Please note

Please note:
• bore all 4 cylinders on the same amount of repair (for larger pistons (repair ¬ Nogo) diameter).
• Install the piston rings ¬ sample size as a repair ¬ pa ¬ a corresponding increase in mu (repair) the size of the pistons.
1. Pick Pistons repair time measure ¬.
Bore repair (increased by 0.5 mm) size: 4A-F, 4A-FE (AE92, AE95. AT171
and AT180) 81.430 - 81.460 mm
4A-FE (AT190 and AE101)
and 7A-FE 81.405 - 81.435 mm
5A-FE 79.105 - 79.135 mm
4A-OE 81.390 - 81.420 mm
2.Calculate the size of the repair bored cylinder.
a) micrometer, measure the piston diameter (see paragraph 2 of subsection "Check the status of the piston and the Sha-tuna").
b) Calculate the diameter of the cylinder after boring.
Cylinder diameter = P + - H (mm), where:
F - Piston diameter in mm (values ??of repair piston diameter and location of measurement, see para-graph 2, subsection "Check with ¬ standing the piston and connecting rod"), and C - the gap between the piston and the cylinder in mm (values ??gap cm . paragraph 2 of subsection "Check the status of the piston and connecting rod")
H - tolerance for honing - no more than 0.02 mm. 3. Bore and othoninguyte cylinder to the required size. Maximum tolerance
on honing 0.02 mm
Warning: excessive honing breaks the circle of the cylinder.
Inspection and maintenance of the shaft kolencha ¬
1. Check crankshaft runout.
a) Place the crankshaft on the prism.
b) The hours indicator, check the crankshaft runout on average it radical neck.
Maximum allowable runout: 4A-FE (AE101, AT190), 5A-FE
and 7A-PE 0.03 mm
4A-F. 5A-F, 4A-FE (AE92, AE95,
AT171 AT180 and) and 4A-OE. 0.06 mm
If more than the maximum run-out-admissible, replace the crankshaft. 2. Check the connecting rod and the root of the neck.
a) micrometer, measure the diameter of each rod and radical neck in two mutually perpendicular planes, as shown in the figure.
The diameter of the root of the cervix:
4A-F, 5A-F, 4A-FE, 5A-7A-FE PEu Rated ... 47.982 - 48.000 mm Repair .... .47,745 - 47.755 mm 4A-OE:
Rated ... 47.982 - 48.000 mm repair. .... 47.745 - 47.755 mm
The diameter of the neck crank: 4A-F, 5A-F, 4A-FE and 5A-FE: Rated ... 39.985 - 40.000 mm Repair .... 39.745 - 39.755 mm
7A-FE
rated., .. 47.988 - 48.000 mm
repair. 47.745 - 47.755 mm
4A-OE:
rated .... 41.989 - 42.000 mm
repair. 41.745 - 41.755 mm
Note: The diameter of the necks of repair is reduced by 0.25 mm compared ¬ in comparison with the nominal. If the diameters of the necks do not coincide with the given values, check for a crank ¬ divisor and indigenous bearings ¬ framework of the crankshaft. If you need ¬ Muste proshlifuyte neck or replace ¬ filamentary crankshaft, b) Check the connecting rod and radical neck taper and at the ellipse, as shown in the previous figure. The maximum value of cone and ellipse: 4A-F, 4A-FE, 7A-4A-OE PEu .... 0.02 mm
5A-F, 5A-PE. 0,005 mm
If the taper / ellipse more acceptable, replace the crankshaft. 3. If required, crankpin pereshlifuyte and cervical root to re-size Montney and pick up the contribution ¬ breathe repair (0.25 mm) size.
Check non-return valves and nozzles for cooling the piston (4A-GE)
1. Check the check valves. Push down on the valve with a screwdriver and Ube-dites in the absence of jamming. In the presence of jamming, replace the valve.
