Disassembling the cylinder

Disassembling the cylinder
1. Remove the seal holder tail ¬ stovika crankshaft by removing 6 screws.
2. Check the value of the axial rod bearing clearance. Hours indicator, measure the axial clearance ¬ howling crank head Chatou ¬ on, moving the head back and forth over the neck crank crankshaft.
Axial clearance:
rated. 0.15 - 0.25 mm
Max. 0.30 mm
If axial play exceeds the admissible ¬ timy, replace the connecting rod and / or knees ¬ chaty shaft.
3. Remove the lid and check the crank¬ those radial clearance under rod bearings ¬.
a) Ensure the availability and coincidence Institute marks on rod and crank on the lid to provide a subsequent right to assembly. If the labels are missing, Punch put them on the cover and connecting rods.
b) Loosen the screws (screws 7A-FE) cover mounting rod.
c) hammer with a plastic head lightly tap on the studs and mastered ¬ bodite lid rod.
Caution: The lower half of the contributions-sha should stay in the lid of the Sha-tuna.
d) Put on the protruding ends of bolts pieces of hose to prevent damage to the surface-vrasheniya crank neck.
Upper aladysch
1

g) Place a piece of plastic ka-libra to crank the neck.
h) Replace the cover and tighten the rod ¬ filamentary nuts (bolts 7A-FE) in two steps:
- First MoH: 4A-F, 5A-F, 4A-FE
and 5A-PE. 29 nm
7A-FE. 25 Nm
4A-OE:
(AE92, AT160 and ASH11) ... 39 Nm (AE101, AE111) 30 Nm
- Then tighten 90 °

