Fig. 3.1. Structural elements of the engine: 1 – cover of a head of cylinders; 2 – laying of a cover of a head of cylinders; 3 – case of bearings of the camshaft; 4 – head of cylinders; 5 – laying of a head of the block of cylinders; 6 – back casing of a gear belt; 7 – camshaft pulley; 8 – gear belt; 9 – forward casing of a gear belt; 10 – water pump; 11 – pulley of a bent shaft; 12 – laying of the oil pump; 13 – oil pump; 14 – oil filter; 15 – laying of the oil pallet; 18 – mesh filter; 17 – oil pallet; 18 – covers of bearings of a bent shaft; 19 – inserts of bearings of a bent shaft; 20 – bent shaft; 21 – flywheel; 22 – block of cylinders

The block of cylinders is manufactured of cast iron and has four cylinders rowed (fig. 3.1). Five radical bearings support a bent shaft and fasten covers. For ensuring necessary coaxiality and the corresponding gaps of an opening are processed for covers together with covers.

The head of cylinders is cast from aluminum alloy and has channels for lubricant. Mechanisms of adjustment of gaps of valves are installed on a head of cylinders near the corresponding valves.

The bent shaft has five basic (radical) necks. The third bearing is the persistent bearing preventing axial movement of a shaft. Lubricant of radical bearings is carried out through openings in channels on the left side of the block of cylinders.

The pig-iron camshaft has five basic bearings located in the aluminum case of bearings installed on a head of cylinders. The pulley established on a forward part of the camshaft from powder metal is given to rotation from a pulley of a bent shaft by means of the gear belt reinforced by fiber glass.

Fig. 3.2. Structural elements of the engine: 1 – piston; 2 – rod; 3 – inserts of bearings of a rod; 4 – rod cover; 5 – the giving branch pipe of the oil pump; 6 – tube of ventilation of a case; 7 – index of level of oil; 8 – index of level of oil; 9 – natyazhitel of a driving belt

1. Pistons are manufactured of aluminum alloy (fig. 3.2).

On each piston are established two compression and one oil scraper ring. For ensuring gradual change of pressure force of the piston on a cylinder wall during movement of the piston of an opening of piston fingers are displaced from a symmetry axis to the right side of the engine on 0,35–1,65 mm. Piston fingers freely rotate in piston reels. In a head of rods fingers are pressed with a tightness.

2. Rods are made of cast iron.

Lubricant under pressure moves to canals of rods through the openings drilled near the next basic necks.

For the drive of valves levers which connect hydraulic compensators of gaps of valves and cores of valves are used.

The inlet collector is made of aluminum, has four channels and is warmed up by circulation of cooling liquid of the engine. On an inlet collector the throttle knot is established.

The engine has one final collector with four entrance ports, the muffler located under the car bottom and the system of production of the fulfilled gases located under the car bottom.

Fig. 3.3. Engine lubrication system

The engine lubrication system – under pressure, through a full-line oil filter, by means of the gear pump (fig. 3.3). Oil is sucked in via the mesh filter in a maslopriyemny branch pipe and under pressure moves the pump on a full-line oil filter. An oil filter – full-line with the paper filtering element. For ensuring supply of oil in the engine in case of a contamination of the filter there is perepuskny a valve.

From the filter oil moves in the trunk main which greases radical bearings of a bent shaft via the crossed oil channels. The oil arriving through small openings in rods greases walls of cylinders and cools the lower part of the piston.

The trunk main has vertical channels on which oil moves through a head of cylinders in the case of bearings of the camshaft up. Oil moves in the camshaft through an opening in a neck of the third bearing. Via the channel drilled along a camshaft axis, oil moves on other necks. The neck of the third bearing has the crossed channels located in the case of bearings which direct oil to the canal drilled along the left side of a head of cylinders. In this channel the safety valve regulating the maximum pressure in the lubrication system is located.

Via this channel oil moves on mechanisms of adjustment of gaps of inlet valves, and via the channels crossing it – on the mechanism of adjustment of gaps of final valves. Lubricant of cams of the camshaft is carried out through the openings drilled in each cam. These openings cross the channel passing along the camshaft. Excess of oil from the valvate mechanism flows down back in a case through openings on the ends of a head of cylinders, and also through the openings close to basic plates of springs of inlet valves of the first, second and third cylinder.

All auxiliary systems of the engine except for the compressor of the conditioner are set in motion by one driving belt.

