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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Mazda 626 / MX-6 (from 1982 to 1991, the year of issue)

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Mazda 626 / MX-6
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626 / MX-6
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Wear of the cylinder group
The car engine is sometimes compared to a man's heart. Indeed, it runs continuously until the car is moving. However, such a comparison is not quite correct. The heart, like any living organism, continuously restores itself: there are constant processes of the extinction of old cells and replacing them with new, young. What can not be said of inanimate mechanism - the engine. He is, despite all our efforts, wears almost irreversible. However, the intensity of the wear life of the engine overhaul, as well as the durability of the entire vehicle as a whole is largely dependent on how well it is done and well maintained.
Particularly susceptible to wear the main engine parts - pistons with piston rings, connecting rods and cylinders. Working piston engine most impressive. After moving reciprocally between the upper and lower dead point, they cover a great distance. Thus, when
engine speed of 5,000 min-1 and the stroke of the piston, for example, 75 mm total path surmounted piston per minute, is 375 m. One hour of engine operation, this distance will be 250 m 2 km, and after a month of operation for 8 hours per day excluding weekends (which, of course, it is unlikely for the average car), the piston will overcome the distance of 460 km. With intensive use of the vehicle for 5 years (ie the duration of operation of such a vehicle to engine overhaul confirmed by statistics), the piston will cover 24,000 km away!
Thus, the wear of the piston and mating with him parts (engine cylinder) is inevitable. However, the values of wear piston (pistons, piston rings) to overhaul the engines for various firms are very different from each other. For example, limiting the wear of piston rings and piston engines Mercedes-Benz, Volkswagen, BMW, the majority of American and Japanese firms comes after a run of about 300 000 km.
At the same time, other motors, for example, less sophisticated models require replacement of pistons and piston rings 50 after the 000 km (about 10 times less).
What was the reason? And the durability of these components depends on the operating conditions? To answer these questions, let us consider two typical designs of piston gasoline engine and a diesel engine. Note first that the gas pressure inside the cylinders of the engine at the beginning of the stroke differ by about two times. The gasoline engine - carburetor or with direct fuel injection, it is 40-55 kg / cm 2, in a diesel engine -
70-80 kg / cm 2. Therefore, the pistons of petrol and diesel engines differ from one another, although the major design decisions have the same.
The typical gasoline engine piston cast from an aluminum alloy and covered outside with a layer of tin to improve the running to the mirror cylinder. The diameter of its upper part - head - 0.1 mm smaller than the inner diameter of the cylinder. This is to prevent jamming of the piston head in the cylinder on heating to the working temperature. The piston ring grooves are located two compression rings and one oil scraper. The lower part of the piston - Skirt - oval in cross-section, and the height of the conical shape: at the top of a smaller diameter than the bottom. Moreover, inside the piston bosses with holes for piston pin has two steel thermostatic insert. All this is done to prevent an increase in friction between the skirt and the cylinder bore when heated piston. With less than that of aluminum, the coefficient of thermal expansion of the insert tightening the skirt in a direction perpendicular to the piston pin axis.
Hole piston pin in modern engines is usually displaced from the axis of symmetry of the piston to the right side of the engine. For proper piston rod assembly and install them into the cylinder near the opening of the boss has a tag which is intended to face towards the front of the engine. Such a shift is made to reduce the lateral component of the force of gas pressure, pressing the plunger to one side of the cylinder during the power stroke.
The connecting rod must also be oriented correctly in the engine. On its front side with holes for supplying oil to jet loaded side mirror of the cylinder (in some engines, these holes are not available). Inserts and cover the bottom of the connecting rod are also provided with corresponding labels for proper assembly. The accuracy of manufacture of the piston and the faithful of his selection to the opening of the cylinder depends essentially on its subsequent performance and durability. Leading engine-building companies used today system, whereby the pistons on the outer diameter typically divided into five or six classes by 0.01 mm. Besides
They are divided into three or four categories increments of 0.004 mm in accordance with the diameter of the piston pin hole. The cylinders of the engine also has a similar division into five classes. This system allows you to more accurately pick up the piston to anyone, even worn-out cylinder and piston pin of the category - the hole in the bosses and the connecting rod. For the overhaul of engines, which consists usually bore (increase in diameter) cylinders, parts manufacturers produce so-called reconstruction pistons increased size.
