3.10. Repair of the engine

The basis for dismantling and repair of the engine are: falling of engine capacity, reduction of pressure of oil, sharp increase in a consumption of oil (over 450 g on 100 km of a run), smoking of the engine, the increased fuel consumption, decrease in a compression in cylinders, and also noise and knocks.
At repair of engines it is necessary to consider their design features. Block of cylinders of the engine of fashion. 4218, unlike the block of engines of models 414, 4178 and 4021.60 with wet easily removable sleeves, has a monolithic design with the filled-in sleeves without consolidations. Sleeves in it are chiseled under the size of 100 mm (instead of 92 mm). The sizes of pistons, piston fingers and rings are respectively increased. Pistons have the combustion chamber in the bottom. Piston fingers have the increased wall thickness, rods – length increased by 7 mm.
When dismantling the engine carefully check a possibility of further application of each its detail. Criteria according to a possibility of further use of details are given in tab. 2.1.
Operability of the engine can be restored by replacement of worn-out details new the nominal size or restoration of worn-out details and application of the new details of the repair size interfaced to them.
For these purposes pistons, piston rings, inserts of conrod and radical bearings of a bent shaft, a saddle of inlet and final valves, plugs of the camshaft and some other details and sets of the repair sizes are issued. The list of details and sets nominal and the repair sizes is provided in tab. 2.2.

Sizes of gaps and tightnesses in the engine
Reduction or increase in gaps against recommended worsens conditions of lubricant of the rubbing surfaces and accelerates wear. Reduction of tightnesses in motionless (press) landings is also extremely undesirable. For such details as the directing plugs and plug-in saddles of final valves reduction of tightnesses worsens transfer of heat from these details to walls of a head of the block of cylinders. At repair of the engine use these tab. 2.3. (and tab. 2.3. part 2)

Removal and installation of the engine on cars of family UAZ-31512
Before removal of the engine from the car installed on a viewing ditch execute the following:
1. Merge liquid from the cooling system and oil from an engine case.
2. Remove the air filter.
3. Disconnect a reception pipe of the muffler from the engine.
4. Disconnect hoses of the cooling system, a heater and the oil heater from the engine.
5. Disconnect and remove a cooling system radiator.
6. Disconnect from the carburetor of draft of the drive of air and throttle gates.
7. Disconnect all electrical wires from the engine.
8. Disconnect the working cylinder of the drive of switching off of coupling and connecting draft from a coupling case.
9. Remove bolts of fastening of pillows of forward support of the engine together with the lower pillows of support.

Fig. 2.41. Removal of the engine from the car


10. Establish a special bracket on the second and fourth hairpins of a head of the block (fig. 2.41), considering from a forward end face of the block.
11. Having raised the engine the elevator, disconnect the transmission from the engine.
12. Lift the engine and remove it from the car, at the same time the transmission with the transfer case will remain on a car frame.
You make installation of the engine on the car in the return sequence.
The engine can be removed, lowering it together with the transmission and the transfer case down, at the same time it is necessary to remove a cross-piece. This way is much more difficult than the first.

Features of removal and installation of the engine on cars UAZ of carriage configuration
It is necessary for removal of the engine:
1. Follow instructions of subitem 1-10 of the section "Removal and Installation of the Engine on Cars of Family UAZ-31512".
2. Remove seats and a cover of a cowl.
3. Open the hatch in a cabin roof, pass via it a hook with a cable (chain) of the lifting mechanism and hook on a hook for a bracket.
4. Raise several engine and disconnect it from the transmission.
5. For simplification of removal of the engine establish a board which would not cave in under engine weight in a doorway.
6. Lift the lifting mechanism in a cowl aperture the engine and, being careful, take out it through a doorway on a board.
You make installation of the engine in the return sequence.

Dismantling and assembly of the engine
Before dismantling carefully clear the engine of dirt and oil.
Sort and assemble the engine at the rotary stand by means of sets of the tool, for example, of the GARO models 2216-B and 2216-M, and also the special tool and devices specified in the appendix 2.
At an individual method of repair of the engine of a detail, suitable for further work, establish on former places where they were earned extra. For providing it mark pistons, piston rings, rods, piston fingers, inserts, valves, bars, yokes and pushers at removal in any way which is not causing damage (a kerneniye, inscribing, paint, an attachment of labels, etc.).
At any kind of repair it is impossible to raskomplektovyvat covers of rods with rods, to rearrange a case of coupling and a cover of radical bearings from one engine on another or to interchange the position of covers of average radical bearings in one block as these details are processed in common.
When replacing a case of coupling check coaxiality of the opening serving for centering of the transmission with an axis of a bent shaft, and also perpendicularity of a back end face of a case of coupling concerning an axis of a bent shaft. When checking fix a rack of the indicator on a flange of a bent shaft. Coupling at the same time has to be removed. The beating of an opening and an end face of a case should not exceed 0,08 mm.
After dismantling of the engine of a detail carefully degrease, clear of a deposit and resinous deposits.
Removal of a deposit from pistons, inlet valves and combustion chambers you make in the mechanical or chemical way.
The chemical way of removal of a deposit consists in keeping of details in a bathtub with the solution which is warmed up to 80–95 °C within 2–3 hours.
Apply the following composition of solution to cleaning of aluminum details (in on 1 l of water):
Soda calcinated (Na2CO3)..... 18,5
Soap economic or green..... 10
Liquid glass (Na2SiO3)..... 8,5
Apply the following composition of solution to cleaning of steel details (in on 1 l of water):
The caustic soda (NaOH)..... 25
Soda calcinated (Na2CO3)..... 33
Soap economic or green..... 3,5
Liquid glass (Na2SiO3)..... 1,5
After cleaning of a detail wash out more hotly (80–90 °C) water and an obduyta compressed air.
Do not wash out a detail from aluminum and zinc alloys in the solutions containing alkali (NaOH).
At assembly of the engine observe the following:
1. Wipe and blow details compressed air, and oil all rubbing surfaces engine.
2. Carving details (hairpins, traffic jams, unions) if they were unscrewed or were replaced in the course of repair, establish on minium.
3. Establish one-piece connections (for example, a cap of the block of cylinders) on a nitrovarnish.
4. Bolts and nuts tighten a dynamometer key, the moment of an inhaling, N · m (kgf · l):
Nuts of hairpins of fastening of a head of the block of cylinders..... 71,6–76,5(7,3–7,8)
Nuts of bolts of a rod..... 66,7–73,5 (6,8–7,5)
Nuts of hairpins of fastening of covers of radical bearings of a bent shaft..... 122,6–133,4 (12,5–13,6)
Nuts of bolts of fastening of a flywheel to a bent shaft..... 74,5–81,4 (7,6–8,3)

Repair of the block of cylinders
Interface of the wearing-out details is carried out, generally by replaceable details that allows to repair the block of cylinders the regrinding or replacement of sleeves, replacement of worn-out plugs of the camshaft semi-processed with their subsequent processing for the required size, replacement of inserts of radical bearings of a bent shaft. Maintenance of couple an opening of the block of cylinders pushers because of their insignificant wear comes down to replacement of pushers.

Repair and replacement of sleeves of the block of cylinders

Fig. 2.42. A stripper for vypressovki sleeves from the block of cylinders: 1 – stripper; 2 – sleeve;
3 – block of cylinders


The most admissible wear of sleeves of cylinders should be counted up increase in a gap between a sleeve and a skirt of the piston to 0,3 mm. With such wear to a vypressuyta a sleeve from the block of cylinders by means of a stripper of 1 (fig. 2.42) also chisel to the closest repair size of the piston with the admission to processing +0,06 mm.
Do not clamp when processing a sleeve in a cam cartridge as it will entail deformation of a sleeve and distortion of its sizes.
Fix a sleeve in adaptation representing the plug with landing corbels with a diameter of 100 and 108 mm. Insert a sleeve into the plug against the stop in the top fillet which clamp a laid on ring in the axial direction. After processing the mirror of the cylinder of a sleeve has to have the following deviations:
1. Ovality and conicity no more than 0,01 mm, and the bigger basis of a cone has to settle down in the lower part of a sleeve.
2. Barrel shape and a korsetnost – no more than 0,08 mm.
3. Beating of a mirror of the cylinder of rather landing corbels with a diameter of 100 and 108 mm no more than 0,01 mm.