Fig. 3.4. An arrangement of a poliklinovy belt on pulleys: 1 – natyazhitel of a poliklinovy belt; 2 – pump of the amplifier of steering; 3 – generator; 4 – poliklinovy belt; 5 – pulley of a bent shaft; 6 – wedge-shaped belt of the drive of the conditioner; 7 – conditioner compressor; 8 – natyazhitel of a belt of the drive of the conditioner

Fig. 3.5. Range of adjustment of a natyazhitel: 1 – minimum length of a belt; 2 – tag; 3 – maximum length of a belt

The drive of the compressor of the conditioner is carried out by means of a maple belt from a pulley of a bent shaft. All equipment set in motion by a poliklinovy belt is rigidly fixed on the engine. The arrangement of a belt is shown in fig. 3.4. The tension of a belt is carried out by the sprung natyazhitel (fig. 3.5). For removal/installation of a belt turn a natyazhitel a face key on 15 mm. Natyazhitel of a driving belt provides a tension of belts with a wide range of lengths, but this range has limits. Use of a belt which length goes beyond a possibility of adjustment by a natyazhitel can lead to an insufficient tension of a belt and/or breakage of a natyazhitel.

       PREVENTION

Be attentive when applying torque to a natyazhitel that not to bend it and not to draw as the natyazhitel can damage it.

At regular survey of a belt in his edges cracks which do not influence its working capacity can be found and, therefore, should not be considered as the reason causing the necessity of replacement of a belt. However if there was a slipping of a belt or there are no several sections of edges of a belt, the belt needs to be replaced.

If burning of a belt is noticed, check that a natyazhitel and a belt lie in one plane and edges of a belt do not rub about sidewalls of a pulley of a natyazhitel. If a natyazhitel or intermediate pulleys make a sound of high-pitch tone, check a condition of bearings.

1. For check of length of a belt, examine the provision of tags of a natyazhitel (fig. 3.5). If the belt too stretched or its length exceeds the limit of the range of regulation of a natyazhitel, replace a belt.

2. Launch the engine (at the switched-off additional equipment) and warm up it up to the working temperature. Switch off the engine and measure by the KM-128-A tool a belt tension, having established it in the middle of a belt branch between the pump of the amplifier of steering and a pulley of a bent shaft. Remove the tool.

3. Launch the engine (at the switched-off additional equipment) and for stabilization leave it to work during 5 with at idling rotation frequency. Switch off the engine. A cap key on 18 mm tighten a bolt of fastening of a pulley of a natyazhitel clockwise. Weaken the enclosed effort and at once measure a belt tension, without violating the provision of a natyazhitel.

4. Using the same key, turn a bolt of fastening of a pulley of a natyazhitel counterclockwise and lift a natyazhitel in situation Install. Slowly lower a pulley in situation At rest and, without changing the provision of a pulley, measure a belt tension.

5. Calculate average value of three dimensions. If average value is less than 195 N and length of a belt is in adjustment range limits, replace a natyazhitel of a poliklinovy belt.

       PREVENTION

Before posting of the engine with the automatic transmission it is necessary to install lifting KM-263 adaptation on the center of a motor compartment and it is reliable to fix it. Misuse of this adaptation can lead to injuries.

The engine mount is not regulated and seldom demands service. At breakage or damage of details of their suspension bracket it is necessary to replace immediately as it leads to increase in load of other details of a suspension bracket and the drive.

Raise the engine so that its weight was perceived by lifting adaptation that will provide removal of loading from support and their minimum stretching. Watch support during raising of the engine. Replace a support if on it the following defects are found:

– the hardened surface of rubber cracked with high temperature;

– separation of a rubber pillow from steel plates;

– the rubber pillow burst in the middle.

If the free wheeling of metal plates concerning fastening points is noticed, tighten bolts or nuts, the fixing support to the engine, an arm or amplifiers.

1. Disconnect a wire from the negative plug of the rechargeable battery.

2. Lifting KM-263 adaptation raise the engine before removal of loading from support.

Fig. 3.6. Forward support of the engine: 1 – arm; 2 – bolt / screw of 54 N • m; 3 – side amplifier; 4 – support knot

3. Turn out 2 bolts of fastening of a support to an arm (fig. 3.6).

4. Turn out 2 top bolts of fastening of a support.

5. Lift the car on the elevator.

6. Turn out the lower bolt of fastening of a support.

7. Remove an engine support.

       PREVENTION

All removed bolts of fastening of support of the engine need to be cleared of dirt and before installation to apply on them the kontryashchy structure interfering their self-unscrewing (the blocking Loctite liquid).

