Attachment 00.2.590
Attachment 00.9.120
Remove and disassemble the engine. Carry out subdivision work «Crankshaft replacement». Pay attention to the repair marking of the crankshaft (12, see fig. 3.10).
1 - bolt; 2 - gasket washer; 3 - damper; 4 - asterisk; 5, 10 - bearing shell; 6, 9 - thrust bearing shell; 7 - gear wheel; 8 - locking bolt; 11 - key; 12 - shaft mark
In the lower part of the engine block, between the beds of main bearings, nozzles are installed on two bolts (8, see fig. 3.3) for piston cooling.
1 - cylinder block; 2 - screw plug (M14x1.5); 3 - sealing ring; 4 - centering sleeve (∅13,5); 5 - shield; 6, 30 - centering sleeve (∅10.5); 7, 8 - nozzle; 9 - bolt (M6x16); 10 - plug; 11 - cover; 12 - centering sleeve (∅14,5); 13 - sealant; 14 - stuffing box cover; 15.16 - bolt (М8x32); 17 - stuffing box; 18 - centering sleeve (∅10,5); 19 - bolt (М8x22); 20 - oil level damper; 21 - bolt (M6x12); 22 - O-ring (17x3); 23 - crankshaft sensor; 24 - bolt (M6x16); 25 - hairpin (M8x35); 26 - hairpin (М10x40); 27 - bolt (М8x22); 28 - intermediate insert; 29 - screw plug (M24x1.5); 30 - centering sleeve (∅13,5); 31 - knock sensor; 32 - bolt (M8x30); 33 - bolt (М10x92); 34 - screw plug (M14x1.5); 35, 36 - cover pin
Remove the old main bearing shells from the pastels of the crankcase. Install liners in the cylinder block (5, see fig. 3.10) main bearings with a yellow mark and grooves for oil supply and one retaining lug. Insert bushings into main bearing caps (10, see fig. 3.10) without oil groove and two retaining lugs.
Centering (persistent) The crankshaft bearing is mounted on support No. 6. Insert (6, see fig. 3.10) with persistent collar (ledge) and install the hole in the cylinder block.
Note. The color marking of the liners in the caps of the main bearings must match the marking of the crankshaft.
Lay the crankshaft in the bed of the crankcase of the cylinder block. Bearing shells have yellow, green and white markings (arrow, fig. 3.89).
1 - simple insert; 2 - centering insert
When installing the bush, pay attention to the repair size of the main bearing journal.
Bearing caps 1-5 are marked on the exhaust side (arrow, fig. 3.90).
Bearing caps 6 and 7 are not marked. Bearing cap 6 is a thrust bearing.
Check the radial clearance of the main bearings by laying down a clean, dry crankshaft and fixing it. The markings of the crankshaft and the main bearing shells must match. Install fixture «00.2.590» (Plastigage Tour PG1) - plastic gauge wire (dark arrow, see fig. 3.92).
Install the main bearing caps so that the guide slots of the bearing shells are on the same side (arrows, fig. 3.91).
Align the bearing caps with the bed along the side plane. Blow out the blind holes with compressed air, the presence of moisture and contamination is not permissible. Tighten all main bearing cap bolts in two steps:
- first, torque 20 Nm (2.0 kgf·m);
- the second, tighten by an angle of 70°.
When tightening the caps during the clearance check, use the bolts removed earlier. Determine the angle of rotation of the bolt using a tool «00.9.120».
Attachment 00.9.120
Remove the main bearing caps and measure the radial clearance in the main bearings directly on the shaft journals (arrow, fig. 3.92), along the width of the flattened calibrated wire.
When doing this, use the measuring scale of the calibration wire package. The value of the radial clearance of the crankshaft bearings should be in the range of 0.020-0.058 mm.
If necessary, to adjust the clearance in the bearing, you should use new liners with a different color coding. Using alcohol, remove the gauge wire from the crankshaft journal.
Lubricate the crankshaft journals and main bearing shells with engine oil. Install the main bearing caps so that the guide slots of the bearing shells are on one side (see fig. 3.91).
Align the bearing caps with the bed along the side surface. Blow out the blind holes with compressed air, the presence of moisture and contamination is not permissible. Install spacers and tighten bolts (27, see fig.3.3) their fasteners.
Lubricate the new main bearing cap bolts with engine oil, do not wash off the factory coating of the bolts. Install and hand-tighten the main bearing cap bolts. Tighten bolts for sheet steel spacers. Install new (oiled) main bearing cap bolts and tighten them to 20 Nm (2.0 kgf·m). Loosen #6 thrust bearing cap fasteners. Tap the end of the crankshaft front and back with a mallet or plastic hammer to center the thrust bearing. Tighten the thrust bearing cap bolts (№6) torque 20 Nm (2.0 kgf·m). Tighten all the bolts of the main bearing caps by 70°, using the tool «00.9.120».
Check crankshaft axial clearance (see fig. 3.87), which should be in the range of 0.080-0.163 mm.
If the permissible axial clearance is exceeded, check and, if necessary, replace the thrust bearing shell, crankshaft and crankcase.