Fig. 2.43. Measurement of a vystupaniye of a sleeve over the block plane


After a sleeve press fitting in the block of cylinders check the size of a vystupaniye of the top end face of a sleeve over the top plane of the block (fig. 2.43). The size of a vystupaniye has to be 0,005–0,055 mm. At an insufficient vystupaniye (less than 0,005 mm) laying of a head of the block can be punched; besides, cooling liquid because of insufficient consolidation of the top corbel of a sleeve with the block of cylinders will inevitably get to the combustion chamber. When checking size of a vystupaniye of an end face of a sleeve over the block it is necessary to remove a rubber sealing ring from a sleeve.

Fig. 2.44. A clip for sleeves: 1 – nut; 2 – washer; 3 – plug


That sleeves did not drop out of nests in the block at repair, fix them by means of washers 2 and the plugs 3 which are put on hairpins of fastening of a head of the block of cylinders as shown in fig. 2.44.
Replace the sleeves of cylinders chiseled under the third repair size of the piston after wear new.

Repair of a head of the block of cylinders
Treat the main defects of a head of the block of cylinders which can be eliminated with repair: a prileganiye plane buckling to the block of cylinders, wear turned gray also the directing plugs of valves.
Not straightforwardness of the plane of the head adjoining to the block at its check on a control plate the probe should not be more than 0,05 mm. Eliminate an insignificant buckling of a head (to 0,3 mm) the shabrovky plane on paint. At the korobleniye exceeding 0,3 mm, the head needs to be ground.

Replacement of piston rings
Replace piston rings through 70 000–90 000 km of a run (depending on car service conditions).
Piston rings establish on three on each piston:
two compression and one oil scraper. Compression rings are cast from special cast iron. The external surface of the top compression ring is covered with porous chrome, and the surface of the second compression ring is covered with tin, or has a phosphatic covering of dark color.

Fig. 2.45. Installation of rings on the piston: and – the piston with UMZ-4178.10 engine rings; in – the piston with UMZ-4218.10 engine rings; 1 – piston; 2 – top compression ring; 3 – lower compression ring;
4 – ring disks; 5 – axial dilator; 6 – radial dilator


On internal cylindrical surfaces of both compression rings pro-points (fig. 2.45, a) are provided at the expense of which rings at the movement of the piston are a little unscrewed down that promotes the best removal of excessive oil from a surface of sleeves. Rings need to be installed on the piston by pro-points up, towards the piston bottom.
The UMZ-4218.10 engine can be completed with two options of execution of compression rings (fig. 2.45, c).
One option of the top compression ring 2 (fig. 2.45, b) has a pro-point on an internal cylindrical surface. The ring needs to be installed on the piston by a pro-point up.
Other option of the top compression ring 2 (fig. 2.45, c) has a barrel-shaped profile of an external surface, the pro-point on an internal cylindrical surface of a ring is absent. The provision of a ring at installation in a piston flute indifferent.
The lower compression ring 3 (fig. 2.45, c) – scraper type, on the lower face surface has a ring pro-point which together with a conical external surface forms a sharp lower edge ("scraper"). The ring is made in two options – with a pro-point on an internal cylindrical surface of a ring (fig. 2.45, b) and without pro-point (fig. 2.45, c). The ring needs to be installed on the piston by a sharp edge "scraper" down.
The oil scraper ring compound, has two ring disks, radial and axial dilators. The external surface of a disk of oil scraper rings is covered with solid chrome.
Lock of rings of a straight line.
Piston rings of the repair sizes (see tab. 2.2) differ from rings of the nominal sizes only in outer diameter.
Rings of the repair size can be installed in worn-out cylinders with the next smaller repair size by a podpilivaniye of their joints before receiving a gap in the lock 0,3–0,5 mm (0,3–0,65 mm for engines of fashion. 4218).

Fig. 2.46. Selection of piston rings for the cylinder (check of a side gap in a ring joint)


You make check of a side gap in a joint of a ring, as shown in fig. 2.46. To repolished cylinders adjust rings by the top part, and to worn out – on the lower part of the cylinder (within the course of piston rings). At adjustment install a ring in the cylinder in working situation, i.e. in the plane, a perpendicular axis of the cylinder for what advance it in the cylinder by means of a piston head. The planes of joints at the compressed ring have to be parallel.

Fig. 2.47. Removal and installation of piston
rings


Remove and install rings on the piston by means of adaptation (fig. 2.47) of model 55-1122.

Fig. 2.48. Check of a side gap between a piston ring and a flute of the piston


After adjustment of rings on cylinders check a side gap between rings and flutes in the piston (fig. 2.48) which has to be: for the top compression ring of 0,050-0,082 mm, for lower compression – 0,035–0,067 mm. At big gaps replacement only of piston rings will not exclude the raised oil consumption because of intensive transfer by its rings in space over the piston. In this case along with replacement of rings replace also pistons (see the head "Replacement of pistons"). Simultaneous replacement of piston rings and pistons sharply cuts an oil consumption.

Fig. 2.49. Cleaning of flutes of piston rings of a deposit


When replacing only of piston rings without replacement of pistons delete a deposit from the bottoms of pistons, from ring flutes in the head of the piston and maslootvodyashchy openings located in flutes for oil scraper rings. Delete a deposit from flutes carefully not to damage their side surfaces, by means of adaptation (fig. 2.49).
Delete a deposit from maslootvodyashchy openings with a drill with a diameter of 3 mm.
When using sleeves of cylinders, new or repolished under the repair size, it is necessary that the top compression ring had the chromeplated covering, and other rings were tinned or fosfatirovanny. If the sleeve is not under repair, and only piston rings change, then all of them have to be tinned or fosfatirovanny as to a worn-out sleeve the chromeplated ring is earned extra very badly.
Before installation of pistons in cylinders part joints of piston rings in at an angle 120 ° to each other.
After change of piston rings during 1000 km of a run do not exceed on the speed car in 45 - 50 km/h.

Replacement of pistons
You make replacement of pistons at wear of a flute of the top piston ring or a skirt of the piston.
Install pistons of the same size in partially worn-out cylinders (nominal or repair) what the pistons which were earlier working in this engine had. However it is desirable to pick up a set of the bigger size of pistons for reduction of a gap between a skirt of the piston and a mirror of the cylinder.
In this case check a gap between a skirt of the piston and a mirror of the cylinder in the lower, least worn-out part of the cylinder.
Do not allow reduction of a gap in this part of the cylinder less than 0,02 mm.
In spare parts pistons together with the piston fingers and lock rings which are picked up to them are delivered (see tab. 2.2).
For selection pistons of the nominal size sort by the outer diameter of a skirt. On the bottoms of pistons alphabetic references of dimensional group which are specified in tab. 2.4 are beaten out.
On pistons of the repair sizes also the size of their diameter is beaten out.
Except selection of pistons to cylinder sleeves on diameter of a skirt, they are selected also for weight. The difference in weight between the easiest and heaviest piston for one engine should not exceed 4 g.
At assembly install pistons in sleeves of the same group.

