1.21. Piston

L engines 2,0 / 1,8

Engines of 1,6 l

Removal

Rod cover

You hold covers of rods with the corresponding rods for the correct repeated installation them in engine cylinders.


 PERFORMANCE ORDER

  1. Turn off nuts and uncover a rod and the lower insert of the conrod bearing. For protection of necks of a bent shaft dress pieces of a rubber or plastic tube on bolts of fastening of covers of rods.
  1. Wooden whetstone or the handle of the hammer push out the piston with a rod from the cylinder.

Removal and installation of a piston finger

 PERFORMANCE ORDER

  1. For dismantling and repeated assembly of the piston and a rod it is necessary to use special tools 09234-33001 and 09234-33002.
  1. Establish universal support in a clip between a rod and the piston.
  1. Insert a stripper through an opening in a clip arch.

Insert a clip with the piston, a rod and a stripper under the press ram.

  1. Stripper squeeze out a piston finger from the piston.
  1. Establish the directing pins via the piston in a rod, and establish a piston finger on the other side of the piston.

The directing pins define the provision of a rod in the piston. After installation of the piston, a rod, a piston finger and the device for installation of a piston finger in the inserts directing pins also define their situation in a clip. If the directing pins too small, the piston does not settle down on the center in adaptation and the clip and / or adaptation can be damaged.

  1. Install the piston assembled on the clip at the same time directing a pin supports a rod in a piston finger. Make sure that the piston approaches a clip until the directing pin contacts with a fork insert.
  2. Check correctness of a relative positioning of the piston and a rod and, rotating a nut with a nakatka, fix the numbered plug on a shaft.
  1. Insert a shaft through an opening in a clip arch. Press a piston finger into a rod until the plug on a shaft contacts with the top part of an arch of a clip, at the same time the directing pin has to drop out of the piston.

The effort of a press fitting of a piston finger should not exceed 350–1350 kg on engines 1,8 and 2,0 of l and 1250±500 kg on the engine of 1,6 l.

Check

Piston and piston fingers

 PERFORMANCE ORDER

  1. Check the external surface of the piston for absence of damage, developments or uneven wear. If necessary, replace the piston.
  2. Check each piston ring for absence of damage and uneven wear. If necessary, replace piston rings. When replacing the piston it is also necessary to replace piston rings.
  3. Check a piston finger, implanting it into a piston opening. The piston finger has to enter smoothly the piston when pressing it a hand (at the room temperature).

Piston rings

 PERFORMANCE ORDER

  1. Insert a new piston ring into a flute of the piston and measure by the probe a gap between a piston ring and a wall of a flute. If the gap exceeds maximum permissible value, replace the piston.

Gap between a piston ring and a flute in the piston:

First compression ring:

- l engines 1,8 and 2,0: 0,04–0,08 mm;
- engines of 1,6 l: 0,04–0,085 mm.

Second compression ring:

- l engines 1,8 and 2,0: 0,03–0,07 mm;
- engines of 1,6 l: 0,04–0,085 mm.

  1. Measure a gap in the lock of piston rings, having manually inserted a piston ring into the engine cylinder. The bottom of the piston push a piston ring in the lower part of the cylinder. Measure by the probe a gap in the lock of a piston ring.

Gap in locks of piston rings:

First compression ring:

- l engines 1,8 and 2,0: 0,23–0,38 mm;
- engines of 1,6 l: 0,15–0,30 mm.

Second compression ring:

- l engines 1,8 and 2,0: 0,33–0,48 mm;
- engines of 1,6 l: 0,30–0,45 mm.

Oil scraper ring:

- l engines 1,8 and 2,0: 0,20–0,60 mm;
- engines of 1,6 l: 0,20–0,70 mm.

Maximum permissible gap:

First and second compression rings: 1,0 mm.
Oil scraper ring: 1,0 mm.

Marking is applied on the top part of a piston ring, from the lock.

Rods

 PERFORMANCE ORDER

  1. At installation be convinced that the rod and a cover of a rod correspond to number of the cylinder in which they are established. At installation of a new rod make sure that the tags defining its situation are from the same party as a tag on other rods.
  1. Replace a rod if there are damages on both basic surfaces. Also replace a rod if there are a wear or damage of the surface interfaced to a piston finger.

Selection of pistons of the engine of 1,6 l

 PERFORMANCE ORDER

  1. Check the code of the size of diameter of the cylinder located on the face of the block of cylinders.
Class
Internal diameter of the cylinder
Size code
And
76,5–76,51 mm
And
B
76,51–76,52 mm
B
With
76,52–76,53 mm
With
  1. Check the code of the size of diameter of the piston located on the piston bottom.

The code of the size of diameter of the piston is beaten out on the piston bottom.

Class
Internal diameter of the cylinder
Size code
And
76,465–76,475 mm
And
B
76,475–76,485 mm
B
With
76,485–76,495 mm
With
  1. Choose the piston which diameter corresponds to a cylinder class. A gap between the piston and the cylinder: 0,025 – 0,045 mm.

Installation

 PERFORMANCE ORDER

  1. Establish a broad ring.
  1. Establish the top side guide. To establish a side guide, at first place one end of a side guide between a wall of a flute of a piston ring and a broad ring, press it then, pressing on perimeter, establish it in a piston flute.
  1. Similarly establish the lower side guide.

Do not use a passatizha for a release of piston rings at installation of a side guide.

  1. Apply a thin film of engine oil on the piston and piston rings.
  1. Establish to Passatizhami for a release of piston rings a compression ring No. 2.
  1. Establish to Passatizhami for a release of piston rings a compression ring No. 1.
  1. Arrange locks of piston rings, as shown in the drawing.
  1. Special adaptation squeeze piston rings on the piston. Install the piston with piston rings over the first cylinder, at the same time the tag on the piston has to be directed to a forward part of the block of cylinders. The handle of the hammer press the piston into the cylinder so that the lower head of a rod was established on a neck of a bent shaft.
  2. Install the top inserts of radical bearings on the block of cylinders of the engine. At repeated installation of inserts establish them on the same place in which they were before removal.
  3. Establish inserts of radical bearings in covers of radical bearings of a bent shaft.
  4. Make sure that tags on the piston and a rod are directed to a forward part of the block of cylinders.
  5. At installation of a new rod be convinced that dredging for an insert of the bearing is on the one hand.
  6. Tighten bolts and nuts of fastening of covers of rods.
    1. engine oil a carving of nuts and bolts;
      3. the required moment tighten bolts and nuts of fastening of covers of rods.

Inhaling moment:

- l engines 1,8 and 2,0: 50–53 N • m;
- engines of 1,6 l: 32–35 N • m.

Do not use more than three times bolts of fastening of covers of rods.

  1. Measure by the probe inserted between a rod and a bent shaft a side gap of a rod. Nominal side gap of a rod: 0,10–0,25 mm. Maximum permissible gap: 0,40 mm
  2. Establish an oil filter.
  3. Install the oil pallet.
  4. Establish a head of cylinders.