2. Make sure that the nozzles exist absence of damage or jamming. Otherwise, replace the nozzle.
Replacing the seals of the shaft-kolencha
Warning: There are two methods ("A" and "B") replacing seals. 1. Replace front oil seal (Sal ¬ nick sock) crankshaft. A. If the removed oil pump. a) Using a screwdriver remove the gland, as shown in the figure.
c) Apply a layer of grease on the working edge seal. B. An oil pump is mounted on the motion gatele ¬,
a) With a knife make an incision in the Salle nickel, as shown in the figure.
b) Using a screwdriver remove the gland. Note: In order not to damage the co-lenchaty shaft, wrap the tip of nimble ¬ duct tape.
a) Apply grease to the working edge seal.
d) Using a suitable adapted-soblenie and hammer, install the gasket in place. His plane should coincide with the plane of the cor-Pusa oil pump.
2. Replace rear oil seal-kolencha of the shaft.
A. If the removed gland holder shank. a) Using a screwdriver and hammer to knock out seal, as shown in the figure.
b) Using a suitable adapted soblenie-and hammer-headed but set the seal into the holder, and the plane must coincide ¬ seal jaws with the plane of the holder.
c) Apply a layer of grease on the working edge seal. B. The holder of the liner seal ¬ tanovlen mustache on the engine.
a) With a knife make an incision at the Salle nickel, as shown in the figure.
b) Using a screwdriver wrapped in masking tape, remove the old gasket.
a) Apply grease to the working edge seal.
Replacing the nozzle (4A-GE)
d) Using a suitable adapted-soblenie and hammer, install the gasket in place, with its plane of plane should coincide with the holder seal.
(4A-F, 5A-F, 4A-FE, 5A-7A PEu-PE)
a) Apply a little engine oil to the piston pin and the hole in the piston bosses.
b) Align the mark "before": the piston (hollow) and Rod (projection).
a) using the tool until cater specifically to the figure, connect the far-shen and connecting rod piston pin.
d) Ensure that the piston rotates freely on the piston finger. (4A-0E)
a) (4A-0E (AE92, AM11 and AT160)) Install a new snap ring groove in the hole a piston bosses.
(4A-0E (AE101, AE111))
- Install the snap ring groove in one end of the "A" (see picture).
- Place the edge of "V" groove in the retaining ring.
- Pressing the point "C" set the lock ring.
- Insert a screwdriver into the groove of "E" and finally install the retaining ring into the groove.
b) Slowly heat the piston in a water bath to 70 - 80 ° C.
c) Apply a layer of motor oil on the piston pin.
g) Align the mark "before": porsche ¬ AEs (cut or hand) and crank (projection). Then the force of the thumb push the piston rings pa ¬ through another boss and the connecting rod bushing to lock into place first bosses, thereby connecting the long ¬ Shen and connecting rod piston pin.
d) Install a new snap ring groove in the other hole lugs piston. 2. Install the piston rings.
a) Install the oil-removable rings (expander, and 2 scraper).
b) expander for mounting piston rings wear nevyh 2 compression onnyh ¬ ring. In this case:
(4A-DE)
• Code label first (№ 1) compression ring ("F" or "T") and the second code label (№ 2) compression ring ("2P" or "2T) must be on top.
(4P-FE, 5A-7P-PE and PE)
• Code label second (№ 2) compression ring ("2P" or "T") should be on top.
c) Place the lock ring as shown in the picture:
• 1 - The upper-scraper maslosem ring.
• 2 - The label "before" (depression or an arrow).
• 3 - Provision of a "GO".
• 4 - Compression ring number 1 and oil ring expander.
• 5 - The bottom scraper maslosem-ring.
• 6 - Compression ring number 2.
Cylinder assembly
Please note:
• Thoroughly clean the parts for assembly.
• Before the team lubricate all parts with engine oil, forming a narrow ¬ ly rotate or slip.
• Replace all gaskets, sealing gaskets and new peripheral devices.
1. Install the main bearings. Attention: the upper halves of the contributions of dyshey (installed in the bore of the cylinder) have oil grooves or holes, and the lower (set to cover indigenous ¬ GOVERNMENTAL bearings) - no.
a) Align antennae bearing block cylinder groove beds ¬ trench and install the top 5 contribution ¬ dyshey.
b) As set in the bottom 5 inserts bearing caps.
