Check the cylinder

Check the cylinder
1. Clean the cylinder block.
a) Remove the pads with the remains of at-felling surfaces of the block.
b) solvent and a soft brush finally clear cylindrical block of wood.
2. Check the surface of a gas cylinder at the junction of nonplanar-borhood with precision whether ¬ Neika and a flat probe.
Maximum
flatness of 0.05 mm
If the flatness exceeds UCA ¬ zannoe value, replace the chi ¬ cylinder.
3. Check the mirror on the existence of vertical cylinders scratches.If there are deep scratches all bore cylinder sleeves to the next oversize. LIS should replace ¬ STI engine block.
4. Check the diameter of the cylinder. Warning: there are 3 groups of size nominal diameter of the cylinder, the digits "1", nevom finger in the direction perpendicular to the "2" and "3", respectively. The label on the perpendicular axis, the piston pin. splits at the top of the cylinder block ¬ Lindrum, as shown in the figure.
b) Manually remove the elements of the oil-removable rings (scrapers and ekspan ¬ der of the ring). Warning: Lay in a ring buoy ¬ triangle order. 3. Separate from the piston rod.
(4A-F, 5A-F, 4A-FE, 5A-FE and 7A-FE)
A suitable device Vypres Pop-piston pin bosses of the piston and piston connecting rod. Remove the connecting rod.
If the diameter of the cylinder more admissible ¬ invertible, bore all the 4 cylinder to the nearest repair size (see Table. Below). If necessary, replace ¬ filamentary block. 5. Remove the comb at the top of the cylinder, provided that the nose ¬ less than 0.2 mm.
Table. Nominal and maximum diameter of the cylinder.
Value of the diameter, mm
Label 4A-F, 4A-FE, 7A-FE and 4A-5A DE-PE and R-5A
"1" 81,000-81,010 78,700-78,710
"2" 81,010-81,020 78,710-78,720
"3" 81,020-81,030 78,720-78,730
The maximum diameter of nominal 81.23 78.93
The maximum diameter of the repair (increased by 0.5 mm) 81.73 79.43