The piston of the modern diesel engine designed to take higher pressures, so the thickness of the bottom of his bosses and more. Furthermore, the design of the piston of a diesel engine is somewhat different from that discussed above. The main difference - is the placement of the combustion chamber directly into the piston head. Since combustion of the fuel mixture occurs when finding the piston near the top dead center, the hot gases are heated more strongly piston head and the walls of the upper cylinder heated slightly smaller than gasoline engines. For a reliable sealing of the piston in the cylinder on its outer surface made five grooves for mounting piston rings. The three upper grooves installed compression rings. In the lower grooves there are two oil ring. Many companies produce compression ring rectangular, almost no different from the rings of gasoline engines. However, a more progressive, although more costly, is the design with a conical upper working surface of the ring. The angle of the cone of such rings are usually made at 10 ?�. The use of cone rings provides some increase in their longevity, as during the travel component of the force of gas pressure on the tapered surface of the ring further presses it to the mirror cylinder. Feature of maintenance and repair pistons with tapered compression ring is a need for precise control of clearances. The gaps between the groove and the oil control rings as well as gasoline engines.
The friction forces between the surfaces of the piston skirt and the cylinder bore in diesel engines than in petrol engines. To increase the durability of the surface of the piston skirt with a layer of special colloidal graphite coating. It greatly improves the running-piston to the cylinder and extend his work to overhaul. A similar treatment of the friction surfaces of pistons used today and gasoline engines.
In addition to surface wear skirts, worn grooves and compression rings of pistons. In addition, wear and groove maslosemnogo ring, although this is usually much less wear. When worn piston ring grooves are becoming more intensively to move up and down the height of the groove and all the more tangible becomes a so-called pumping action of the rings. This effect is all the more increases the cost of the engine motor oil. In the combustion chamber, oil is burnt there to form a blue smoke, which emerges from the exhaust pipe of a vehicle. With a significant deterioration of the replacement ring grooves in the new situation a little better. It occurs objective need to replace the entire piston, wherein the cylinder bore is very desirable to oversize. All these kinds of wear - it is a natural and, unfortunately, irreversible process.
Nevertheless, the wear and tear can stretch over time, so prodlivaya engine life. America does not need to open here. Just be sure to comply with the manufacturer's manual, using high-quality motor oil and oil filters, fuel equipment properly adjusted. Good results are obtained by the use of high-quality oil modifiers and fuel, drugs that alter the microstructure of the surface layers of the friction surfaces of engines.
In addition, the deterioration of the engine, as well as the entire vehicle as a whole is largely dependent on the driver, from his skill and technical expertise. It is not for nothing that the cars of the same brand in some drivers are long and trouble-free, while others - repaired almost every week. An experienced driver is almost never run the engine with overdrive, and especially with
detonation. He always listens to how the engine of his car, and immediately respond to any overloading, usually accompanied by a low-pitched sound of booming at low engine speeds. Acceleration mode also
accompanied by increased engine wear. Here the analogy with horse and rider: careful owner will not be unnecessarily whipping his four-legged friend, forcing him to run off the bat, especially if the horse has not yet warmed up. Of course, in an emergency, the driver can not afford dashing, very sharply accelerate the vehicle. But if such a cool style of driving is a habit, engine repair will be provided twice before the stipulated specifications.
Often, there is another not covered by any type of wear instructions. This emergency breakdown elements shatunno? Piston rings and above all bridges and piston ring grooves. In gasoline engines, it is primarily due to the detonation. Recall that knocking - is the explosive combustion of the fuel mixture in the cylinder, followed by an abrupt pressure rise in the combustion chamber. This is equivalent to a sharp blow with a sledgehammer on the stationary piston and rings. Details, of course, are not designed for this load and can break, then its fragments damaged the cylinder bore. Knock a few reasons. However, the main of them - the work of the engine on gasoline lower than that provided by the technical specifications, octane, as well as overheating and working on pereobogaschenie combustible mixture. An experienced driver is obliged to hear the detonation knocking when the engine and immediately reduce the supply of fuel during acceleration, and then remove the causes detonation. The sound of the detonation - a high-pitched metallic clicks that match the frequency with the frequency of rotation of the crankshaft. They may be barely audible in the background of other sound of the engine, especially at a slightly earlier the ignition, and disappear in the very slight decrease in supply of fuel (gas). This barely noticeable detonation indicates correctly adjusted ignition timing angle, but it also happens that the detonation knocking appear immediately when you press the accelerator pedal, which, of course, unacceptable. Continue to move in this mode is equivalent to breaking hammer engine internals.