1. Fix an engine support by the lower bolt.

2. Lower the car.

3. Screw 2 top bolts of fastening of a support.

4. Screw bolts of fastening of a support to an arm.

5. Remove KM-263 adaptation.

6. Connect a wire to the negative plug of the rechargeable battery.

1. Disconnect a wire from the negative plug of the rechargeable battery.

2. Lifting KM-263 adaptation raise the engine before removal of loading from support.

Fig. 3.7. Back support of the engine: 1 – bolt of 54 N • m; 2 – right amplifier; 3 – support knot; 4 – motor compartment; 5 – amplifier; 6 – nut of 24 N • m; 7 – nut of 54 N • m; 8 – arm; 9 – natyazhitel

3. Turn out 2 bolts of fastening of a support to an arm (fig. 3.7).

4. Turn out 2 top bolts of fastening of a support.

5. Turn off the lower nuts of a support of fastening and the amplifier.

6. Remove an engine support.

1. Fix a support with the amplifier 2 nuts.

2. Lower the car.

       PREVENTION

All removed bolts of fastening of support of the engine need to be cleared of dirt and before installation to apply on them the kontryashchy structure interfering their self-unscrewing (the blocking Loctite liquid).

3. Screw bolts of fastening of a support to an arm.

4. Remove KM-263 adaptation.

5. Connect a wire to the negative plug of the rechargeable battery.

1. Remove the air filter.

2. Merge cooling liquid.

3. Take off poliklinovy a belt.

4. Remove the generator and an arm from the case of bearings of the camshaft.

5. Remove an arm of the amplifier of steering from an inlet collector.

6. Remove the pump of the amplifier of steering with an arm and take aside.

7. Remove ignition coils with an arm.

8. Remove an accelerator cable from an arm on an inlet collector.

9. Remove a cable of an accelerator and throttle knot from the case of system of injection of fuel.

10. Disconnect wires from elements of system of injection of fuel.

11. Disconnect a hose of the vacuum amplifier of brakes from the air filter. Take off pressure in fuel system.

12. Disconnect pipelines of giving and return of fuel.

13. Disconnect engine cooling system hoses from the following elements:

– the water pump and on an inlet collector;

– entrance branch pipe of the water pump.

14. For access to the lower nuts of fastening of an inlet collector remove fastening of wires of the block of electronic control.

15. Remove an inlet collector. Clear privalochny surfaces on a head of cylinders and on an inlet collector.

Fig. 3.8. Inlet collector: 1 – nut, 20–27 N • m; and – the sequence of tightening of nuts of fastening of an inlet collector

1. Establish an inlet collector with new laying (fig. 3.8).

2. Screw fixing nuts with washers and tighten their moment 22 N • m.

3. Establish fastening of wires of the block of electronic control.

4. Connect cooling system hoses to the following elements:

– to the water pump and inlet collector;

– to an inlet branch pipe of the water pump.

5. Connect pipelines of giving and return of fuel.

6. Connect a hose of the vacuum amplifier of brakes.

7. Connect wires to the case of the device of system of injection of fuel.

8. Connect cables of an accelerator and establish throttle knot.

9. Connect an accelerator cable to an arm on an inlet collector.

10. Install the ignition coil.

11. Install the pump of the amplifier of steering with an arm on an inlet collector.

12. Install the generator and an arm to the case of bearings of the camshaft.

13. Establish poliklinovy a belt.

14. Fill in cooling liquid.

15. Install the air filter.

1. Remove the air filter.

2. Disconnect wires from spark plugs and remove them holders.

3. Pick up the phone of the index of level of oil and a hose of ventilation of a case.

4. Remove a reception exhaust pipe.

5. Turn off nuts, remove a final collector and laying.

Clear privalochny surfaces on a head of cylinders and on a final collector.

Fig. 3.9. Final collector

1. Establish a final collector with new laying and tighten nuts the moment of 22 N • m. At first tighten nuts No. 2 and No. 3, then No. 1 and No. 4 (fig. 3.9).

2. Attach a reception exhaust pipe to a final collector and tighten nuts the moment of 25 N • m.

3. Establish a tube of the index of level of oil and a hose of ventilation of a case.

4. Establish wires of spark plugs and their holders.

5. Install the air filter.

1. Remove the air filter.

2. Remove a hose of ventilation of a case.

3. Turn out bolts.

4. Uncover a head of cylinders.

Clear privalochny surfaces on a head of cylinders and on a cover.

