TURBONutter Lada Niva 4x4 Service Manual Fuel Injection This manual and a host of other wonderful Lada Niva documentation is available free of charge at: http://www.turbo-nutter.com You can do anything you like with this manual except sell it or otherwise make money from it. While | can’t stop you sticking it on your own website | would much prefer you linked to its original location on turbo-nutter.com You use the information contained with this manual at you own risk. If you're not sure how to do something either don’t do it or ask someone who knows about such things. The font of all Lada knowledge can be found at: http://www. lada.co.uk/forum For Lada parts, advice and general all round Lada wonderfulness these blokes aren't bad: Lada UK Ltd Lada Parts Australia P/L Askew Rigg 42 Aerodrome Road Troutbeck Caboolture Penrith, Cumbria Queensland CA11 0SZ 4510 United Kingdom Australia T: +44 (0) 17 6877 9794 T: +61 7 5495 5100 F: +44 (0) 17 6877 9197 F: +61 7 5495 5152 E: alan@lada.co.uk E: andy@ladaparts.com W: http://www. lada.co.uk W: http://www. ladaparts.comSection II ENGINE ie Longitudinal end cross avotions of the engine are show in Pigs 2-1 and 2-2. Fig. 2-1. Engine. Longitudinal SectionFig. 2-2, Bngine. Cross Section © SS .OUBLE SHOOTING conta Cause Remedy 4, No. fuel in car vurettor: (e) fuel pipes oF carburettor and fuel pump filters clogged (>) fuel pump foulty 2. Ignition systen Anoperative 3. Cerburettor choke valve renains closed when starting engine je wonky or Stall 1, Wrong 1a1ing sajustaent (e) wash and atrblast fuel tank and pipes end filters (2) examine fuel pump ond replace faulty parte 2. See Chapter "Ignition systen 3, Eliminate poor tight ‘ness of carburettor choke mechanion hen 14 1. Adjust 1€ling speed 2. aie inleakage ‘through damaged drain pipe 3, aie inleakage ‘through damaged hose leading from intake manifold to brake vacuun booster 4. Air imleaksge ‘through gaskets in joints between intake manifold and carburet= tor or cylinder head 5. Wrong clearanct between valve rockers end camshaft cans 6. carburettor feulty: (a) carburettor 2. Replace érein pipe Replace damaged hose 4. Tighten up mats oF replace gaskets 5. Adjust clearances (e) atzblast Jets andconta contra Cause Renety Cause Renedy jets or channels channels 1. Spark advance angle 1. Adjust ignition timing obstructed too early (®) water in car- (b) renove water from com 2.04] pressure too «2 -‘See "O41 Pressure Too burettor vorettor, drain sediment yoy law ab TaLing Speed” from fuel teak 3. Loosening of fly- 3. Tighten up to specified (e) choke mecha- (ce) replace dtaphragn wheel bolts torque mien diephrags 4. Excessive clearance 4, Grind joumals and Leaky detween main joule replace shells + Ignition ayaten 1. See Chapter "Ignition gaa thet bearing eulty syste" ae 5. Excessive clearance 5. Replace thrust balf- ‘agine Lacks Power and Pisiup between thrust helf- rings by new and thicker «Carburetor throttle 1. Adjust throttle valve rings and crankshaft’ ones lvea open incompletely control Linkages 2. Air cleaner clogged 2. Replace cleaner ¢1 BigcBnd Bearing Mocks nent Vaually knocking of bigeend bearings 1s }. Tenttion systen 3. See under "Ignition sbaxper than that of the nain bearings. It ie heart ceulty Syatent fat engine idling speed when the throttle valve is {. uel pump faulty 4. Check pump performance sharply opened. the origin of mocking can be and replace damaged parts easily identified by étscomnecting spark plug wires carburettor faulty: one after another. (2) acceleration (a) check pump capectty, 4, tasurricient of) 1. See "011 Pressure too punp defective replace faulty parta preesure paerechialine eee (&) main jets (0) atrblaat Jota 2. Bxcessive clearance 2. Replace