Fig. 2.50. The device for installation of the piston with rings in the cylinder


Install pistons in cylinders by means of adaptation of model 59-85 shown in fig. 2.50.
At installation of pistons the tag "before" cast on the piston has to be turned into cylinders to a forward part of the engine, on the piston with a cutting skirt a tag "back" – towards a coupling case.
On all pistons of the repair sizes of an opening in lugs under a piston finger become the nominal size with breakdown on groups. If necessary these openings are chiseled or developed to the next repair size with the admission of-0,005 - 0,015 mm. Conicity and ovality of an opening – no more than 0,0025 mm. When processing provide perpendicularity of an axis of an opening to a piston axis, a permissible deviation – no more than 0,04 mm on length of 100 mm.

Repair of rods
Repair of rods comes down to replacement of the plug of the top head and its subsequent processing under a piston finger of the nominal size or to processing of the plug which is available in a rod under a finger of the repair size.
In spare parts the plugs of one size manufactured of the bronze film OTsS4-4-2,5 1 mm thick are delivered.
At a press fitting of the new plug in a rod provide coincidence of an opening in the plug with an opening in the top head of a rod.
Openings serve for supply of lubricant to a piston finger.
After a press fitting of the plug condense its internal surface with a smooth brooch to diameter of 24,3+0,045 mm, and then develop or chisel under the nominal or repair size with the admission +0,007 - 0,003 mm.
For example, deploy the plug or chisel under a finger of the nominal size to diameter 25 +0,007 - 0,003 mm or under a finger of the repair size to diameter of 25,20 +0,07 - 0,003 mm.
The distance between axes of openings of the lower and top heads of a rod has to be (168±0,05) mm [(175±0,05) mm for model 4218] engines; admissible not parallelism of axes in two mutually perpendicular planes on length of 100 mm has to be no more than 0,04 mm; ovality and conicity should not exceed 0,005 mm. To sustain the specified sizes and admissions, deploy the plug of the top head of a rod in the conductor.

Fig. 2.51. Operational development of an opening in the top head of a rod: 1 – derzhavka; 2 – grinding head; 3 – clip


After expansion you make operational development of an opening on a special grinding head, holding a rod in hand (fig. 2.51). Establish grinding whetstones of a head by the micrometric screw on the required repair size.
Rods which openings under inserts in the lower head have ovality more than 0,05 mm are subject to replacement.

Replacement and repair of piston fingers
The repair sizes of piston fingers and number of sets are specified in tab. 2.2.
The piston fingers increased on diameter by 0,08 mm are applied to replacement of piston fingers without preliminary processing of openings in the piston and in the top head of a rod. Application of the fingers increased by 0,12 mm and 0,20 mm demands preliminary processing of openings in lugs of the piston and in the top head of a rod as it is described above (see chapters "Replacement of pistons" and "Repair of rods").

Fig. 2.52. Removal of a lock ring of a piston finger


Fig. 2.53. Adaptation for vypressovki and press fittings of a piston finger: 1 – guide; 2 – finger; 3 – plunger


Before a vypressovka of a piston finger take from the piston lock rings of a piston finger flat-nose pliers, as shown in fig. 2.52. Vypressovka and a press fitting of a finger you make on adaptation, as shown in fig. 2.53. Before a vypressovka of a finger heat the piston in hot water to 70 °C.
Repair of piston fingers consists in their regrinding from the big repair sizes on smaller or in chromium plating with the subsequent processing under the nominal or repair size.
The fingers having breaks, vykrashivaniye and cracks of any size and arrangement, and also overheat traces (color of a pobezhalost) are not subject to repair.

Assembly of conrod and piston group

Fig. 2.54. Selection of a piston finger


Piston finger to the top head of a rod select 0,0045 - 0,0095 mm with a gap. At the normal room temperature the finger has to move smoothly in an opening of the top head of a rod from effort of a thumb of a hand (fig. 2.54). The piston finger at the same time has to be slightly oiled by low-viscous.
Finger install in the piston with a tightness 0,0025–0,0075 mm.
Almost piston finger is selected so that at the normal room temperature (20 °C) it would not enter the piston from effort of a hand, and when heating the piston in hot water up to the temperature of 70 °C would enter it freely. Therefore before assembly heat the piston in hot water to 70 °C. The finger press fitting without preliminary heating of the piston will lead to damage of a surface of openings in piston lugs, and also to deformation of the piston. You make assembly of conrod and piston group on the same adaptation, as dismantling (see fig. 2.53).
For ensuring the correct balancing of the engine the difference in the weight of the pistons installed in the engine assembled with rods should not exceed 8 g.
Lock rings of a piston finger have to sit in the flutes with a small tightness. Do not apply the rings which were in the use.
Install piston rings on the piston as it is specified in the head "Replacement of piston rings".
Considering complexity of selection of a piston finger to the piston and a rod (for ensuring nominal landings), pistons are delivered in the spare part assembled with a piston finger, lock and piston rings.

Repair of a bent shaft
Repair of a bent shaft consists in regrinding of radical and conrod necks under the next repair size.
The repair sizes of conrod and radical necks are defined by the sizes of sets of the connecting and radical rods delivered in spare parts which are given in tab. 2.2.
Radial gaps in conrod and radical bearings of a bent shaft have to be 0,020–0,049 mm and 0,020–0,066 mm respectively. Regrinding of necks you produce 0,013 mm with the admission.
If the sizes of conrod and radical necks do not coincide among themselves, it is necessary to pereshlifovat them under one repair size.
Facets and openings of the forward and back ends of a bent shaft are not suitable for installation in the grinder. For this purpose make the removable centers glasses. The forward center to a napressovyvayta on a neck with a diameter of 38 mm, and back align on the outer diameter of a flange (mm Zh122) of a shaft and you fix to it bolts. At production of the transitional centers provide concentricity of center and adjusting openings. Without meeting this condition, it is impossible to provide necessary concentricity of seats of a flywheel and a gear wheel to axes of radical necks.
When grinding conrod necks establish a shaft on the additional centers, coaxial axes of conrod necks. For this purpose it is possible to use the centers glasses, having provided on them flanges with two additional center openings remote from an average opening on 46±0,05 mm.
For the forward end it is better to make the new center flange which is established on a neck with a diameter of 40 mm (on a spline) and in addition is fixed by a bolt (ratchet) screwed in a carving opening.
Before grinding of necks deepen facets on edges of oil channels so that their width after removal of all allowance for grinding was 0,8–1,2 mm. Do it by means of an emery stone with a corner at top 60–90 °, brought into rotation by the electric drill.
When grinding conrod necks do not concern a grinding wheel of side surfaces of necks not to break an axial gap of rods. Radius of transition to a side surface maintain 3,5 mm. You make grinding with plentiful cooling with an emulsion.
In the course of regrinding maintain:
1. Distance between axes of radical and conrod necks of 46±0,05 mm.
2. Conicity, barrel shape, saddle shape, ovality and facet of necks no more than 0,005 mm.
3. Angular arrangement of conrod necks ±0 °10'.
4. Not parallelism of axes of conrod necks with an axis of radical necks no more than 0,012 mm on all length of a conrod neck.
5. A beating (at installation of a shaft extreme radical necks on prisms) average radical necks no more than 0,02 mm, necks under a distributive gear wheel to 0,03 mm, and necks under a nave of a pulley and a back epiploon to 0,04 mm.
After grinding of necks wash out a bent shaft, and clear oil channels of an abrasive and resinous deposits. At the same time turn out traffic jams of mud-catchers. After cleaning of mud-catchers and channels wrap traffic jams into place and a zakernita each of them from a spontaneous vyvertyvaniye again.
Clear oil channels also at operational repair of the engine when you take out a bent shaft from the block.

Fig. 2.55. Installation of coupling on tags:
1 – tags


After repair collect a bent shaft with the same flywheel and coupling which stood before repair. Establish coupling on a flywheel on the factory tags "About" put on both details one against another around one from bolts of fastening of a casing of coupling to a flywheel (fig. 2.55).
Before installation on the engine assembled dynamically balance a bent shaft with coupling on the special machine. Previously center the conducted clutch plate by means of a shaft of the transmission or a special mandrel.
Eliminate an imbalance with drilling of metal in a flywheel rim on the radius of 158 mm a drill with a diameter of 12 mm. Depth of drilling should not exceed 12 mm. An admissible imbalance – no more than 70 гс • see.