2. Install the 2 upper thrust in the middle lukoltsa root necks ¬ ku, oil grooves oriented outward.
3. Place the crankshaft in the bed of the block.
4. Set the cover of indigenous sub-thrust bearings and the lower half-ring.
a) On average (№ 3) cover the bearing set 2 lower stress-GOVERNMENTAL semiring oil channel-workers, facing outward.
b) Place the lids 5 bearings ¬ sources (with liners) to at ¬ rennye crankshaft journals. Attention: Each cover has its own number and orientation of the arrow ("before"), as shown in the figure.
c) Apply a thin coat of engine oil on the threads and under the head ¬ bol comrade mounting bearing caps.
g). Wrap and tighten the 10 bolts in stages and in the sequence shown in Figure (MZ = 60 N m).
e) Verify that the crankshaft rotates freely by hand.
e) Check the axial clearance of the shaft geniculately ¬ (see paragraph 5 of subsection • Demolition of the cylinder ").
5 Insert the piston assembly with a sha ¬ Tun.
a) Attach the threaded part of the connecting rod bolts pieces of hose to prevent damage to the crankshaft journals.
b) Using the device to compress the rings, set in the cylinder piston kits in accordance with their numbers oriented marks (notches) on the pistons in the direction of the front of the engine-Chairman, as shown in the figure.
6. Set the lid rods (with the bearing inserts). A. Set the lid on the connecting rods connecting rod bolts, aligning with the corresponding label covers ¬ E on rods rods. In this case the label "before" (projection) on the cover of the rod should be directed toward the front of the engine (the side opposite to the PTO), as shown in the figure.
B. Place the nuts on the connecting rod bolts (or screw the bolts 7A-FE). Please note:
• Nuts (Bolts 7A-FE) follow-tyagivat in two stages.
• Deformed or damaged nye bolts must be replaced. Apply a layer of motor oil to the threads of bolts, nuts under the wing ¬ nis rods or under the head ¬ bol comrade (7A-FE).
(4A-F, 5A, 4A-Ri-PE (AE92, AE95, AT171 and AT180))
a) Uniformly tighten the nuts every doy-rod cover in several passes.
Torque. 49 Nm
b) Verify that the crankshaft rotates freely.
c) Check the value for the axial-tensor rod bearing (see section we pa-2 of the "Demolition of the cylinder").
(4A-FE (AE101 and AT190) 4A-OE, 5A-FE and 7A-FE)
a) Perform initial puff ha ¬ ek (screws 7A-FE) covers rods evenly in several passes.
Tightening torque:
nuts 4A-FE and 5A-PE. 29 nm
nuts 4A-OE:
(AE92, AM11 and AT160) 39 Nm
(AE101, AE111) 30 Nm
Bolts 7A-FE. 25 Nm
If a nut (bolt 7A-FE) is not delayed specified moments ¬ is, replace the bolt and nut.
7A-FE,
b) Check paint the nuts and bolts (or bolt head 7A-FE) as shown in the figures.
a) Make sure that the labels on those nuts ¬ We now are located at 90 ° with respect to ¬ respect to the label on the connecting rod bolts (or marks on the heads of the bolts on the back ¬ up to 90 ° from its initial position 7A-FE).
d) Verify that the crankshaft rotates easily and smoothly.
d) Check the value for the axial-tensor rod bearing (see section we pas ¬ 2 subtitle "Disassembling the cylinder").
7. Install the rear oil seal holder crankshaft with a new gasket, fixing unit 6-bolts.
Tightening torque of bolts:
4A-BE (AE101, AE111) 7.5 Nm
Others. 9.3 Nm
Final assembly of the engine
1. Install the oil pump.
a) Put a new gasket on the surface of the cylinder ¬, ¬ muyu butted with the oil pump housing.
b) Align the keyway am ¬ schego rotor (drive gear) to ¬ Sosa with a large dowel crankshaft and to implant the pump in the shaft as shown in Figure ¬.
a) Secure the pump bolts. Tightening torque: 4A-F, 4A-FE, 7A-FE and 4A-OE ... 21 Nm
5A-PE 17 nm
Please note that you use pain-varying length (see illustration):
long bolts. 35 mm
the remaining bolts. 25 mm