shells and clogged tween big-end jour- grind joumale (6) choke valve (c) adjust choke valve Serfeataanisie — opens incomple- Linkage vey Piston Shap (4) wrong fuel (4) adjust carburettor Sores penny Ao a mule it ia a dull imocking caused by cheaber slacknese of piston in the cylinder. Tt is best a een ene audible at @ low engine speed and under @ loed. tovcam clearence: 1. Bxcessive piston-to- 1. Replace pistons, 7. Boor coapression, ~cylinder clearance rebore and hone cylinders be 1 Mee (10 ket/en?) 2. Excessive piston ring 2. Replace rings oF pis- (a) detective (a) replace gnaket side clearance tons with rings cylinder head gasket Yatve mocks (b) burning of Qian Excessive clearances in valve gear cause pistons, breaking grooves and rings, characteristic knocks, usually with regular inter foe fees cb tne ot acer eerie vals. Knocking frequency 1 lower than that of any piston rings and pistons other engine knocks, since the valves are operated (8) poor seating (0) replace faulty by the camshaft which rotates at balf the crank~ of valves valves, reface seate peatteais (@) excessive (a) replace pistons, wear of cylindere rebore and hone cylinders 1+ Excessive valve-to- 1, Adjust clearanc: ee eieeacines ~rocker clearanc 2. Valve spring broken 2. Replace spring 3. Bxcossive clearance 3. Replace worn parte detween valve stem and guide a yrenkshatt Main Enoe! As a we this knocking ts of a dull metallic nature, detected when the throttle valve ia sharply opened at {dling speed. Grows with increase of crankshaft speed. Bxcessive crankaheft end Pl8Y 5. roosening of adjust- 5. Adjust valve rocker-to~ csuses @ sharper sound with uneven intervals Bost 3 yore ascunut vem clearance €af conspicuous during gradual throttling up and dow ‘Hghten lockaut F of camshaft cana 4, Replace cemshaft and valve rockers: contra Conta cance Renedy Cause Tenedy Gemebaft Drive Chain Noise The camshaft drive chain notes becomes noti- cosble against the backgroud of general engine noise in case of excessive clearances between the cbain and sprockets and it is particularly loud at low engine speed. 1. Chain becomes slack through netural wear 2. Chain tensioner shoe 2. Replace tensioner shoe or damper broken or damper 3+ Chain tensioner plun~ 3, Eliminate jeming ger rod jaming 1 Tenoton chair O11 Pressure 00 Low et Idling speed of Warm Engine 1. Foreign matter get- ting under reducing valve of of1 pump 2. O41 pump gears worn 2. Repair oi] pump 3. Bxcessive clearence 3., Grind journals and Detween crankshaft main replace ahelle Journals and bearing mhelis 1, Clean valve of foreign matter and burre, wash out of2 pusp 42 Pressure Too Ess 0f1 pump reducing valve jamming 4m Wom Engine Replace valve essive O11 Consumption 1, 0:1 leaking past 1. ‘Tighten fastenings oF engine seals replace gaskets and glance 2 2, Rebore cylinders ond rings, pistons or replace pistons and ringe cylinders 3. Broken piston 3. Replace rings rings 4+ Gumed slots in oil control rings or cutouts in piston grooves 5. Valve ofl-deflecting 5. Replace cape caps worn or damaged 6. Heavy wear of valve stens or guides 4+ Remove carbon deposits from slots and cutouts 6. Replace valves, repair cylinder bead Exgessive Fue] Consumption 1s Choke valve fails 1. Adjuat choke valve to open completely Linkage 2. High rewistance to 2. Check and adjust tyre car motion pressure, brake systen, ‘front wheel aligment 3s Adjust ignition timing 3+ Wrong tenition tin tng 4.% Replace vacuum timer oF ignition dtetrituter 4.