Replacement of inserts of radical and conrod bearings of a bent shaft
In spare parts inserts of radical and conrod bearings nominal and seven repair sizes which are specified in tab. 2.2 are delivered. Inserts of the repair sizes differ from inserts of the nominal size in the internal diameter reduced on 0,05; 0,25; 0,50; 0,75; 1,0; 1,25 and 1,50 mm.
Replace inserts of radical and conrod bearings without any adjustment.
Depending on wear of necks at the first change of inserts apply inserts nominal or, as a last resort, the first repair size (reduced by 0,05 mm).
And the subsequent repair sizes install inserts of the second in the engine only after regrinding of necks of a bent shaft.
If as a result of repeated regrindings diameters of necks of a bent shaft are reduced so that inserts of the last repair size will be unsuitable for it, then collect the engine with a new shaft.
The radial gap in conrod and radical bearings of a bent shaft has to be respectively 0,020-0,049 mm and 0,020–0,066 mm.
You make check of size of radial gaps by means of a set of the control probes executed from copper a foil 0,025 thick; 0,05; 0,075 and 0,1 mm cut in the form of strips 6-7 mm wide and a little less than width of insert long. Edges of probes have to be smoothed out for an exception of damage of a surface of an insert.
You make check of a radial gap in the following order:
1. Uncover with checked necks with an insert and put previously oiled control probe 0,025 mm thick across an insert.
2. Establish into place a cover with an insert and tighten bolts, at the same time bolts of other covers have to be released.
3. Turn a bent shaft a hand on a corner no more than on 60-90 °, in order to avoid damage of a surface of an insert by the probe.
If the shaft is turned too easily, the gap more than 0,025 mm means. In this case repeat check by probes 0,05; 0,075 mm, etc. until it becomes impossible to turn a bent shaft.
Probe thickness at which the shaft is turned with notable effort is considered to the equal actual size of a gap between an insert and a neck of a bent shaft.
When replacing inserts observe the following:
1. Replace inserts without subracing operations.
2. You watch that the fixing ledges on joints of inserts freely (from effort of a hand) entered grooves in shaft beds.
3. Along with replacement of inserts clear mud-catchers in conrod necks.
Replacement of connecting rods can be made, without removing the engine from the car chassis. You make replacement of radical inserts on the engine removed from the car chassis.
After replacement of inserts roll the engine as it is specified in the section "Engine Running in after Repair".
If when replacing inserts the engine was not removed from the car, then throughout the first 1000 km of a run speed should not exceed 50 km/h.

Fig. 2.56. Forward end of a bent shaft: 1 – cuff; 2 – pulley nave; 3 – damper nave; 4 – laying; 5 – pulley damper;
6 – persistent washer; 7 – forward washer;
8 – back washer; 9 – pin


Along with replacement of inserts check an axial gap in the persistent bearing of a bent shaft which has to be 0,075–0,175 mm. If an axial gap more than 0,175 mm, replace washers of 7 (fig. 2.56) and 8 new. The forward washer is made four sizes on thickness: 2,350–2,375; 2,375–2,400; 2,400– 2,425; 2,425–2,450 mm.

Fig. 2.57. Check of an axial gap of a bent shaft


For check of a gap in the persistent bearing put the screw-driver (fig. 2.57) between the first crank of a shaft and a forward wall of the block and wring out a shaft by the back end of the engine. Then determine by the probe a gap between an end face of a back washer of the persistent bearing and the plane of a burt of the first radical neck.
Before installation of inserts check coaxiality of radical necks of a bent shaft (a deflection arrow). For this purpose establish a bent shaft in the centers and check the provision of axes of radical necks according to indications of the indicator.

Fig. 2.58. Back end of a bent shaft:
1 – block of cylinders; 2 – bent shaft; 3 – samopodzhimny epiploon; 4 – epiploon cover;
5 – flywheel


The forward and back ends of a bent shaft are condensed with epiploons (fig. 2.56 and 2.58).

Repair of the camshaft and replacement of its plugs
You make restoration of necessary gaps in plugs of the camshaft regrinding of basic necks of a shaft, reducing their size no more than by 0,75 mm, and replacement of worn-out plugs semi-processed with the subsequent their boring for the sizes of repolished necks.
On engines without plugs you make restoration of necessary gaps boring of openings in the block under plugs, being guided by these tab. 2.3. (and tab. 2.3. part 2), and subsequent press fitting of plugs of the nominal or repair size.
Before regrinding of necks of the camshaft deepen flutes on the first and last necks at a size of reduction of diameter of these necks in order that after regrinding of necks to provide intake of lubricant to distributive gear wheels and to an axis of yokes. Grinding of necks you carry out in the centers with the admission 0,02 mm. After grinding of a neck polish.
Vypressovka and a press fitting of plugs it is more convenient to do by means of carving hairpins (the corresponding length) with nuts and podkladny washers.
The semi-processed camshaft plugs delivered in spare parts by a set on one engine have the sizes of outer diameter same, as well as plugs of the nominal size therefore they are pressed in block openings without preliminary processing.
For ensuring sufficient thickness of a layer of babbit (antifrictional material) the size of repair reduction of internal diameter of all plugs has to be identical.
At a press fitting of plugs you monitor coincidence of their side openings to oil channels in the block. Chisel plugs, reducing diameter of each subsequent plug, beginning from a forward end face of the block, on 1 mm. Boring conduct with the admission +0,050 +0,025 mm that gaps in plugs after installation of a shaft corresponded to these tab. 2.4.
When boring plugs and openings in the block under plugs maintain distance between axes of openings under cranked and distributive shaft (118±0,025) mm. Check this size at a forward end face of the block. The deviation from coaxiality of openings in plugs has to be no more than 0,04 mm, and the deviation from parallelism of cranked and distributive shaft has to be no more than 0,04 mm on all length of the block. To provide coaxiality of plugs in the set limits, process them at the same time by means of long and rather rigid borshtanga with the cutters or development got on it on number of support. Establish a borshtanga, being based concerning openings for inserts of radical bearings.
Smooth out camshaft cams at insignificant wear and teases a grinding skin: at first coarse-grained, and then fine-grained. At the same time the grinding skin has to cover not less than a half of a profile of a cam and have some tension that will provide the smallest distortion of a profile of a cam.
At wear of cams on height more than on 0,5 mm, replace the camshaft new.
Check curvature of the camshaft the indicator on napes (on a cylindrical surface) inlet and final cams of the second and third cylinders. At the same time establish a shaft in the centers. If the beating of a shaft exceeds 0,03 mm, then correct a shaft or replace.

Restoration of tightness of valves and replacement of plugs of valves
Violation of tightness of valves at the correct gaps between cores of valves and yokes, and also during the correct operation of the carburetor and system of ignition is found on characteristic cottons from the muffler and the carburetor. The engine at the same time works with interruptions and does not develop full capacity.
Carry out restoration of tightness of valves grinding in of working facets of valves to their saddles. In the presence on working facets of valves and saddles of sinks, ring developments or рисок which cannot be removed grinding in, a facet proshlifuyta with the subsequent grinding in of valves to saddles. Replace valves with the jarred-on heads.

