3.4. Assembly of the engine

Install the washed-up and cleared block of cylinders at the stand and wrap the absent hairpins.
Lay in a nest of the average bearing an insert without flute on an internal surface, and in other nests... inserts with a flute. In covers of bearings lay inserts without flute.

NOTE
Oil engine cylinders, and also pistons and epiploons, inserts of bearings and persistent half rings of a bent shaft before installation engine.

Lay in a nest of the average bearing and in its cover — inserts without flute on an internal surface, and in other nests and the corresponding covers — inserts with канавкой*.

Fig. 3-12. Installation of persistent half rings on a back support

Fig. 3-13. Tags on covers of radical bearings (count of support is kept from a forward part of the engine) and conditional number of the block of cylinders

Lay a bent shaft in radical bearings and insert into nests of a back support two persistent half rings (fig. 3-12) which are picked up for thickness as directed of the head "Bent shaft and a flywheel". Establish covers of radical bearings according to tags (fig. 3-13).

PREVENTION
Install covers of radical bearings in the former block. For this purpose the block of cylinders and covers belonging to it are marked with identical conditional number (see fig. 3-13 and 3-24). Establish persistent half rings by dredging to persistent surfaces of a bent shaft, and from the forward party of a back support put a steel-aluminum half ring, and from the back party — ceramic-metal (yellow color).


Fig. 3-14. Holder of a back epiploon of a bent shaft. Shooters specified ledges for centering of the holder concerning a flange of a bent shaft

Put on laying of the holder of an epiploon a flange of a bent shaft, and enclose bolts of fastening of a forward cover of a case of coupling in nests of the holder (fig. 3-14). Put on the holder with an epiploon a mandrel 41.7853.4011 and, having moved it from a mandrel on a flange of a bent shaft, attach to the block of cylinders.

Fig. 3-10. Removal of a flywheel: 1 — a key; 2 — a flywheel; 3 — a bolt of fastening of a flywheel; 4 — a washer;
5 — a clamp of A.60330/R for deduction of a flywheel from a provorachivaniye; 6 — a forward cover of a case of coupling

Establish on two aligning plugs a forward cover 6 (see fig. 3-10) a coupling case.
Establish a flywheel on a bent shaft so that the tag (a cone-shaped hole) about a rim was against an axis of a conrod neck of the fourth cylinder, block a clamp of A.60330/R a flywheel and attach it bolts to a flange of a bent shaft.

Fig. 3-15. Installation of the piston with piston rings in the cylinder by means of the assembly plug from the A.60604 set. Shooters specified plugs for centering of a head on the block of cylinders

By means of the plug from the A.60604 set insert into cylinders pistons with rods (fig. 3-15). In set there are plugs of the nominal and repair sizes of pistons.

PREVENTION
The opening for a finger on the piston is displaced on 2 mm therefore at installation of pistons the tag "П" on pistons has to be turned into cylinders to a forward part of the engine.

Therefore it is necessary to pick up the plug suitable for this size of the installed piston. It is possible to use also adjustable plug 67.7854.9517.
Establish inserts in rods and covers of rods. Connect rods to necks of a bent shaft, put covers and tighten conrod bolts.
Establish an asterisk on a bent shaft. Install the roller of the drive of the oil pump and fix by a persistent flange.

Fig. 3-16. Order of tightening of bolts of a head of cylinders

Establish on two aligning plugs on the block a head of cylinders with laying, with a final collector and the inlet pipeline. Tighten in a certain sequence (fig. 3-16) in two steps fastening bolts:
— previously moment of 33,3-41,16 N · m (3,4–4,2 kgfs · l) bolts 1–10;
— finally moment of 95,94-118,38 N · m (9,79–12,08 kgfs · l) bolts 1–10 and moment of 30,67-39,1 N · m (3,13–3,99 kgfs · l) bolt 11.

Fig. 3-17. Check of coincidence of an adjusting tag on an asterisk of a bent shaft with a tag on the block of cylinders

Turn a flywheel so that the tag on an asterisk of a bent shaft coincided with a tag on the block of cylinders (fig. 3-17).

Fig. 3-18. Order of tightening of nuts of the case of bearings of the camshaft

Fig. 3-19. Check of coincidence of an adjusting tag on a camshaft asterisk with a tag on the case of bearings: 1 — a tag on an asterisk; 2 — a tag on the case of bearings

Install an asterisk on the camshaft assembled with the case of bearings and turn a shaft so that the tag on an asterisk was against a tag on the case of bearings (see fig. 3-19). Remove an asterisk and, without changing the provision of a shaft, install the case of bearings on a head of cylinders and fix, tightening nuts in a certain sequence (fig. 3-18).
Establish on a head of cylinders an uspokoitel of a chain.
Establish a camshaft drive chain in the following order:
— put on a chain an asterisk of the camshaft and enter into a drive cavity, establishing an asterisk so that the tag on it coincided with a tag on the case of bearings (fig. 3-19). Do not tighten a bolt of an asterisk against the stop;
— install an asterisk on the roller of the drive of the oil pump, also without tightening finally a fastening bolt;
— establish a boot of a natyazhitel of a chain and a natyazhitel, without tightening the cap-type nut that the spring of a natyazhitel could press a boot; wrap a restrictive finger of a chain in the block of cylinders;
— turn a bent shaft on two turns in the direction of rotation that will provide the necessary tension of a chain; check coincidence of tags on asterisks with tags on the block of cylinders (see fig. 3-17) and on the case of bearings (see fig. 3-19);
— if tags coincide, then having blocked a flywheel a clamp of A.60330/R (see fig. 3-10), finally tighten bolts of asterisks, the cap-type nut of a natyazhitel of a chain and unbend lock washers of bolts of asterisks; if tags do not coincide, then repeat operations on installation of a chain.
Adjust a gap between cams of the camshaft and levers of the drive of valves.

Fig. 3-20. Camshaft drive cover. Shooters showed ledges for centering of a cover concerning a nave of a pulley of a bent shaft

Establish a cover of the drive of the camshaft (fig. 3-20) with laying and an epiploon on the block of cylinders, without tightening finally bolts and nuts of fastening. A mandrel 41.7853.4010 center the provision of a cover concerning the end of a bent shaft and tighten finally nuts and bolts of its fastening.
Establish a pulley of a bent shaft and wrap a nut.
Oil engine a sealing ring of an oil filter and install the filter, having manually tightened it to the union on the block of cylinders. Establish an oil separator of ventilation of a case, a cover of a sapun and fix a clamp of a drain tube of an oil separator.
Install the oil pump and an oil case with laying.
Install the pump of cooling liquid, an arm of the generator and the generator. Put on a belt pulleys and adjust its tension.
Establish the bringing tube of a radiator of a heater and a final branch pipe on a head of cylinders. Attach the taking-away heater radiator tube to the pump of cooling liquid and a final collector.
Install sensors of control devices.
Establish a gear wheel of the drive of the oil pump and distributor of ignition. Install the distributor of ignition and adjust the ignition moment. Wrap spark plugs, establish on them a key 67.7812.9515 and tighten a dynamometer key.
Install the fuel pump according to indications of the head "Power supply system".
Install the carburetor, attach to it hoses and close it a technological cap.
Establish a cover of a head of cylinders with laying and an arm of a fuel-supply line.
Fill in oil in a mouth on a cover of a head of cylinders.