Fig. 3.10. Cover of a head of cylinders

1. Establish a cover of a head of cylinders with new laying and fix by bolts, having tightened their moment 8 N • m (fig. 3.10).

2. Install the air filter and connect a hose of ventilation of a case.

1. Disconnect a wire from the negative plug of the rechargeable battery.

2. Take off a conditioner compressor drive belt.

3. Remove an internal protective cover.

4. Take off poliklinovy a belt.

5. Remove a pulley of a bent shaft.

1. Establish a pulley of a bent shaft.

2. Apply the kontryashchy structure interfering their self-unscrewing (the blocking Loctite liquid) on a carving of bolts and tighten bolts the moment of 27 N • m.

3. Establish poliklinovy a belt.

4. Establish a protective cover.

5. Establish a conditioner drive belt.

6. Connect a wire to the negative plug of the rechargeable battery.

1. Take off poliklinovy a belt.

2. Weaken a bolt of fastening of a natyazhitel of a poliklinovy belt (weaken a bolt and the lever of a natyazhitel will turn down).

3. Turn out bolts and a nut of fastening of a casing of a gear belt.

4. Remove a casing of a gear belt.

1. Establish a casing of a gear belt and fix by bolts and a nut, having tightened their moment 10 N • m

2. Establish a natyazhitel in a starting position and tighten a bolt the moment of 25 N • m.

3. Establish poliklinovy a belt.

1. Take off a conditioner drive belt.

2. Take off poliklinovy a belt.

Fig. 3.11. Gear belt

3. Remove the pump of the amplifier of steering, an arm and a natyazhitel of a gear belt assembled (fig. 3.11).

4. Remove a casing of a gear belt.

Fig. 3.12. MKM-472 adaptation

Weaken bolts of fastening of the water pump and reduce a belt tension by means of MKM-472 adaptation (fig. 3.12).

Lift the car on the elevator.

5. Remove a pulley of a bent shaft.

6. Lower the car and take off a gear belt.

1. Turn pulleys of cranked and distributive shaft clockwise before combination of tags on pulleys and on a back casing of a gear belt.

2. Establish a gear belt.

3. By means of MKM-472 adaptation turn the clown of fastening of the water pump clockwise until the natyazhitel does not rest against the belt tension force limiter. Slightly tighten bolts of fastening of the water pump.

4. For final landing of a gear belt on teeths of pulleys turn a bent shaft of the engine for a bolt of fastening of a pulley of a bent shaft clockwise on 720 °.

5. Turn the clown of the water pump counterclockwise before combination of openings in the lever of a natyazhitel and in the basis. Operations have to be performed at the room temperature of the engine (about 20 °C).

6. Tighten bolts of fastening of the water pump, watching to breaking the combination of openings received on a step 5.

7. Establish a pulley of a bent shaft.

8. Establish a casing of a gear belt.

9. Install the pump of the amplifier of steering and a natyazhitel of a belt assembled.

10. Establish poliklinovy a belt.

11. Establish a conditioner compressor drive belt.

1. Gear belt.

2. Turn out bolts of fastening of a natyazhitel and remove a natyazhitel.

1. Establish a natyazhitel, having convinced that privalochny surfaces pure.

2. Screw a hairpin and a bolt, having tightened their moment 25 N • m.

3. Establish a gear belt.

1. Uncover a head of cylinders.

2. Take off a gear belt.

3. A wrench hold the camshaft from a provorachivaniye.

Fig. 3.13. Otvorachivaniye of a bolt of fastening of a pulley of the camshaft

4. Turn out a bolt of fastening of a pulley and remove a washer and a pulley (fig. 3.13).

1. Establish a pulley and screw a bolt with a washer, having combined tags on a pulley and a back casing of a gear belt. Tighten a bolt the moment of 45 N • m.

2. Establish a gear belt.

3. Establish a casing and a cover of a head of cylinders.

1. Take off a gear belt.

2. Turn out a bolt of fastening of a pulley and remove a washer and a pulley.

1. Establish a pulley on a spline of a bent shaft.

2. Screw a bolt with a washer and tighten a bolt the moment of 155 N • m.

3. Establish a gear belt.

1. Take off a gear belt.

2. Remove pulleys of cranked and distributive shaft.

3. Remove a natyazhitel.