Fig. 2.59. Grinding in of valves


Grind in facets of valves a pneumatic or electric drill of the GARO model 2213, 2447 or manually by means of rotation. You make grinding in returnable rotary motions at which the valve is turned in one party slightly more, than in another. For the period of grinding in under the valve establish a squeezing spring with small elasticity. Internal diameter of a spring has to be about 10 mm. The spring has to raise several the valve over a saddle, and by easy pressing the valve has to sit down on a saddle. Contact of the tool with the valve is carried out by a rubber prisos, as shown in fig. 2.59. For the best coupling of a prisos with the valve of their surface have to be dry and pure.
For acceleration of grinding in use the pritirochny paste made of one part of micropowder of the M20 brand and two parts of engine oil. Carefully mix mix before application. Conduct grinding in before emergence on working surfaces of a saddle and a plate of the valve of a uniform opaque facet on all circle. By the end of grinding in reduce the content of micropowder in pritirochny paste. Finish grinding in on one pure oil. Instead of pritirochny paste it is possible to use the emery powder No. 00 mixed with engine oil.
It is recommended to use GARO R-108 or OPR-1841 grinders to grinding of working facets of valves. At the same time clamp a core of the valve in the aligning boss of the grandma established at an angle 44 °30' to a working surface of a grinding stone. Reduction on 30' a tilt angle of a working facet of a head of the valve in comparison with a corner of a facet of saddles accelerates to extra earnings and improves tightness of valves. When grinding remove the minimum quantity of metal from a valve head facet. Height of a cylindrical corbel of a working facet of a head of the valve after grinding has to be not less than 0,7 mm, and coaxiality of a working facet concerning a core within 0,03 mm of the general indications of the indicator. A valve core beating – no more than 0,02 mm. Replace valves with a big beating new. Not to a pereshlifovyvayta valve cores on the smaller size as there will be a need for production of new croutons of plates of valvate springs.

Fig. 2.60. Device for grinding of saddles of valves: 1 – cutting plug; 2 – mandrel; 3 – grinding circle; 4 – lead washer; 5 – the directing plug; 6 – head case; 7 – pin; 8 – lead; 9 – tip;
10 – flexible shaft; 11 – electric motor shaft; 12 – elekt-rodvigatel


Grind facets of saddles at an angle 45 ° coaxially to an opening in the plug. Width of a facet has to be 1,6–2,4 mm. It is recommended to use adaptation represented in fig. 2.60 to grinding of saddles. Grind a saddle without pritirochny paste or oil until the stone does not begin to process all working surface.
After rough processing replace a stone with fine-grained and make fair grinding of a saddle. The facet beating concerning an axis of an opening of the plug of the valve should not exceed 0,03 mm. Replace worn-out saddles new. In spare parts the saddles of valves having outer diameter are delivered it is more nominal on 0,25 mm. Take worn-out saddles from a head by means of a vertical drill.
After extraction of saddles chisel in a nest head for the final valve to diameter of 38,75+0,025 mm and for the inlet valve to diameter of 49,25+0,25 mm. Before a press fitting of saddles heat a head of the block of cylinders to temperature of 170 °C, and cool saddles with artificial ice. You make a press fitting quickly, without giving the chance to saddles to heat up. The cooled-down head densely covers saddles. For increase in durability of landing of saddles fuller them on outer diameter by means of a flat mandrel, trying to obtain filling of a facet of a saddle. Then a proshlifuyta to the required sizes also grind in.
If wear of a core of the valve and a guide of the plug is so big that the gap in their joint exceeds 0,25 mm, then restore tightness of the valve only after replacement of the valve and its plug. In spare parts valves only of the nominal sizes, and the directing plugs – with the internal diameter reduced by 0,3 mm for the subsequent their development under the final size after a press fitting in a head of the block of cylinders are delivered.
Develop the pressed plugs to diameter of 9+0,022 mm. The core of the inlet valve has diameter of 9 - 0,050 - 0,075 mm, final 9 - 0,075 - 0,095 mm, therefore, gaps between cores of inlet and final valves and plugs have to be respectively equal 0,050–0,097 mm and 0,075–0,117 mm.

Fig. 2.61. Drift of plugs of valves: And – temper the specified surface


Press off the worn-out directing plugs from a head of the block of cylinders by means of the drift shown in fig. 2.61.
Press the new plug from yokes by means of the same drift against the stop in the lock ring which is available on the plug. At the same time, as well as at a press fitting of saddles of valves, heat a head of the block of cylinders to temperature of 170 °C, and cool the plug with artificial ice.
After replacement of plugs of valves make grinding of saddles (being aligned on openings in plugs) and then grind in to them valves. After grinding of saddles and grinding in of valves all channels and places where the abrasive could get, carefully wash out and blow compressed air.
Plugs of valves – ceramic-metal, porous. After final processing and washing impregnate them with oil. For this purpose insert into each plug at several o'clock the felt match impregnated in a spindle oil. Grease cores of valves before assembly with a thin layer of the mix prepared from seven parts of oil colloidal and graphitic medicine and three parts of engine oil.

Replacement of valvate springs
Can be the possible malfunctions of valvate springs appearing in use: elasticity reduction, fiascos or cracks on rounds.
Check elasticity of valvate springs when dismantling the valvate mechanism. The effort necessary for compression of a new valvate spring to 46 mm on height has to be 267–310 N (27,3–31,7 kgfs), and to 37 mm – 686–784 N (70–80 kgfs). If effort of compression of a spring to 46 mm on height less than 235 N (24 kgfs), and to 37 mm less than 558,6 N
(57 kgfs), replace such spring new.
Replace springs with fiascos, cracks and traces of corrosion new.

Replacement of pushers
The directing openings in the block under pushers wear out slightly therefore restore a nominal gap in this interface replacement of worn-out pushers with new. In spare parts pushers only of the nominal size are delivered.
Pushers select to openings with a gap 0,040–0,015 mm. Pushers depending on the size of outer diameter are broken into two groups and are marked by a branding: in figure 1 – with a diameter of pusher of 25 - 0,008 - 0,015 mm and figure 2 – with a diameter of a pusher
25 – 0,015 – 0,022 mm. Correctly picked up pusher oiled by liquid mineral has to fall smoothly under own weight to a nest of the block and it is easy to be turned in it.
Replace the pushers having at end faces of plates beam teases, wear or a vykrashivaniye of a working surface new.

Repair of the drive of the distributor

Fig. 2.62. Drive of the oil pump and distributor of ignition: the provision of a cut of the roller A – on the drive installed on the engine; B – on the drive before its installation on the engine; In – on the roller of the oil pump before installation of the drive on the engine; 1 – roller of the oil pump;
2 – plug; 3 – intermediate roller; 4 – pin; 5 – drive gear wheel; 6 – gear wheel of a distributive shaft; 7 – persistent washer;
8 – block of cylinders; 9 – laying; 10 – drive roller;
11 – drive case;
12 – ignition distributor drive


The roller 10 (fig. 2.62) of the drive of the distributor which is worn out on diameter is restored by chromium plating with the subsequent grinding to diameter of 13-0,011 mm.
Replace the gear wheel of the 5th drive of the distributor having fiascos, colourings or considerable developments of a surface of teeths, and also wear of an opening under a pin to the size more than 4,2 mm new.
For replacement of the roller or a gear wheel of the drive of the distributor remove a gear wheel from the roller, having taken out previously a gear wheel pin with the help a small beard with a diameter of 3 mm. At removal of a gear wheel from the roller install the case 11 of the drive by the top end face on a support with an opening in it for pass of the roller of the drive assembled with the persistent plug.
You make assembly of the drive taking into account the following:
1. At installation of the roller (assembled with the persistent plug) in the case of the drive of the distributor oil the roller engine.

