Fig. 2.207 . Components of the klapanny mechanism: 1–a bolt of 20 N · m + to tighten on 1/4 about. (90 °); 2–axis of roller levers; 3–bearing cover; 4–tarelchaty pusher; 5–conic cracker; 6–plate of a spring of the valve; 7–external spring of the valve; 8–internal spring of the valve; 9–sealant of a core of the valve; 10-a washer with a diamond covering; 11-plug; 12-head of the block of cylinders; 13-valves; 14-pump nozzle; 15-washer; 16-bearing loose leaf; 17-camshaft; 18-bearing loose leaf; 19-bolt of a head of the block of cylinders; 20-a bolt of 8 N · m + to tighten on 1/4 about. (90 °)

Verification of the provision of pistons in the top dead point

Measurement of a vystupaniye of the piston in conditions HUNDRED is impossible. Connection of a head of the block of cylinders with the aluminum block the cylinder is carried out by an anchor principle by means of anchor bolts. Thus it is reached such obzhaty the block of cylinders which cannot be reached at the dismantled head of the block of cylinders. On it at replacement of laying of a head of the block of cylinders it is necessary for reason to establish new laying of a head of the block of cylinders with identical index marking.

Fig. 2.208 . Piston and rod: 1–a rod bolt, 30 N · m + to tighten on 1/4 about. (90 °); 2–rod cover; 3–support loose leaf; 4–rod; 5–lock ring; 6–piston; 7–piston finger; 8–piston rings

Sizes of pistons and cylinders

NOTE Repair standard sizes are not provided.

Check of a thermal gap of piston rings

Fig. 2.209 . Check of a thermal gap of piston rings

Drive a piston ring from above, at right angle to a cylinder wall, to the bottom opening of the cylinder, at distance about 15 mm from its edge (fig. 2.209) .

Check of a gap of piston rings on height

Fig. 2.210 . Check of a gap of piston rings on height

Before check clear a ring flute (fig. 2.210) .

Check of diameter of the cylinder

Fig. 2.211 . Scheme of check of diameter of the cylinder

Measure in three places by a cross cross-section distance And and longitudinal In (fig. 2.211) .

The tolerance from the nominal size is maximum: 0,05 mm.

Piston: assembly situation and belonging to the piston / cylinder.

Marking is put on a bottom of the piston:

– pistons 1-5 for a number of cylinders 1;

– pistons 6-10 for a number of cylinders 2.

Arrangement: the arrow at the bottom of the piston shows on the absorption party.

Check of axial shift of a cam-shaft

Fig. 2.212 . Check of axial shift of a cam-shaft

Check at the dismantled tarelchaty pushers and the established covers of a support (fig. 2.212) .

First row of cylinders:

– covers of bearings 2, 4 and 6 are established

Second row of cylinders:

– covers of bearings 9, 11, and 13 are established

Limiting wear: Max. 0,15 mm

Put hermetic on landing surfaces of external covers of bearings.

Works order

Fig. 2.213 . Scheme of drawing of hermetic

To put AMV 176 501 hermetic on surfaces with a thin uniform layer 1 (fig. 2.213) .

First row of cylinders:

Put hermetic – AMV 176 501 on landing surfaces of covers of bearings 1 and 7

Second row of cylinders:

Put AMV 176 501 hermetic on landing surfaces of covers of bearings 8 and 14

Sizes of valves

Fig. 2.214 . Sizes of the valve

NOTE Valves are forbidden to be processed. Grinding in is allowed only.

Camshaft marking (gazoraspredeleniye phase)

Main circle of a klapanny cam: a= mm

Fig. 2.215 . Camshaft marking (gazoraspredeleniye phases from a drive)

Marking is put in the form of the stamped figures and letters on a face surface of the party of a drive of a camshaft (fig. 2.215) .

Drive party

First row of cylinders: 07Z G.

Second row of cylinders: 07Z H.

Gazoraspredeleniye phases at a valve stroke 1мм

Processing of saddles of valves

NOTE At repair of engines with leaky valves to process or replace saddles of valves and valves it is not enough. Especially in engines with long service life it is necessary to check directing plugs of valves on wear. Saddles of valves should be processed only so to reach a faultless type of a working surface. Before processing it is necessary to calculate the most admissible allowance on processing. At allowance excess on processing function of hydraulic regulation of a gap in a drive of valves (hydrojacks) that will cause GBTs replacement can be broken.

Count the most admissible allowance on processing as follows:

– insert the valve in directing and densely press it to a saddle;

NOTE If the valve at repair is replaced, at measurements it is necessary to use the new valve.

Fig. 2.216 . Distance And between the end of a core of the valve and the upper edge of a head of the block of cylinders

– measure distance And between the end of a core of the valve and the upper edge of a head of the block of cylinders (fig. 2.216) ;

– calculate the most admissible allowance on processing on the basis of the measured distance And and minimum admissible size.

Minimum sizes:

The inlet valve – 43,4 mm

The final valve – 43,2 mm

The measured distance a minus the minimum size = the most admissible allowance on processing.

Example:

The measured distance – 44,1 mm

The minimum size – 43,4 mm

The most admissible allowance on processing of 44,1-43,4=0,7 mm

Processing of a saddle of the inlet valve

Fig. 2.217 . Scheme of processing of a saddle of the inlet valve

a–Ж35,7 mm

b–1,6 mm

45 ° – the Corner of a basic surface of the valve

NOTE Frezerovka at an angle in 30 ° saddles of the valve is necessary because of a ratio of streams in the inlet channel.

Processing of a saddle of the final valve

Fig. 2.218 . Scheme of processing of a saddle of the final valve

a–Ж31,4 mm

b–2,7 mm

45 ° – the Corner of a basic surface of the valve

Check of directing plugs of valves

Insert the new valve into directing plug. The end of a core of the valve should be blocked by the directing plug. Because of various diameter of a core use the inlet valve only in the directing plug of the inlet valve and the final valve in the directing plug of the final valve.

Fig. 2.219 . Definition люфта

Define люфт when rocking valve (fig. 2.219) .

Limiting wear: Max. 1,3 mm.

At values люфта exceeding limits of wear – to replace a head of the block of cylinders.

Replacement of sealants of cores of valves (at the established head of the block of cylinders)

Dismantle a camshaft.

Take tarelchaty pushers of valves and put them a working surface down. Do not interchange the position of tarelchaty pushers.

Transfer the piston of the corresponding cylinder to situation VMT.

Fig. 2.220 . Adaptation installation for dismantle of springs of valves

Establish the assembly adaptation for valves 2036 and establish a support by means of rasporny bolts (fig. 2.220) .

Dismantle springs of valves by means of the lever for dismantle of springs of VW valves of 541/1 A and VW 541/5 opravka.

NOTE Thus valves lean on a piston bottom.

Fig. 2.221 . Removal of sealants

Pull together a sealant of cores of valves by means of a stripper of 3047 A (fig. 2.221) .

Installation

Fig. 2.222 . Installation of a new sealant

Put on the corresponding core of the valve entering in ремкомплект a plastic cover And (fig. 2.222) . It helps to avoid damages of a new sealant of a core of the valve B.

Establish a new sealant of a core of the valve in an opravka 3129.

Grease a working edge of a sealant of a core of the valve and carefully establish on directing plug of the valve.

Establish a camshaft.