b) Slowly heat the piston to 70-80 ° C.
a) Using a plastic hammer and brass punch light UDA-ramie Vypressuyte piston pin from piston connecting rod.
Note:
• Do not have razukomplektovyvayte ¬ Shen and piston pin.
• Lay out the details of the piston in the desired order.
Check the status of the piston and connecting rod
1. Clean the piston.
a) a scraper to remove soot and carbon deposits from the relatives of the bottom piston.
b) Clean the groove of the piston from the applied piece of a broken ring.
c) solvent and a soft brush Volosyan ¬ Noah finally clean the piston.
Caution: Do not use a metal brush.
2. Check the piston and piston rings.
A. Check the piston-cylinder gap. Warning: there are 3 groups of size nominal diameter piston ¬ AEs, designated "1", "2" and "3", respectively. Label jams the piston (usually in the price ¬ triangle), as shown in the figure. For engines which are not ¬ (in particular, for motor 4A-DE), this label can be shifted ¬ Jet at the front of the engine.
Pay attention to the label "front" (the arrow or notch), at which time ¬ shen qi must be installed in a cylinder ¬,
a) (4A-FE (AT190 and AE101), 5A-F, 5A-FE and 7A-FE)
A micrometer, measure the piston diameter at a distance of 24.5 mm from the surface of the piston, as shown by ¬ in the figure.
(4A-F, 4A-FE (AE92, AE95, AT171 and AT180) and 4A-OE (AE92, AT160 and ASH11))
A micrometer, measure the piston diameter at a distance specified by the lower edge of the piston skirt, as shown in the figure. This distance is:
4A-F, 4A-FE. 38.5 mm
4A-OE (AE92, A number 1, 42.0 mm ).... AT160
b) Measure the diameter of the cylinder in the transverse direction, see "Checking the cylinder."
c) Subtract the piston diameter from measurements of the diameter of the cylinder and rennogo determined divide the value of the gap between the cylinder and the piston (see table "Nominal and maximum per-tensors between the cylinder and piston").
If the clearance exceeds the allowable value, replace all 4 pistons and bore all 4 cylinders. Caution: When using a new cylinder is necessary to use ¬ ized pistons of the same size group as the cylinder block (number of marks on the pistons to match the numbers on the label block ¬ ke cylinders).
If the gap is greater than the values ??given, listed in Table "nominal gap between the compression ring groove and the wall", replace the plunger. B. Check the clearance in the lock piston-ring.
a) Install the ring in the cylinder block.
b) push the piston ring at a distance of 80 mm (4A-OE (AE101, AE111)) 87 mm (4A-FE, 5A-FE and 4A-GE (AE92, ASH 1, AT160)) or 104 mm
(7A-FE) from the surface of the cylinder block, as shown in the figure.
If the gap is larger than allowed, deputy ¬ filamentary ring (see table "Nominal ¬ ny and maximum clearance in the lock piston rings"). If the gap is larger than allowed, even if established ¬ ke new rings, bore all 4 of the cylinder and set the ring repair ¬ first (larger) size, or replace ¬ are the engine block. 3. (4A-DE)
Check the fit piston pin: 80 ° C pas ¬ piston rings should be included in the piston bosses under the force of the thumb.
4. Check the connecting rod. A. Check the alignment rod.
• Using special adapted ¬ soblenie and a flat probe, check the bending of the rod.
Maximum bend is 100 mm long:
4A-FE, 5A-FE and 7A-FE. 0.05 mm
4A-OE 0.03 mm
If the bending is larger than allowed, replace the connecting rod.
• In a similar way, check twisting rod.
The maximum twist
100 mm long and 0.05 mm
If more torsional admissible ¬ ICDO, replace the connecting rod (a rod with a lid). B. Check the connecting rod bolts.
• Screw the nut onto each bolt and make sure that the nut easily navora ¬ ourselves to hand over the whole length of the bolt thread.
• (4A-FE, 5A and 4A-PE-CE) If the nut
not welling hand, measure the outside diameter of the bolt thread caliper in the area of ??greatest ¬ wear. If this zone is difficult to detect visually, then measure the distance of 15 mm from the end of the bolt, as shown in the figure.
Table. Nominal and maximum piston diameter (mm).
Engine type (model car)
Piston 4D-F, 4A-FE
(AE92, AE95, AT171 and AT180) 4A-FE (AE101 and AT190) and 7A-FE 4A-GE (AE92, AM 1 and AT160) 4A-GE (AE101, AE111) 5A-FE
Nominal, label "1" 80.930 - 80.940 80.905 - 80.915 80.980 - 80.900 80.895 - 80.905 78.605 - 78.615
Nominal, mark "2" 80.940 - 80.950 80.900 80,915-80,925 - 80.910 80.905 - 80.915 78,615-78,625
Nominal, label "3" 80.950 - 80.960 80.925 - 80.935 80,910-80,920 80,915-80,925 78.625 - 78.635
Repair (increase in chenny ¬ 0.5 mm) 81,430-81,460 81, 405 - 81.435 81,390-81,420 81,395-81,425 79,195-79,135


Table. Nominal and maximum clearance in the lock piston rings (in mm).
Engine type (model car). Compression-ring number 1 Compression-ring number 2 Maslosem-I ring *
4A-F: maximum nominal 0.250 - 0.350 1.070 0.1 50-0,300 1.020 0.1 00-0,600 1.620
4A-FE (AE92, AE95, AT171 and AT180): maximum nominal 0.250 - 0.450 1.050 0.1 50-0,400 1.000 0.1 00-0,700 1.300
4A-FE (AT190 01 and AE1): the maximum nominal 0.250 - 0.450 1.050 0.350 - 0.600 1.200 0.1 00-0,500 1.100
5A-FE: maximum nominal 0.200 - 0.350 1.050 0.350 - 0.500 1.200 0.1 00-0,400 1.05
7A-FE: maximum nominal 0.250 - 0.350 1.050 0.350 - 0.500 1.200 0.1 50-0,450 1.100
4A-GE (AE92, A number 1 1, AT160) nominal maximum 0.250 -0.470 1.070 0.200 - 0.420 1.020 0.1 1.120 50-0,520
4A-GE (AE1 01.AE111):
maximum nominal 0.280 - 0.440 0.950 0.380 - 0.540 1.050 0,130-0,490 1.000