Fig. 2.63. The provision of a gear wheel of the drive on the roller: B – a gear wheel tooth end face; About – the axis passing through the middle of hollows of teeths


2. Having connected the drive roller 10 to the intermediate roller plate 3 drives and having put on a persistent washer 7, a napressuyta a gear wheel the roller, having sustained a gap between a persistent washer and a gear wheel of the drive 0,25 - 0,15 – 0,10 mm (fig. 2.63).
At the same time it is necessary that the axis of Au-oh, passing through the middle of hollows between two teeths at an end face of B was displaced concerning an axis V-in a roller vent on 5 °30 '±1.
3. An opening in a gear wheel and the roller under a pin you drill diameter (4±0,037) mm, maintaining distance from an opening axis to an end face of a gear wheel (18,8±0,15) mm.
When drilling an opening and at installation of a gap between a persistent washer and a gear wheel the distributor drive roller assembled with the persistent plug has to be pressed to the drive case in the direction of the oil pump. The pin connecting the roller to a gear wheel has to have a diameter of 4-0,025 mm and 22 mm long.
In the assembled drive of the distributor its roller has to be turned freely by hand.

Repair of the oil pump
At big wear of details of the oil pump pressure in lubricant system goes down and noise appears. When dismantling the pump check elasticity of a spring of the reducing valve. Elasticity of a spring is considered sufficient if for compression it to 24 mm on height it is necessary to make effort (54±2,45) N [(5,5±0,25) kgfs].
Repair of the oil pump usually consists in grinding of end faces of covers, replacement of gear wheels and laying.
When dismantling the pump previously drill a rasklepanny head of a pin of fastening of the plug 2 (see fig. 2.62) on its roller 1, beat out a pin, remove the plug and a cover of the pump. After that take out the pump roller together with the leading gear wheel from the case towards its cover.
In case of dismantling of the leading gear wheel and the roller drill a pin a drill with a diameter of 3 mm.
The conducting and conducted gear wheels with the painted teeths, and also with noticeable developments of a surface of teeths replace new. The conducting and conducted gear wheels established in a pump housing have to be turned easily by hand for the leading roller.
If on the internal plane of a cover there is considerable (more than 0,05 mm) a development from end faces of gear wheels, its proshlifuyta.
Between a cover, a plate and a pump housing paronitovy laying 0,3 - 0,4 mm thick is established.
Use of shellac, paint or other pressurizing substances at laying installation, and also installation of thicker laying is not allowed as it causes reduction of giving of the pump.
You make assembly of the pump taking into account the following:

Fig. 2.64. Fastening of the plug on the roller of the oil pump


1. Napressuyte on the leading roller the plug, having sustained the size between an end face of the leading roller and an end face of the plug of 8 mm (fig. 2.64). At the same time the gap between a pump housing and other end face of the plug has to be not less than 0,5 mm.
2. Drill in the leading roller
and in the plug an opening diameter
4 +0,03–0,05 mm, maintaining the size of (20±0,25) mm.
3. Razzenkuyte an opening on both sides on depth of 0,5 mm at an angle 90 °, press in it a pin with a diameter of 4 - 0,048 mm both 19 mm long and its rasklepayta from two parties.
If operability of the pump by means of repair cannot be restored, then replace it new.
You make installation of the drive of the oil pump and distributor of ignition on the block in the following order:
1. Turn out a candle of the first cylinder.
2. Establish in an opening for a candle компрессометр and turn the starting handle a bent shaft prior to the movement of an arrow. It will occur at the beginning of a compression step in the first cylinder. It is possible to stop up an opening for a candle with a paper pyzh or a thumb of a hand. In this case at a step of compression will jump out пыж or the air outlet from under a finger will be felt.
3. Having convinced that compression began, carefully turn a bent shaft before coincidence of an opening on a rim of a pulley of a bent shaft with the index (pin) on a cover of distributive gear wheels.
4. Turn the drive roller that the cut at its end face for a pricker of the distributor was located as it is specified fig. of 2.62 B, and turn the roller of the oil pump by means of the screw-driver in the situation specified fig. of 2.62 Century.
5. Carefully, without touching with a gear wheel block walls, insert the drive into the block. After installation of the drive to the place of its roller has to reach the position specified fig. 2.62 A.

Fig. 2.65. A mandrel for centering of the oil pump


For reduction of wear in hinged connections of the drive install the pump coaxially to an opening for the drive. For this purpose use the mandrel (fig. 2.65) which is densely entering an opening for the drive in the block and having a cylindrical shaft with a diameter of 13 mm. Center the pump on a shaft of a mandrel and enshrine in this provision.

Repair of the pump of the cooling system

Fig. 2.66. Engine cooling system pump: and – the pump of the cooling system 21-1307010-52;
– the pump of the cooling system 421-1307010-01; 1 – nut; 2 – roller; 3 – pump case; 4 – control opening of an exit of lubricant; 5 – press-butterdish; 6 – expansion plug; 7 – sealing washer;
8 – rubber cuff; 9 – spring; 10 – krylchatka; 11 – bolt of fastening of a krylchatka; 12 – lock ring; 13 – bearings; 14 – fan pulley nave; 15 – belt; 16 – pulley; 17 – fan;
18 – bolt; 19 – the roliko-ball bearing assembled with the roller; 20 – clamp; 21 – epiploon;
22 – pump housing cover


Can be possible malfunctions of the pump (fig. 2.66): a liquid leak through an epiploon of a krylchatka as a result of wear of a sealing washer or destruction of a rubber cuff of an epiploon, wear of bearings, fiascos and cracks of a krylchatka.
 Repair of the pump 21-1307010-52 of the cooling system

Fig. 2.67. Removal krylchatki pump


Eliminate dribble of liquid from the pump with replacement of a sealing washer and rubber cuff. For replacement remove the pump from the engine, disconnect it from an arm, remove adaptation 71-1769 a krylchatka (fig. 2.67), take out a sealing washer and a cuff of an epiploon.
For assembly of an epiploon of a krylchatka insert in the holder of an epiploon located on a pump housing, at first a rubber cuff assembled and then a sealing washer and a lock ring. At the same time grease the part of the roller of the pump interfaced to a rubber cuff before installation of an epiploon and napressovky krylchatka with soap, and the end face of a krylchatka adjoining to a sealing washer, a thin layer of graphitic lubricant.
Before installation of an epiploon check its end face (an end face of a sealing washer) for paint: at compression of an epiploon up to the height of 13 mm the print of an end face has to have not less than two completely closed circles without gaps.
To Krylchatk to a napressovyvayta on the roller on a manual press against the stop its naves in a lyska end face. At the same time the pump has to lean a forward end face of the roller on a table, and effort – to be put to a nave of a krylchatka.
For replacement of bearings or the roller of the pump disassemble the pump completely in the following order:
1. Remove a krylchatka from the pump roller and take out a sealing washer and a rubber cuff.

Fig. 2.68. Removal of a nave of a pulley of the pump


2. Turn off a nut of fastening of a nave of a pulley and remove it by means of adaptation, as shown in fig. 2.68.

Fig. 2.69. Vypressovka pump roller:
1 – pump case; 2 – roller; 3 – support


3. Take a lock ring of bearings from the case 1 (fig. 2.69) of the pump and on the press to a vypressuyta or beat out the copper hammer the roller 2 with bearings from the case, оперев a forward end face of the case on a support 3 with an opening for pass of bearings.

