Dump pressure of fuel. Disconnect a negative cable from the accumulator. Merge engine oil. Merge antifreeze. Remove a head of the cylinder with an inlet collector, a collector of an exhaust system and a water taking away pipe, having addressed to Section Valves and a head of the block of the cylinder in this Chapter. Remove the oil pump, having addressed to Section the Oil pump in this Chapter. Note cylinder number on all pistons, rods and covers of bearings of a rod. Remove covers of bearings of a rod.

Remove a deposit from top of an aperture of the cylinder before to get the piston from the cylinder. Push out the piston and rod knot at the top from a cylinder aperture.

Remove a piston finger from a rod. Ослабьте lock rings of a piston finger (1).

Check up walls of cylinders about scratches, roughnesses or the ledges specifying in excessive deterioration. If a cylinder trunk very rough or strongly scratched, or with ledges, chisel the cylinder and use the piston большего the size. With the help компрессиметра measure internal diameter of the cylinder in a direction of draught and an axial direction in two positions. If you notice something from following positions, chisel the cylinder.
Internal diameter of the cylinder falls outside the limits norms. The difference of measurements in two positions falls outside the limits a bias. The difference between measurements of axial section and a draught direction leaves with a deviation from круглости.

Investigate pistons about defects, cracks and other damages. The damaged or faulty pistons should be replaced.

Diameter of pistons

Diameter of the piston should be measured in a point of 26.5 mm (1.04 inches) from the end of a skirt of the piston in a direction perpendicular to a piston finger.

Diameter of the piston:
Standard diameter of the piston: 83.970 – 83.990 mm (3.3059 – 3.3066 inches) Diameter of the piston большего the size (0.50 mm (0.0196 inches)): 84.470 – 84.490 mm (3.3256 – 3.3263 inches)

Piston backlash

Backlash of grooves of rings

If the backlash does not correspond to technical requirements, replace the piston.
Backlash of a groove of rings
The top: 0.03 – 0.07 mm (0.0012 – 0.0027 inches) The second: 0.02 – 0.06 mm (0.0008 – 0.0023 inches)

Backlash of a piston finger

Piston backlash on the top head of a rod
Norm: 0.003 – 0.014 mm (0.0001 – 0.0005 inches)
Internal diameter of a small head of a rod: 21.003 – 21.011 mm (0.8269 – 0.8272 inches) Diameter of a piston finger: 20.997 – 21.000 mm (0.8267 – 0.8267 inches)

Lateral backlash of the big bottom head of a rod

Lateral backlash of the big bottom head of a rod
Norm: 0.25 – 0.40 mm (0.0099 – 0.0157 inches) Limit: 0.45 mm (0.0177 inches)

Rod alignment

Establish a rod on the equalizer to check up it on presence of bends and twisting. If the limit is more than norm, replace it.
Limit of bends: 0.05 mm (0.0020 inches) Twisting limit: 0.10 mm (0.0039 inches)

Before to check a bearing backlash, clean the bearing and a rod neck. Establish the bearing in a rod and a bearing cover.

Establish a cover of the bearing of a rod on a rod.

If it is impossible to result a backlash in norm limits even with the new bearing of the standard size, replace коленвал or переточите шатунную a neck on the size less nominal as follows. Establish the 0.25-millimetric bearing of the smaller size on the big head of a rod. Measure internal diameter of the big head of a rod. Переточите шатунную a neck till next complete diameter.

Be convinced of that a backlash of the bearing within the standard value specified above.

Check up the printed figures on a rod and its cover. Three types of numbers (1, 2 and 3) represent the next internal diameters of the big head of a rod. For example, printed number 1 specifies that internal diameter of a corresponding big head of a rod makes 53.0000 – 53.0060 mm (2.0867 – 2.0868 inches).

Internal diameter of the big bottom head of a rod

Further check up diameter шатунной necks. On a cheek коленвала the cylinder №3 4 letters are printed. Three types of letters ("And", "In" and "With") represent the following of diameter шатунных necks, accordingly. For example, the printed letter "And" specifies that diameter of a corresponding neck коленвала makes 49.9940 – 50.0000 mm (1.9683 – 1.9685 inches).

Diameter of a neck коленвала

There are five types of bearings of the standard size different from each other on a thickness. That they could be distinguished, they are painted in following colours in a point shown in drawing. Each colour designates the next thickness in the bearing centre.

Thickness of the bearing of a rod of the standard size

Under number printed on a rod both its cover, and the letters printed on a cheek коленвала of the cylinder №3, define the new size of the bearing which should be established in the big bottom head of a rod, having addressed to the table. For example, number printed on a rod and its cover, - 1 and the letter printed on a cheek коленвала of the cylinder №3 – "In", establish the new bearing of the standard size painted in "Black" colour in the big bottom head of a rod.

Technical characteristics of the new standard size of the bearing of a rod

On the block of the cylinder (2) numbers (6 1 or 2 also are printed, and it also is painted in red or blue colour (3). Number specifies in internal diameter of the cylinder.

Number printed on the piston, and mark a paint (or printed number) on the cylinder block should coincide. I.e. establish the piston number 2 on the cylinder which is noted by a blue paint or number 2 (4), and the piston number 1 on the cylinder with a red mark or at number 1 (3).

Piston and cylinder technical characteristics

On a piston head letters also are printed And, In or With, but as a rule there is no necessity to distinguish each piston under this letter.

Establish a piston finger in the piston (1) and a rod: Having greased with engine oil a piston finger and apertures of a piston finger in the piston and a rod (3), establish a rod in the piston and insert a piston finger into the piston and a rod, and put lock rings of a piston finger.

After installation of three rings (the first, the second and маслосъемного), distribute their backlashes of a cut.

Grease with engine oil pistons, rings, walls of cylinders, bearings of a rod and шатунные necks.

At installation of the piston and rod knot in a trunk of the cylinder of the marksman on a piston head should specify in the pulley party коленвала (1).

Repeat dismantle procedure upside-down for the purpose of installation. Adjust a tension of a belt of a drive of the cooling fan, having addressed to Section Regulation and check of a tension of a belt of the cooling fan in the Head engine Cooling. Adjust люфт a rope of an accelerator and люфт a cable of a drive throttle заслонок А/Т (for vehicles with А/Т). Check up, whether all removed parts are put into place. Repeatedly establish any necessary parts which have not been earlier established. Fill the engine with engine oil, having addressed to Section Engine oil and the filter in the Head Maintenance service and greasing. Fill cooling system, having addressed to Section Washing and filling of system of cooling in the Head engine Cooling. Fill the case of forward differential трансмиссионным with oil, having addressed to Section Servicing in the Head Forward differential. Fill system of a steering with a special liquid, having addressed to Section the Liquid of the hydraulic booster of a wheel in the Head System of the hydraulic booster of a wheel. Connect a negative cable to the accumulator. Check up, whether there is no leak of fuel, antifreeze, oil and exhaust gas on each connection. Be convinced of that installation of a corner of an advancing of ignition or fuel injection corresponds to technical requirements, and adjust if necessary, having addressed to Section Check and adjustment of time of an advancing of ignition in the Head System of ignition for engine J20.