* Note: For oil ring gap is defined between the scrapers.
Table. Nominal gap between the compression ring groove and the wall (in mm).
Engine type (model car) Compression ring number 1 number 2 Compression ring
4A-F and 4A-FE (AE92, AE95, AT171, AT180) 0.040 - 0.080 0.030 - 0.070
4A-FE (AT190 and AE101), 5A-FE and 7A-FE 0.045 - 0.085 0.030 - 0.070
4A-GE (AE92, AM11, AT160) 0.030 - 0.080 0.030 - 0.070
4A-ye (AE101.AE111) 0.040 - 0.080 0.030 - 0.070


Table. Nominal and maximum clearance between the cylinder and the piston (mm).
Engine type (model car)
Gap 4A-F, 4A-FE
(AE92, AE95, AT171, AT 1 80) 4A-FE (AE1 01 AT1 90), 5A-FE 7A-FE 4A-GE (AE92, AM11, AT1 60) 4A-GE (AE101, AE111)
Rated 0,060-0,080 0,085-0,1 05 0,100-0,120 0,095-0,115
Maximum 0,100 0,130 | 0,200 0,150 0,200



The outer diameter of the thread:
Rated 8.860 - 9.000 mm
Minimum 8.600 mm
Warning: if the diameter is less than acceptable, replace the bolt and nut.
• (7A-FE) Measure the outer diameter ¬ meter caliper bolts in the area of ??greatest wear. If this zone is difficult to detect visually, then measure the distance races ¬ 20 mm from the bolt head, as shown in the figure.
Table. 4A-GE (AE101, AE111) diameters of the piston pin and the hole in the piston (mm).
The diameter of the holes in the piston pin diameter
Label Label
20,003-20,007 20,004-20,006 AB A
In the 20,006-20,008
SE 20,007-20,01 1 C 20,008-20,01 0
E 0-20,01 20.01 2
EP 1 20.01 -20.01 5 E 20.01 2-20,014
P 20,014-20,01 6

The outer diameter of the thread:
Nominal. 8.860 - 9.000 mm
Minimum. 8.600 mm
Warning: if the diameter is less than-admissible, replace the bolt and nut. 5. (4A-Be (AE101, AE111)) Measure the diameter of the piston pin. Rated
diameter. 20.004 - 20.016 mm
If necessary, pick up the Neva piston pin, in accordance with label ¬ E on the plunger and the finger (see table "4A-GE (AE101. AE111) diameters of the piston pin and the hole in the piston (mm)").
4A-GE (AE101, AE111). 1 - the front of the engine, 2 - label "before" 3 - mark-diameter holes for the piston pin, 4 - pa ¬ mark diameter piston.
6. (4A-DE)
Check the clearance between the piston pin and bushing rod. a) an indicator, measure the inside diameter bushing rod.
Rated
diameter. 20.004 - 20.016 mm
c) Subtract the value of outer diameter of finger values ??of inner-diameter of the connecting rod bushing.
Gap:
Nominal. 0,004 - 0,008 mm
Max. 0.050 mm
If the gap is greater than the maximum, over ¬ menite bushing rod. If necessary, replace ¬ Muste piston with piston pin. 7. (4A-DE)
If necessary, replace the piston connecting rod bushing. a) with a suitable adapted sobleniya Vypressuyte-sleeve piston connecting rod Neva.
b) Align the holes for passing through ¬ da oil in the sleeve and the piston connecting rod and suitable for ¬ sposobleniem zapressuyte new sleeve.
c) Proshlifuyte zapres-consistent hole bush to get once-a measure that provides a nominal
d) Ensure that the piston pin (after lightly oiled with motor oil) is in ¬ zapres upon by the connecting rod bushing for com ¬ perature under the force of the thumb.