Diesel engines are not as sensitive to changes in composition of the fuel, although they get into trouble, leading to increased wear of parts of the crank mechanism. This is primarily the engine to overheat and the associated reduction in viscosity of the oil, especially if the quality of the oil is low. Increased wear may also be due to incorrect adjustment of high pressure fuel pump and the deterioration of fuel atomization in the combustion chambers due to the disruption of the nozzles. And, of course, much depends on the driver.
So from all this we can draw the following conclusions. The durability of the engine of your car, as well as the whole vehicle as a whole, depends on two factors: the quality of workmanship, which is responsible for the manufacturer, and the level of technical operation for which is ultimately responsible driver. This should be remembered as when buying a car, and in the preparation and training of drivers.

Engine Bearings
What bearings installed in your engine? Not all motorists can answer this question convincingly.
However, bearings are there. And it is not any, and it is quite certain. They are durable, but not eternal, and when fail, then without understanding the essence of the case is necessary. But for professional repairmen it is the ordinary matter.
How does bearing
The modern automobile engines bearings for crankshafts and camshafts in almost all cases are the bearings. Rolling bearings (ball, roller, needle) is used for such purposes only small motorcycle engines.
The required performance sliding bearings is achieved by using the effect of the so-called oil wedge. When rotating smooth shaft in the gap between the shaft and the oil supply hole. Since the load acting on the shaft is eccentrically offset oil as it is drawn into a tapering gap and forms part of the oil wedge, which prevents contact of the shaft with the hole wall. The greater the pressure and viscosity of the oil in the gap, the greater the load (to the ground surface) withstand the slide bearing.
The actual oil pressure in the zone of the wedge reaches 50-80 MPa (500-800 kg / cm 2), and in some designs and more. This is several hundred times higher than in the flow system (engine lubricating system). But we should not think that the supply pressure has little effect on the operation of the bearing. The higher it is, the more intense is pumping oil through the bearing and the better it cools.
Under certain conditions, operation with a minimum of friction (also called a liquid) may be broken. This happens at low viscosity, for example due to overheating due to lack of supply, and reducing the engine speed as the load increases.
Often, especially after engine repairs, it affects non-optimal geometry node. With slight deviations from the cylindrical shape of surfaces, with misalignment and other defects of parts possible local increase in the specific load (ie, load, divided by the surface area) above the allowable limit. Then the oil film in these places becomes thin, and the surfaces of the shaft and the bearing contact on start microroughness. There is a mixed lubrication regime characterized by an increase in friction and gradual heating of the bearing. Further it may lead to the so-called boundary lubrication with full contact of the friction surfaces, which will result superheat setting (teaser), galling, melting and destruction of the bearing.
It is understood that the operation mode of the boundary friction is unacceptable. Nevertheless, it takes place in violation of the oil supply, and it most often occurs because of its shortage of housing, either due to negligence of the driver, or if damaged sump resulting from a collision with an obstacle.
Mixed lubrication regime is allowed only for a short time when he did not have time to affect the wear of the bearing. Example - start a cold engine. However, there is another danger: at very low temperatures the oil may become too viscous and normal supply is restored it for too long (20-30 or more). In this case, mixed lubrication and is able to significantly influence the wear.
Improving the design of automobile engines due to the constant increase in engine speed and an increase in engine power. Simultaneously, there is a tendency to increase the compactness of structures, including reducing the width and diameter of the bearings. This means that the specific voltage at the node increasing friction. Since the load on the bearing when the engine cycle varies in magnitude and direction, it increases the likelihood of the so-called fatigue failure of parts. To ensure the health of bearings in such circumstances requires special designs, materials and technologies.
