks. Nominal Diameter:
TED: 26,940-26,965 mm
BFD: 25,940-25,965 mm
The minimum allowable diameter:
TED: 26,910 mm
Maximum allowable roundness: 0.05 mm | | 7. If the wear of the camshaft bearing journals exceeds the limit, replace the camshaft. | 8. Measure the clearance in the bearings of camshafts in remote hydraulic valve compensators. | | 9. Clean the grease from the neck of the camshaft bearing, bearing caps and bearings in the cylinder head. | | 10. Install the camshafts on the cylinder head. . | | 11. In order to measure the clearance using a plastic calibrated round bar Plastigage. Plastigage rod is compressed between the bearing and the neck of the camshaft. After removing the camshaft bearing cap, the deformed plastic core Plastigage measured by a special pattern, which is available in the kit. Cut pieces of plastic rod and place them on the neck of a camshaft | | 12. After installing the plastic core are not turn the camshaft. | | 13. In accordance with the label, set the camshaft bearing caps. |  | 14. Install the bearing cap bolts and tighten them to 5-6 stages. The inhaling moment: 11,3-14,2 N ??? m | 
| 15. In certain sequence for 5-6 stages turn out bolts of fastening of covers of bearings of camshafts. | | 16. Remove the camshaft bearing caps. |  | 17. By measuring the pattern width of the deformed plastic core, identify gaps in the camshaft bearings. Nominal backlash: 0,035-0,081 mm
Maximum permissible backlash: 0,15 mm | | 18. If the backlash exceeds the limit, replace the cylinder head. | | 19. Install the camshafts in the cylinder head. | | 20. Establish a measuring tip of a dial indicator on the end of the camshaft. | | 21. Move a camshaft along the axis of the way to one side. | | 22. Establish an arrow of a dial indicator to 0. | | 23. Move a camshaft along the axis of the way to the other side. |  | 24. Review the evidence on the dial gauge, which shows the amount of axial play of the camshaft. Nominal axial clearance: 0.08-0.10 mm
Maximum permissible backlash: 0,20 mm |
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Check of hydraulic jacks of backlashes of valves
| PERFORMANCE ORDER | | 1. Check the front side of the hydraulic jacks of backlashes of valves for wear or damage and, if necessary, replace them. |  | 2. Fill the hydraulic jacks of backlashes of valves clean engine oil and squeeze them on both sides. If the hydraulic valve clearance compensator is compressed, replace it. Never attempt to rebuild or repair the hydraulic jacks of backlashes of valves. |  | 3. In the opposite direction, measure the diameter of the cylinders for hydraulic jacks of backlashes of valves. Diameter: 30,000-30,025 mm | | 4. In the opposite direction, on two levels, measure diameters of hydraulic jacks of backlashes of valves. Diameter: 29,959-29,975 mm |  | 5. Calculate the clearance between the cylinder of the hydraulic jacks of backlashes of valves and hydraulic jacks. If the backlash exceeds maximum permissible, replace the hydraulic jacks of backlashes of valves and / or the cylinder head. Nominal backlash: 0,025-0,066 mm
Maximum permissible backlash: 0.180 mm |
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Checking cylinder blocks | PERFORMANCE ORDER | 1. Check the cylinder block for the following damages:
- Local damage or leakage;
- Cracks;
- Development of the cylinder. |  | 2. The metal ruler and probe in six directions check the flatness of the mating surface of the cylinder. Deviation from flatness: 0.15mm |  | 3. If the flatness exceeds the allowable limits, pereshlifuyte block. Maximum permissible rounding: 0.20 mm. | | 4. If necessary regrinding of the cylinder to a larger value, replace the cylinder block. |
A warning Before rounding the cylinder, measure the height of the cylinder from the axis of the crankshaft to the top mating surface.