Fig. 2.70. A roller press fitting together with the bearing in the pump case: 1 – roller; 2 – pump case; 3 – mandrel; 4 – support


We make assembly of the pump upside-down. At the same time press the new bearing on the roller 1 (fig. 2.70) and in the case 2 at the same time by means of a manual press and a mandrel 3. The felt epiploon of the bearing has to be turned towards a lock ring. Having put on the expansion plug the roller, press the second bearing a felt epiploon outside.
After installation to the place of a lock ring to a napressuyta on the forward end of the roller a pulley nave, having rested the roller against a back end face of a ring. Pulley naves on the roller of the pump of the engine of model 4218 you make Napressovka after installation of a clamp 19 (see fig. 2.66, b). At a napressovka of a nave do not allow a gap between the bearing and a lock ring.
After assembly of the pump a case cavity between bearings fill in with lubricant as directed tables of greasing.
At installation of the assembled pump pay attention to suitability of paronitovy laying between the case and an arm of the pump to the engine.
 Repair of the pump 421-1307010-01 of the cooling system
Eliminate dribble of liquid from the pump with replacement of an epiploon 21 (see fig. 2.66, b) assembled. At wear of the roliko-ball bearing 19 replace it assembled with the roller.
For replacement of an epiploon or the roller assembled with the bearing remove the pump from the engine, disconnect it from a cover, remove adaptation 71-1769 krylchatku (see rice. 2.67).
By means of adaptation (see fig. 2.68) remove a nave of a pulley of the fan and a vypressuyta the roller with the bearing. Before a bearing vypressovka surely turn out a clamp 20 (see fig. 2.66, b). Vypressuyte epiploon.
You make assembly of the pump in the return sequence. At the same time you make a press fitting of a nave of a pulley of the fan against the stop in a fillet, and a press fitting of a krylchatka – to the size 117,4 +0,925-1,035 (see fig. 2.66, b).
Before assembly grease the part of the roller of the roliko-ball bearing interfaced to an epiploon with soap, and the end face of a krylchatka adjoining to an epiploon – graphitic lubricant.
At installation of the assembled pump pay attention to suitability of paronitovy laying between a cover and a pump housing to the engine.

Repair of the fuel tanks
Violation of tightness because of formation of the cracks, holes or other damages arising in use can be possible malfunction of tanks. For repair remove a tank from the car, clear of dirt and wash out outside.
For detection of malfunction ship a tank in a bathtub with water and give in a tank compressed air under pressure of 30 kPa (0,3 kgfs/cm2). All openings of a tank have to be previously muffled. In places of violation of tightness the tank will leave vials of air. Note all damages paint.
Then make full dismantling of a tank, carefully wash out it hot water for removal of vapors of gasoline from within and blow compressed air. Solder small cracks soft solder. On big cracks and holes impose metal patches. Seal of cracks by means of epoxy pastes and imposing of multilayered patches from fiber glass fabric is possible. After repair test a tank for tightness.
Eliminate the small cracks in a stopper of the fuel tank which resulted from blows. You make seal of cracks epoxy paste. After paste will harden, check operation of valves of a stopper.

Repair of the fuel pump
Can be possible malfunctions of the pump: violation of tightness of a diaphragm and valves, decrease in elasticity or breakage of a spring of a diaphragm, wear of details of the drive of the pump.
For dismantling of the pump uncover with it 10 (see fig. 2.19) heads, laying 9 and the filter 8. Then unscrew screws of fastening of a head of the 14th case, separate a head from a diaphragm.
Removing a head of the case be careful not to damage a diaphragm as the diaphragm sticks to flanges of a head and a pump housing. Further you make dismantling of the mechanism of the drive for what previously to a vypressuyta an axis of 19 levers of the drive and remove the lever 17 and a spring 16. Carefully release a diaphragm 6 and remove it both a spring 5 and a sealant 3 with a washer 4.
Sorting a head, remove inlet 7 and delivery valves. For this purpose to a vypressuyta of a holder of valves.
After dismantling wash out all details in kerosene or unleaded gasoline, an obduyta compressed air, dry and make their check.

Fig. 2.71. Device for assembly of a diaphragm of the fuel pump: 1 – case; 2 – adjusting pin; 3 – pump diaphragm;
4 – key; 5 – handle; 6 – handle axis


The diaphragm has to be tight, its varnish covering should not have peelings. In need of replacement of petals of a diaphragm you carry out its assembly on special adaptation (fig. 2.71).
The spring of a diaphragm has to have in a free state height of 50+5 mm, and under load (5±0,2) kgfs – 15 mm.
Check elasticity of a spring of the pump on the device of the GARO model 357.
Valves should not have korobleniye, cracks, dents and visible wear tracks. Springs of valves have to densely, without gaps to press valves to saddles.
Levers of the drive of the pump and their axis should not have big wear. The maximum gap between an axis of levers and its plug, and also between the plug and levers has to be no more than 0,25 mm.

Fig. 2.72. Lever of the drive of the fuel pump


Special attention should be paid on wear of working surfaces of the lever (fig. 2.72) in places of their contact. Before assembly check a prileganiye of flanges of a head and a pump housing. The deviation from the plane has to be no more than 0,08 mm. If necessary make grinding in.
For dismantling of the pump "Station wagon" (see fig. 2.20) unscrew screws of fastening of a cover 14, uncover also the filtering element 8, unscrew screws of fastening of the case 13 to the lower cover, separate them, take out knot of diaphragms and a spring 7.
Wash out gasoline all details and blow compressed air.
Check integrity of springs.
Check whether there is no jamming of valves. Check diaphragms. On them there should not be cracks or hardening.
After check replace all worn-out or damaged details new. Always replace laying of the pump new and before installation grease with a thin layer of lubricant.
You make assembly of the pump as it should be, the return to dismantling.

Fig. 2.73. The provision of a head of the fuel pump at its installation


At installation of a head of the pump B9V-B its situation concerning the case has to correspond to fig. 2.73. You make an inhaling of screws of fastening of a head at the diaphragm delayed in extreme lower situation by means of the lever of manual pumping.
Such assembly provides necessary sagging of a diaphragm and unloads it from the excessive stretching efforts leading to sharp reduction of durability of a diaphragm. After assembly check the pump on the device of the GARO models 527B or 577B.
With a frequency of rotation of the mines-1 camshaft 120 and with a height of absorption of 400 mm the pump has to provide the beginning of supply of fuel not later than through 22 from later inclusion, to create pressure of 150 - 210 mm of mercury. and depression not less than 350 mm of mercury. Pressure and depression created by the pump have to remain in the specified limits at the switched-off drive during 10 pages.
Giving of the pump with a frequency of rotation of the mines-1 camshaft 1800 has to be not less than 120 l/h. In the absence of the special device for check of the pump, it can be checked directly on the engine as it is described in the section "Maintenance".