How does the plain bearing
Typically, bearings of crankshafts in a modern engines made in the form of thin-walled bushings or sleeves thickness of 1.0 to 2.5 mm (rarely more). Inserts crankshaft bearing is thicker because of the need to place them in a circular groove to supply oil to the connecting rod bearings. The general trend - a reduction of thickness of loose leaves which now averages 1,8-2,0 mm at radical and 1,4-1,5 mm at the connecting rod bearings. The thinner the ear, the better they adhere to the surface of the bearing housing (bed), the better the heat is removed from the bearing, precise geometry, less admissible backlash and noise at work, a great resource site.
In order when installing the bed liner exactly it took shape in a free state, he should have a tightness on diameter of bed (so-called straightening) and not cylindrical form of variable radius. In addition, for a good fit to the retention surface and the necessary tightness against rotation and along the length of the liner - called protrusion. All these parameters depend on the thickness, width and diameter of the liner, is a straightening
average of 0.5-1.0 mm, and the protrusion - 0.04-0.08 mm. However, for reliable operation of the bearing it is not sufficient. Near the parting line liner thickness is reduced by 0,010-0,015 mm to avoid burrs in these areas. Bullies can appear due to the deformation in the bearing housing holes in the cylinder block under the workload when operating clearance in the bearing is small.
Materials for the inserts may be different. Their selection will depend on the choice of the material crankshaft and heat treatment, and the degree of forcing engine specified resource. To a certain extent affect here and traditions of automobile firm.
Inserts are always made layered. The base liner - steel tape which provides durability and reliability of landing in the bearing housing. Based on the different ways a layer (or multiple layers) of a special anti-friction material, whose thickness is 0.3-0.5 mm. The main requirements for antifriction materials are low friction on the shaft, high strength and thermal conductivity (ie the ability to dissipate heat well from the surface of the shaft to the bearing housing). The first requirement is best to provide soft metals, such alloys with a high content of tin and lead (in particular, are widely known babbitt metal).
In the past, babbitt metal widely used in the low-speed engines maloforsirovannyh. With growth of loadings durability of such loose leaves with a thick layer of babbitt was insufficient. The problem was solved by replacing all of this layer to a kind of "sandwich" - lead-tin bronze, covered with a thin (0.03-0.05 mm) layer of the same babbitt. The liner has become multi-layered.
In modern engines stalebronzobabbitovye liners usually operate chetyrehhsloynymi (under the babbitt is still very thin layer of nickel) or double-double, when to improve the running on top of the working surface is applied a thin layer of tin. That is how the bearings on many foreign engines.
Along with this widespread and steel-aluminum inserts. Antifriction materials herein are aluminum alloys with tin, lead, silicon, zinc or cadmium as a coated or without them. The most frequently used in the world aluminum alloy with 20% tin uncoated. It has good resistance to high loads and rotational speeds of modern engines, including
diesel engines, and at the same time possesses satisfactory "softness." Nevertheless steel-aluminum inserts tougher than babbitovye (or babbitt coating), so more prone to scuffing in case of insufficient lubrication.
Auxiliary and camshafts of engines rotate, as a rule, with fewer than cranked and test much smaller loadings, therefore, the conditions of their work easier. Inserts of these shafts and bushings are conventionally made of materials similar to those described. In addition, it is sometimes used Babbitt bronze or uncoated. Often, these bearings do not have sleeves or inserts and bore a hole formed directly in the cylinder head. In such designs, the head is made of aluminum-silicon alloy, which has some good anti-friction properties.
General Bearing modern engines, especially when it comes to bearings of crankshafts, it is a suitable material and construction of the liner material and shaft working conditions (speed, load, lubrication conditions, etc.). Therefore, an arbitrary part replacement when, for example, repair inserts put on another engine, can not be recommended. Otherwise the life of the repaired unit may be very small. to be decided on this step, you need to have the relevant information.
Plain bearings are highly accurate (precision) parts. to ensure a small, but definite (average 0,03-0,06 mm) working clearances in the bearings, in the manufacture of a thickness of the liner is kept within about 5-8 microns, and the length - 10-20 microns. Violation of these requirements can lead to a change in working backlash in the bearing or density of landing liner in the housing, which is unacceptable, because it can lead to reduced reliability and service life of all engine as a whole.