|  | 5. Measure the diameter of the cylinder in diametrically opposite directions in three dimensions by adjustment cylinders. Bore:
Nominal:
TED: 81,006-81,019 mm
BFD: 78,006-78,019 mm
Repair 0.25 mm:
TED: 81,256-81,269 mm
BFD: 78,256-78,269 mm
Repair 0.50 mm:
TED: 81,506-81,519 mm
BFD: 78,506-78,519 mm |  | 6. To determine the conicity of the cylinder, measure the diameter of the cylinder in the upper, middle and lower parts. Maximum allowable taper:
TED: 0,019 mm
BFD: 0,15 mm
Roundness: 0,019 mm | Check nozzles for cooling pistons |  | 7. Feeding compressed air into the hole A spray gun, check that the air comes out of the hole B. If the air does not pass, replace the dispenser. Air pressure: 245,3-301,4 kPa | | 8. Check the oil spray tip to the absence of pollution of internal channels. If necessary, replace the spray tip. |
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Checking the pistons
A warning When replacing the piston as the piston rings must be replaced.
| PERFORMANCE ORDER |  | 1. Check the outer surface of the piston for damage, develop or uneven wear. If necessary, replace the piston. |  | 2. Measure the outer diameter of each piston rod 90 ?� to the piston pin, at a distance of 21.5 mm in the engine TED and spaced 17.6 mm engine BFD lower edge scraper ring.
Bore TED
Rated 80,9540-80,9720 mm
1st repair (0.25) 81,204-81,222 mm
2nd repair (0.50) 81,454-81,472 mm
BFD
Rated 77,954-77,974 mm
1st repair (0.25) 78,204-78,224 mm
2nd repair (0.50) 78,454-78,474 mm |  | 3. Calculate the clearance between the piston and the cylinder wall by subtracting the diameter of the largest diameter of the piston cylinder, in each cylinder. Nominal backlash:
TED: 0,040-0,053 mm
BFD: 0,032-0,065 mm
Maximum permissible backlash: 0,15 mm | | 4. If the backlash exceeds the limit, replace the piston to the larger size of the repair and chisel cylinders. |
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Checking of piston rings | PERFORMANCE ORDER |  | 1. Insert the new piston ring in the groove of the piston, and the probe, measure the clearance between the piston ring and the wall of the groove. The gap between the piston ring and the groove in the piston,
1st compression ring TED: 0,04-0,08, BFD: 0,030-0,065
Maximum permissible backlash - 0.15
2nd compression ring TED: 0,03-0,070, BFD: 030-0,065 | | 2. If the clearance exceeds the limit, replace the piston. | | 3. Check the piston rings for damage or wear or breakage. | | 4. If necessary, replace the piston rings. | | 5. Measure the end gap of the piston rings, piston ring is manually inserted into the engine cylinder. |  | 6. piston crown push the piston ring into the bottom of the cylinder. |  | 7. The probe measure the end gap of the piston ring. The gap piston ring:
The first compression ring: 0.15-0.30 mm
The second compression ring: 0,30-0,45 mm
Scraper ring: 0,20-0,70 mm
Maximum permissible backlash: 1,0 mm | | 8. If the backlash exceeds the limit, replace the piston rings. |
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Check piston pin | PERFORMANCE ORDER |
| 1. Measure the hole diameter of the piston pin in the piston in two diametrically opposite directions, the four planes. Diameter:
TED: 19,994-20,002 mm
BFD: 19,998-20,000 mm |  | 2. Measure the diameter of each piston pin in two opposite directions, the four planes. Diameter:
TED: 19,987-19,993 mm
BFD: 19,974-19,980 mm | | 3. Determine the clearance of the piston pin in the piston by subtracting the diameter of the piston pin hole diameter of the piston pin. Gap:
TED: 0,001-0,015 mm
BFD: 0,008-0,026 mm | | 4. If the clearance exceeds the standard value, replace the piston and piston pin. |
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Checking the connecting rod | PERFORMANCE ORDER |
| 1. Measure the inner diameter of the connecting rod. The inner diameter of the connecting rod:
TED: 20,003-20,013 mm
BFD: 19,943-19,961 mm | | 2. Determine the clearance of the piston pin in the connecting rod by subtracting the diameter of the piston pin hole diameter of the connecting rod. Gap:
TED: 0,010-0,027 mm
BFD: 0,013-0,037 mm | | 3. If the clearance exceeds the standard value, replace the plug in the top head of a rod. | 
| 4. Check the bending of each rod. | | 5. If necessary, replace connecting rods. Replace the connecting rod is held together with a rod cover. |
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Checking crankshaft | PERFORMANCE ORDER | | 1. Check the neck main and connecting rod bearings of the crankshaft for wear and generation. | | 2. Check the opening for lubricating the crankshaft to clogging. | | 3. Place the first and last cervical crankshaft bearing on the V-shaped blocks. |  | 4. Install the measuring head dial indicator, the average crankshaft bearing journal and set the dial indicator to 0. Turn the crankshaft and measure its palpation. If the runout exceeds the nominal heartbeat, replace the crankshaft. Heartbeat: 0.04 mm |  | 5. micrometer measure diameters of necks of the crankshaft in two diametrically opposite directions. | | 6. If you have a development or oval, pereshlifuyte crankshaft. | | 7. reground crankshaft journals is carried out only until the next repair size. | | 8. If the crankshaft reground to repair size 0.50 mm, draw the heat treatment of the shaft to increase its durability. The diameters of the necks of the crankshaft bearing:
1st repair size (0.25 mm):
TED: 54,688-54,706
BFD: 49,688-49,706
2nd repair size (0.50 mm)
TED: 54,438-54,456
BFD: 49,438-49,456
3rd oversize (0.75 mm):
TED: 54,188-54,206
BFD: 49,188-49,206
The diameters of the necks connecting rod bearings of the crankshaft:
1st repair size (0.25 mm):
TED: 44,690-44,708
BFD: 39,960-39,706
2nd repair size (0.50 mm)
TED: 44,440-44,458
BFD: 39,440-39,456
3rd repair size (0.75 mm)
TED: 44,190-44,208
BFD: 39,190-39,206 |
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Checking the connecting rod and indigenous inserts
| PERFORMANCE ORDER | 
| Check the connecting rod and indigenous inserts the absence of local corrosion, development and other damage. If necessary, replace the pads. |
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Checking toothed belt
A warning Strongly do not bend a gear belt or change its direction of rotation. Do not allow oil and lubricant to come into contact with toothed belt, as it will lead to its destruction.
| PERFORMANCE ORDER |  | 1. Replace the timing belt, if it is contaminated with oil or lubricant. |  | 2. Check the toothed belt for damage, wear, separation, cracks in the teeth and at the base of teeth, and the defects at the ends and back of the belt.
In the presence of defects, replace the timing belt. |
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The mechanism of a tension of a gear belt and the guide roller
A warning Do not clean the roller mechanism of a tension or guide roller toothed belt with cleaning fluids. Ointment is allowed to clean the rollers with a soft cloth. Do not scratch the surface of the work rolls, as it will lead to premature wear of the toothed belt.
| PERFORMANCE ORDER |  | | | Check roller tensioner and idler roller for smooth rotation and lack of noise during rotation. If necessary, replace the tensioner roller or guide roller. |
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Spring tensioner | PERFORMANCE ORDER |  | Measure length of a spring mechanism of a tension in a free state. If the length of the spring is different from the nominal value, replace it. The length of the spring in a free condition
TED: 35.6 mm
BFD: 59,5 mm |
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Ribbed camshafts
A warning Do not clean the pulleys using cleaning fluids. If necessary, use a clean, soft cleaning cloth. Do not scratch working surfaces of pulleys, as it will lead to premature wear of the toothed belt.
| PERFORMANCE ORDER |  | Check the teeth of pulleys for wear and damage. If necessary, replace the pulleys. |
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