™ Ignition dtetribu- tor vacuum epark tiner faulty 5. Carburetor fuel Jevel too high: (a) carburettor needle valve or ite gnaket leaky (a) 100k for foreign particles between valve ‘sent and needle; replace gasket or valve, Af necesaary (>) Jaming or (b) examine float and friction interfer replace it, if necessary ing with normal motion of float; float Leaky 6. carburettor air 6. Clear up jets Sete clogged Engine ovexne 1, Stackening of pump 1. Adjust Delt tension ant altemator drive deat 2. Lack of coolant sn cooling eysten 3. Wrong ignition timing 4, Radiator heevily soiled on outaide 5. Thermostat faulty 6. Defective valve in radiator cap [opening preanure below 9.05 Mra (0.5 kgt/cn*)] 7. Coolant pump fouity 2. Add coolant into eool- ing systen 3+ Adjust ignition timing 4, Clean radiator with Jet of weter 5. Replace thermostat 6. Replace op 7. Check, replace oF repair coolent pump Rapid Drop of Coolant Level in Expansion enk 1, Radiator damaged 1. Replace radiator 2, Damaged hoses or 2. ‘Replace Pipe joint gaskets oF gaskets 3. Coolant leaking from heater cock 4+ Loosening of hose 4. ‘TMehten up clamps clamps 3. Replace cock 5. Coolant lesks 5s Replace gland ‘through coolant pup giana 6. Radiator cop or ite 6, Replace cap gasket danaged 7. cylinder head gas- 7. Replace gasket ket damaged * Defects relating to the engines with carburettor 2107-1107010-20.ENGINE REMOVAL AND INSTALLATION Flace the car ona lift or inspection pit. jove the hood. Take anay the spare whool and move ite supporting tube. Disconnect the wires from the storage battery 14 from the engine-mounted electrical device Drain the coolant from the radiator, cylin- sr block and heater; for this purpose unscrew the luge on the LH. aide of the cylinder block and 1 the radiator bottom tank; obirt the he antrol upper lever to the right (this lever pene the heater cock) and take off the caps from ne expansion tenk and the radiator. ‘Caution To avoid danging the radiator, unscrew the vain plug with one wrench and hold the plug union sldered into the radistor with another. Prefera y use @ socket or box wrench not to mutilate the Iug fact Sp move the fan shroud, first disconnecting ta halves. Discomect the coolant inlet end out gt hoses from the engine and take off the radie~ or complete with the themostat end host Remove the air cleaner, first discomecting ne hoses, removing the cover and the Filter ele- ant. a Unscrew the nuts which hold the muffler inlet pipe to the exhaust manifold, Detach the inlet pipe from the bracket on the gearbox and down. Detach the throttle valve control red and choke valve cable from the engine. Disconnect the fuel feed hove from the engine and detach the hoses leid to the heater and vacuum brake booster. Using articulated socket wrench 02.7812-9500, unscrew the bolts which hold the starter to the clutch housing. Unscrew the bolts which fasten the clutch housing cover to the loner part of the housing. Uning articulated socket wrench 4.55035, ‘tum off the clutch housing-to-cylinder block bolts. Suspend eros bean 700-3/379 from a lifting tackle and sling the engine by the shackle instal~ led on the exhaust manifold front fastening stud et the R.w. side and by the clutch housing fasten= ing hole at the LH. side. Tension the tackle chain little, unscrew ‘the nuts which fasten engine front mount pads 3 (ig. 2-3) to the side brackets and unscrew the mute end the dolt which fastens the front axle housing to the engine brackets. ‘Take out the engine, first moving it upward to withdraw the mount pad bolts from the bracket holes, then shift it forward so as to pull the end of the gearbox clutch shart out of the bear ing in the crankshaft flange. at Pig. 2-3, Engine Mounts: 1 = RH. mount bracket with pad; 2 - LH. mount Dracket; 3'- pad; 4 - engine rear mount crosmen- der; 5 - engine rear mount bracket with mupportRemove the heat-insulating shield of the starter, the starter proper and the hot air intake ‘complete with the