Who produces bearings
The complexity of the whole range of issues related to the creation of high-quality automotive bearings of sliding, led to the fact that their production is gradually transferred to specialized firms. Abroad, many of these companies simultaneously produces other engine parts, and the supplies are both conveyors automobile plants and sold - as spare parts. Some firms of this kind are part of the well-known transnational industrial and commercial and industrial corporations. Of the world's manufacturers of plain bearings for engines should first be noted the company Kolbenschmidt (KS), Glyco, TRW, Sealed Power, Glacier, Clevite, Bimet. In recent years, the bearings and began to make such firms "luminaries" as Mahle and Goetze. Among the "young" is worth mentioning specialized firm King (Israel), began bearing production in the early 80-ies. Most of these manufacturers produce a huge range of bearings and sells its products in spare parts everywhere, including on our market (through dealers or wholesale trading companies). Basically, of course, it's bearings for engines of foreign cars - European, Japanese and American.
The inserts can be found commercially, both standard and repair various sizes (different from the standard, usually not more than 0.75 mm) for the most common models. In the less common models, as well as having to buy more liners repair size usually have to issue an order and wait for an average of 5-10 days (at different trading firms, these terms are different).
The quality of such products is usually not in doubt either in geometry or in materials. Although, if you have a choice, and doubt what the manufacturer's give preference, we must bear in mind the following. Such firms as Kolbenschmidt, Glyco, Glacier - is one of the main suppliers for mass production. When buying their products you can even get the same pads that put on the engines "at birth." The difference is only in the absence of details on the new emblem of the company - the manufacturer of the vehicle. By the way, search for "native" (or so-called original) loose leaves of the repair sizes can be problematic. Not all car repair firms supply inserts in parts, and the price of loose leaves in the "original" pack are usually significantly higher than directly from the manufacturer.
Inserts made by other, less famous firms are usually cheaper, but find differences in workmanship will be difficult. Moreover, if there is a choice, then you can try to take into account the use of the vehicle. Thus, relatively inexpensive liners, oddly enough, a little bit better withstand low-quality motor oil and oil filter, "walk" through our shops and markets, the more expensive stalebronzobabbitovye. In particular, experience has shown the use of steel-aluminum inserts repair company instead of the regular King bronzobabbitovyh: this substitution does not prejudice the reliability of the engines, but it allows you to save considerably.

Timing belt timing
Today, timing belts have found a "second wind." Nearly all automakers equip their vehicles elastic drive. German designers have gone further. They are widely used double-toothed belt (Duplex) as a reliable connection of the camshaft with a crank mechanism.
The toothed belt has a number of advantages over the drive chain. The latter is clearly more expensive. Craft belt is much easier than a chain. In essence, the toothed belt - is a closed strip of oil and petrol resistant rubber reinforced with nylon cord with her teeth start vulcanised. If you compare with a chain belt, the comparison will be not in favor of the latter. The belt is much easier to the chain, which, of course, can not affect the weight of the engine. In addition, the engine is equipped with a belt, much quieter than its sibling equipped with the chain. And mounts "gum" is the motor housing, which affects the time of its installation or replacement. For example, to replace the timing belt vosmiklapannogo four-engine with its subsequent installation on labels takes about 25-30 minutes. With chain such focus will not pass.
With proper maintenance timing belt goes long. Domestic manufacturers, as we give a guarantee on running 60 th. Km, foreign - and even more. Rover was able to push the replacement time of the belt up to 160 thousand. Km.
What is the proper maintenance belt drive? Not less frequently than every 15-30 thousand. Km should be checked belt tension. However, this does not mean that it is only necessary to bend the casing and check on whether the belt. It is best to examine it, removing the engine. Sometimes it is difficult to notice that one of the teeth trimmed. If this happens, I am sure that it will not last long. ???????�??????, ???????? ???�???�????, ?????�?�?�???�?� ???� ???�?? ???�???�?�???? ???�?�????, ?� ???�?�?�?� ?�???� ?�?� ?�???�???? ?????????�?????�?� ?�????. ???????�?� ?????�?�?????????? ?�?�???�?� ???�???�?�?????????? ?????????????�?????�?????????�?�?? ?????�???�?�?????� ???�?????�???�?????�?�???? ?? ???�?�???�???????? ?????�????????. ?�???� ???�?? ???�?�???�???�?� ?????�?�???� ???�?�???????�?????? ?? ?????????? ???�???????????�??, ?? ???????�?????????? ???�???�?�?� ???�???�???? ?�?????�?� ???�?�???�?�?�?? ?? ???�???�??????????, ?�?�?? ?�???�?�???�?�?�?????? ?????�?????????� ?�???? ???�????????.