Repair of the carburetor
You make repair of the carburetor in case of breakage of its any details or during the unsatisfactory operation of the carburetor after adjustment on all power setting.
Before dismantling wash up the carburetor kerosene for removal of dust and dirt. During the work on ethylated gasoline previously keep the carburetor in kerosene within 10–20 min.
 Order of dismantling and assembly of the K-131 carburetor
Unscrew five screws of fastening of a cover of the float-operated camera. Having carefully raised a cover not to damage the float-operated mechanism, disconnect draft of small frequency of rotation, uncover also laying of the float-operated camera.
Turn a cover and, holding a float, take out a float axis from racks. Remove a float and carefully take out from the fuel supply valve case its needle with the condensing polyurethane washer. Unscrew the case of the valve and remove its laying. Turn off a filter stopper, remove its laying and take out a filter grid. Turn out a spray of the accelerating pump and remove a sealing washer.
Disassemble the mechanism of the drive of the air gate and remove the gate only during the unsatisfactory operation of the mechanism and also if gaps between a wall of an air branch pipe and the gate at its closing exceed 0,2 mm.
Separate the mixing camera from the case of the float-operated camera for what turn off two bolts and, расшплинтовав an earring of the drive of the accelerating pump, take out it from a rod and the lever.
Having removed laying of the mixing camera, take out the big diffuser from the case of the float-operated camera.
Take out the piston of the accelerating pump assembled with details of its drive and a rod of the drive of the economizer. Turn out the economizer valve assembled and take out it from a well. Turn off a stopper of a well of an emulsion tube together with laying and take out this tube, turn out an air jet of idling.
Turn off traffic jams of channels of fuel and air jets of the main dosing system and a fuel jet of idling, remove laying of these traffic jams and turn out the corresponding jets.
Remove the lock of the valve of the accelerating pump and take the valve from a well.
Take out a lock ring and a ball of the return klapapan of the accelerating pump.
Needlessly do not press off the small diffuser.
When dismantling the mixing camera turn out the screw of adjustment of quality of mix of idling and remove its spring.
Remove a butterfly valve and its axis only in case:
– the axis of a butterfly valve does not rotate freely in camera lugs;
– gaps between walls of the camera and the gate in a closed position more than 0,06 mm;
– the top edge of a butterfly valve in a closed position does not coincide with an axis of a transitional opening of 1,6+0,06 mm (the deviation of ±0,15 mm is allowed).
After dismantling wash out all details of the carburetor in unleaded gasoline or in hot water with a temperature not below 80 °C, then blow compressed air.
All details of the carburetor have to be pure, not have a deposit and resinous deposits.
Jets and other dosing elements have to have the set capacity or the sizes.
The valve of the economizer has to be assembled tight. When checking its tightness under pressure of 1200 mm w.g. course no more than four drops of water a minute is allowed.
Degree of wear of the piston of the accelerating pump and walls of its well, and also tightness of the backpressure valve has to be such to provide giving of the pump not less than 8 cm3 for 10 working courses of the piston.
Check a float for tightness, having shipped it in water with a temperature not below 80 °C. An exit of bubbles from a float demonstrates violation of its tightness.
Solder places of damages of a float soft solder, previously having removed the fuel which got to a float.
After the soldering check the weight of a float which has to be equal (13,3±0,7) g. You make adjustment of weight removal of excess solder, without breaking tightness of a float.
The surface of the socket of the case and cover of the float-operated camera have to be flat, a tolerance from the plane no more than 0,2 mm.
You make assembly of the carburetor as it should be, the return to dismantling, taking into account the following:
1. If when dismantling acted throttle or air gates, then at assembly you zakernit screws of their fastening.
2. Make check of full turning on of the economizer and, if necessary, adjust as "Service of a power supply system" is specified in the head.
3. Adjust fuel level in the float-operated camera (see the head "Power supply system").
On the assembled carburetor check interrelation between air and throttle gates. At completely closed air gate the butterfly valve has to be slightly opened on a corner 17–21 ° that corresponds to a gap between a wall of the mixing camera and an edge of the gate (2,5±0,2) mm. At discrepancy to the specified requirement turn in draft of small frequency of rotation of a bent shaft.
 Order of dismantling and assembly of K-151V, K-151E and K-151U carburetors
Dismantling of the carburetor
You make dismantling of the carburetor in the following sequence:
1. Take out the forelock and disconnect draft of the air gate from the lever.

Fig. 2.29. K-151B carburetor: 1 – air gate; 2 – screw; 3 – starting spring; 4 – carburetor cover; 5 – a bracket (only for K-151H); 6 – laying; 7 – the pneumoproofreader's diaphragm with draft assembled; 8 – laying; 9 – pneumoproofreader's cover; 10 – spring; 11 – screw; 12 – screw displacer; 13 – ball (inlet valve); 14 – float; 15 – case of the float-operated camera; 16 – fuel supply union; 17 – washer; 18 – filter fuel; 19 – washer; 20 – bolt of toplivoprovodyashchiya; 21 – stopper; 22 – cover of the accelerating pump; 23 – lever of the drive of the accelerating pump; 24 – union of ventilation of crankcase gases; 25 – butterfly valve of the secondary camera; 26 – case of mixing cameras; 27 – screw; 28 – cam; 29 – screw; 30 – butterfly valve of primary camera; 31 – economizer valve assembled; 32 – screw adjusting composition of mix; 33 – locking element of the EPHH valve; 34 – EPHH valve case; 35 – laying; 36 – EPHH valve cover; 37 – tube; 38 – screw of operational adjustment of turns of idling; 39 – laying heat-insulating (textolite); 40 – laying heat-insulating (cardboard); 41 – the diffuser is small; 42 – spray of the accelerating pump;
43 – screw adjusting fuel restart-up; 44 – spring; 45 – diaphragm of the accelerating pump assembled; 46 – laying; 47 – screw; 48 – stopper;
49 – washer; 50 – jet emulsion idling; 51 – electromagnet; 52 – draft; 53 – clamp; 54 – nut; 55 – lever; 56 – union; 57 – screw;
58 – ventilation valve cover; 59 – ventilation valve; 60 – spring; 61 – laying


2. Unscrew seven screws 2 (see fig. 2.29) fastenings of a cover of the carburetor, carefully uncover the carburetor 4 and laying under it.
3. Disassemble the diaphragm device of the pneumoproofreader, for this purpose unscrew three screws 11, uncover 9, laying 8, the pneumoproofreader's diaphragm with draft assembled 7 and a spring 10.
4. Unscrew the screw and remove a spray 42 of the accelerating pump.
5. Unscrew the adjusting screw 43 restart-up of fuel, turn the case of the float-operated camera 15 before loss of a ball of the 13th inlet valve.
6. Unscrew the screw displacer 12.
7. Turn off a cylindrical stopper and take out a float axis, remove a float and take out the fuel valve. Turn out a saddle of the fuel valve together with laying.
8. Turn off a toplivoprovodyashchy bolt 20, remove the union of a toplivopodvod 16 and the fuel filter 18.
9. Unscrew four screws 47 of fastening of a cover of the accelerating pump, uncover 22, laying 46, a diaphragm of the accelerating pump assembled 45 and a spring 44.
10. Turn off removable jets, pull out emulsion tubes.
11. Unscrew two screws 29 and disconnect the case of mixing cameras 16 from the case of the float-operated camera 15, trying not to damage cardboard 40 and textolite the 39th laying.
12. Unscrew two screws of fastening of the EPHH valve in collecting (poses. 31) also remove the last from the case of mixing cameras.
13. Unscrew two screws of fastening of a cover of the 36th EPHH valve, uncover 36, cardboard laying 35 and the case 34 of the EPHH valve.
For dismantling of the K-151B carburetor, except the above-mentioned, execute:
1. Turn off a clamp 53, bring out of gearing draft 52 with the lever 55 and remove the lever 55.
2. Unscrew two screws 57, uncover 58, the valve 59, laying 61 and a spring 60.
Control and survey of details
All details have to be pure, without deposit and resinous deposits. Jets after washing and a purge with compressed air have to have the set capacity. All valves have to be tight, laying whole and to have traces (prints) of the condensed planes. Diaphragms of the accelerating pump, the pneumoproofreader and the EPHH valve have to be whole, without damages. Replace the faulty or damaged details new.
Assembly of the carburetor
The carburetor should be assembled in the sequence, the return dismantling. At first it is necessary to podsobrat all case details of the carburetor – a carburetor cover, the case of the float-operated camera and the case of mixing cameras, and then to connect them among themselves.
At assembly:
1. You watch safety and the correct installation of laying.
2. You watch that throttle and air gates turned freely, without jammings and densely covered the channels.
3. Tighten all threaded connections densely, but without excessive efforts.
4. Make sure that the fuel valve freely slides in the saddle, without distortions and jammings.
5. Check and if necessary adjust fuel level in the float-operated camera, at the same time the float has to rotate freely on the axis, without touching camera walls.
6. Acquire screws 47 (see fig. 2.29) fastenings of a cover of the accelerating pump, press the drive 23 lever against the stop, wrap screws and release the lever.
7. Acquire two screws of fastening of a cover of the 36th EPHH valve, delay a locking element 33 of the EPHH valve on the size of 13,5-0,5 mm from the plane A (see the "EPHH valve" hub in fig. 2.29), wrap the mentioned screws, tighten two screws the economizer valve assembled 31 to the case of mixing cameras.
8. At assembly do not mix in places jets.
9. Check a gap between a wall of the mixing camera and an edge of a butterfly valve at completely open butterfly valve of primary camera. The gap has to be at least 14,5 mm. If necessary provide a gap with 1 podgibaniye of an emphasis of the lever.