The cylinder block-4D CE. 1 - bolt main bearing caps (MH = 60 nm), 2 - cover main bearing crankshaft, 3 - thrust half rings crankshaft, 4 - main bearing inserts, 5 - the crankshaft, 6 - sock crankshaft oil seal, 7 and 8 - housing and housing gasket oil pump, 9 - nozzle for piston cooling, 10 - check valve piston cooling jets, 11 - cylinder block, 12 - connecting rod nut fastening the cover (pre-MV = 39 Nm, then dovernut another 90 °), 13 - connecting rod bearings the bearing, 14 - connecting rod, 15 - piston 16 - circlip wrist pin, 17 - piston rings, 18 - piston pin, 19 - piston pin bush, 20 - a cover of Rod, 21 - knock sensor, 22 - Pipe, 23 - Flywheel (manual transmission) or the leading plate gidrotransfor ¬ monochromator (automatic transmission), 24 - bolt flywheel (manual transmission) or the leading plans ¬ Springsteen converter (automatic transmission) MH = 74 Nm, 25 - back plate cylinder, 26 - end of the crankshaft oil seal, 27 - Tel ¬ holding end of the crankshaft oil seal, 28 - gasket seal holder, 29 - plate increase the stiffness (stiffening)
30 - tap to drain the coolant from the cylinder,
31 - oil pressure sensor, 32 - laying, 33 - maslopriemnik, 34 - maslouspokoitel, 35 - oil pan, 36 - gasket, 37 - ¬ ka samples to drain the oil, 38 - pressure reducing valve, 39 - spring of reduction ¬ Nogo valve, 40 - stop the spring, 41 - locking ring, 42 - sealing-ring, 43 - directing the oil level indicator (probe), 44 - the driven gear oil pump, 45 - oil pump cover ¬ ca, 46 - pinion gear oil pump.
a) Measure the maximum width of the flattened conductivity gauge ¬ Loka, defining it by the value of radial clearance under rod bearings ¬. Connecting rod bearing clearance:
Nominal. 0.020 - 0.051 mm
Repair (0.25 mm):
4A-OE 0.079 - 0.073 mm
others. 0.079 - 0.065 mm
Max. 0.08 mm
If the clearance exceeds the allowable, replace the pads. When the need for cervical or pereshlifuyte-menite crankshaft. Caution: When using deposits ¬ necks nominal size should be kept in mind three size groups, marked numbers "1", "2" and "3" as shown in the figure. In this tab (labeled "before") on the top rod should be directed to the front of the engine (towards, against ¬ vopolozhnuyu selection of power).
l) Remove the remnants of the caliber of work-surfaces, sneeze and neck liner. 4. Remove the piston assembly from Chatou ¬ nom.
a) scan to remove carbon deposits in the upper part of the cylinder as shown.
b) Attach the threaded part of the ball ¬ Comrade rod pieces of hose to prevent damage to the necks of the rotation ¬ ¬ chatogo knee shaft.
c) Remove the piston rod with Th ¬ cut the top of the cylinder. Set the lid rods with ¬ dyshami contribution and position of the piston connecting rod, taken from the motor ¬ telya, in a certain order.
5. Check the axial clearance of crankshaft.
Pointer indicator, measure the axial clearance of crankshaft, re-meschaya it back and forth with a screwdriver.
Nominal gap .... 0.020 - 0.220 mm
The maximum gap of 0.30 mm
If the gap exceeds the maximum, replace the thrust semi ¬ ring.
The thickness of the refractory
semirings 2.440 - 2.490 mm
6. Remove the lid bearing the root-workers, and measure the radial clearance in the bearings.
a) Uniformly loosen a not-how and techniques in the sequence shown above, and remove the bolts fastening the main bearing caps.
b) Shaking twisted bolts in the holes of covers of radical sub-bearings, peel and remove the roof ¬ ki together with the lower liners and lower thrust half rings laid down only in the area of ??media there ¬ (third) root of the neck. Sobe ¬ rite along the bearing caps and liners. Lay the roofs removed ¬ ki and thrust half rings in the required order ¬ IOM.
a) Remove the crankshaft. Attention: the upper half of the contributions of dyshey and persistent ¬ semirings leave those in the beds of the cylinder.
g) Clean every radical neck crank and working on the surface of a liner.
d) Check the condition of working on surfaces of the necks and inserts.
If there are scratches, vykrashiva-of, the deep signs of wear replace with earbuds. If necessary, pereshlifuyte neck or replace the crankshaft.
e) Place the crankshaft in the post ¬ a block.
Table. Size groups of inserts.
Damage Number
Number on the cylinder block 1 2 3
Number on the crankshaft 0 1 2 0 1 2 0 1 2
Number of the desired insert 1 2 3 2 3 4 3 4 5
g) Place the neck of each of the Ku-caliber plastic Socko.
Warning: do not turn the knee-chaty shaft. i) Remove the cover under the Indigenous ¬ bearings (see paragraphs "a" and "b"). a) Measure the flattened caliber at its widest part.
Main bearing clearance: Rated: 4A-GE (AE101,
AE111) 0.015 - 0.045 mm
rest 0.015 - 0.033 mm
Repair (0.25 mm): 4A-OE (AE101,
AE111) 0.015 - 0.053 mm
rest 0.016 - 0.056 mm
Maximum:
4A-BE (AE101, AE111) 0.08 mm
the remaining 0.10 mm
Please note:
• When replacing a cylinder-but the gap in Indigenous minalny the bearing may amount to 0.015 - 0.045 mm.
Table. For reference.
Mating parts label (№) Size, mm
The diameter of the bed of the indigenous "1" 52.025 - 52.031
bearing cylinder "2" 52.031 - 52.037
"3" 52.037 - 52.043
The diameter of root neck "0" 47.994 - 48.000
Crankshaft "1" 47.988 - 47.994
"2" 47,982-47,988
Nominal wall thickness of "1" 2.002 - 2.005
insert "2" 2.005 - 2.008
"3" 2,008-2,011
"4" 2,011-2,014
"5" 2,014-2,017
• If the gap is larger than allowed, replace the pads. When necessary to pereshlifuyte neck-shaft or replace lenchatogo co-lenchaty shaft.
• When replacing the bearings the nominal size of the Nogo ¬ ¬ ized to use liners of one size group. If the number of inserts can not be sized op ¬ thinning, selection of the necessary ways of folding the liner is carried out among a group of size nN ¬ cylinder with a number of times ¬ dimensional group crankshaft (see illustration and table). There exists ¬ 5 ¬ contributions size groups necks marked "1", "2", "3", "4 and" 5 "(see table below).
Example: The cylinder block has a meth ¬ ku "2" crankshaft is labeled "1" to sum = "3" must be used to use the insert with the label "3". l) Finally, remove the remnants of ka-libra with work surfaces indigenous ¬ Noah neck and the liner.
7. Remove the crankshaft by lifting it out of bed bearings. Then remove the upper bearings and the bearing thrust upper half-ring the block.
Lay the cover of indigenous ¬ Cove bearings, bushes, thrust half rings in the order of reassembly.
8. (4A-DE)
Remove the check valves and forsun ¬ ki to periodically spray butter the bottom of the piston.