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?�???�?? ???�???� ???????�?????�?? ???????????????????�?�??, ?�?? ???????�?�?????�?????? ???� ?�?�???�?�?????� ???�?�?? ?????�???? ?�???�?�??. ?�?�???�?� 40-50 ?�?�??. ???? ?�?� ???�?�?� ???�?�?????????�?????? ???�?????? ?�???? ???�?�???�?�?????� ?????�?�?�?�?�?� ?? ???? ???�?�???�?� . ?� ???�?�???�???�?�?�?� ???�?????? ???�???????�???�?�???�?�?�?????�?? ???�?� ?????�?�?�?�?�???? ???� ???????�?????????? ?? ?????�?�???�?�?�?�?? ???�?�????, ?� ?? ???�???�?�???�?????�??. ?�?�?� ???�?�???�?� ???????????????� ?? ?�?�?� ?�???�?????�???? ?????�?�?�?�???�?????? ???�?�???�?�?????? ???�??????. ?� ???�?????� ?????�???????�?�?� ?�???�?�???�?????�?? ???�???????�???� ???� ?�???�????.
Breakage of several teeth in a row may lead to the fact that at one point, the camshaft will remain stationary, while the crankshaft is rotated. That's when the cylinder valves open "meet" with pistons. Result - breaking or bending the valve stem, broken guides, breaking camshaft. There are, however, exceptions when breakage passes almost painless. However, this is possible only on those cars, engines which are specially made for the occasion in the piston bore. These include, for example, are our vases, namely the VAZ-2105 engine with 1300 cm 3 and VAZ-2108 engine with 1500 cm 3.

Valves
You can reanimate any "tired" car. However, the technical difficulties in this large. Without spare parts, machine tools, welding equipment and other technological support going. The main thing - factory repair manuals (and they are now available), do not say anything about possible alternative solutions, especially on the issue of choice among parts, materials and tools that are on the domestic market. That is the range of issues in which the enthusiast and a single, and the mechanics of a small car repair shop lack of information.
Sooner or later, any engine becomes a source of trouble: stalls on the way, does not want to indulge in the morning, worse draws, "eats" excess fuel and oil. It is likely that the reason for his capricious behavior uncomplicated: it is enough to clean the carburetor or injector fuel injection system, adjust the ignition and replace the valve seals, that all went back to normal. But it happens that traditional approaches recover the function of the engine does not help, and when measuring the compression becomes clear that in one or more cylinders it is below the allowable.
Then, first of all clarify the nature of the problem: the wear of the cylinder group, scorching plates or wear rods and valve guides. Technique diagnosis is quite simple and is described in many textbooks repair engines.
After that determined the repair. It was only necessary to take it a rule to be
away from any miraculous liquids. The effect is possible in principle, but rarely achieved; the usual result - the extra cost and hassle. It is better to rely on a complete repair procedure.
Find a workshop where the engines are treated, it is now difficult, and not only in large cities. But whatever work it is organized and what its quality? Experience shows that despite the importance of the experience and skills of good performance without special equipment and facilities are unattainable, and in this regard the spread of technical equipment of our service stations and mechanics, alas, great. And if the above is mainly concerned motorist-operating company, the further it is addressed not so much how many mechanics, because it will be about technology.
In cases where the diagnostic results indicate a problem with the timing, the cylinder head must be removed. The first thing to do after the removal, disassembly and inspection of the total - to assess the gaps between the valve stems and the guide bushings. If they are more than the maximum allowable, the valves are replaced with new ones. But when this half-hearted measure is insufficient, it must be replaced, and the sleeve.
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