inlet hose. Remove two side prackets "from the cylinder block complete with the engine front mount pads. Unscrew the clutch fastening bolts and remove ‘the cluteh. ‘fo install the engine reverse the removal Wash the engine on the washing stand, put it on the disassembly bench and drain the of] sump. Disconnect the hoses ané throttle valve control rod from the carburettor snd remove the latter. Remove the fuel pump and ignition distribu- tor; unserew the spark plugs end the coolant tem- perature trenmitter with wrench 67.7512.9514- ‘Take off the altemator and coolant pump Grive belt, remove the altemator and ite bracket. Remove the coolant pump, disconnecting the heater pipe from the pump and oxhaust manifold. Detach the coolant outlet pipe and the pipe conducting coolant to the heater and remove then from the cylinder head. Using remover tool 4.60312 unscrew and take off the of] filter with the gasket (Pig. 2-4). ‘Unscrew the of] pressure and of} pressure warning lamp trenmitters and remove their unions. Bake off the crankease breather cover, the of1 mump end the of} pump. Take off the retainer of ‘the of1 separator drain pipe and take out the crankcase breathing ofl separator. Remove the crankshaft pulley securing the flywheel with fixing tool 4.60330/R (Fig. 2-10) and tmscrewing the crankshaft starting jews with wrench 4.50121 (Pig. 2-5): Remove the cylinder head cover and the cover of the camshaft chain drive, Tuacrew the bolts of ‘the camshaft end oil pump drive shaft sprockets. Fig. 24. Removing O11 Pilter with Remover Tool 4.60312 £ a he operations. Pay particular attention to the con~ nection of the engine with the gearbox: the clutch shaft should enter accurately into the splines of ‘the clutch driven diec. Besides, for proper aliganent of the engine with the transfer case, ‘the aligning washers of the engine front mount pads must enter the cozresponding holes in the ide bracket Pig. 2-5. Unscrewing Crankshaft Starting Jow with Wrench 4.50121 Pig. 2-6. Removing Chain Tensioner and Damper: 1 = tensioner cap mut; 2 - tensioner body 3 = tensioner fastening mut; 4 - tensioner shoe: 5 ~ shoe bolt; 6 - camshaft drive (timing) chains 7 = ofl pump drive shaft sprocket bolt; 8 - damper volts Loosen cap mut 1 (Pig- 2-6) of the chain ‘tensioner, mocrew nuts 3 which hold it to the cylinder head, renove the tensioner and, unecrewing dolt 5, take off chain tensioner shoe 4,Fig. 2-10, Removing Flywheel: 4 = wrench; 2 -flywheel; 3 - Flywheel bolt; 4 - washer; 5 - fixing tool 4.60330/R to prevent tuming of flywheel; 6 - clutch housing front cover g- 2-8. Renoving O11 Pusp Drive shaft: ~ thrust flange; 2 - flange bolt; 3 - of] pump tv natty 4 ~ wrench Fig. 2-11, Pressing Out Gearbox Shaft Bearing trom Crankshaft with Reaover Tool 4.40006 Unscrew the chain limiting pin, take off the rive sprockets of the ofl pump and camshaft and take out the chain. Looeen the mute of studs 4 (Pig. 2-1). Take off the camshaft bearing housing. Unscrew the muts of studs 4, remove thrust flange 1 and take out the commbaft taking care not to damage the surfaces of ‘the bearing housing supports. Unserew the cylinder head bolts and take off ‘the head complete with the exhaust and intake manifolds. Homove thrust flange 1 (Pig. 2-8) of the oil pump artve shaft and take the shaft out of the cylinder block. Migs 2-9. Removing Crankshaft Sprocket with General-Purpose Renover Tool 4.40005/1/7 3BUsing general-purpose renover tool 4.40005/1/7 from ef 4.40005, renove the sprocket from the orenkshart (Pig. 2-9). Unscrew the connecting rod bolt nute, take off the comecting rod caps and lift out the pie ‘tons with the comecting rode cautiously through ‘the cylinders. ‘Fete. When Gionssenbling the engine, mark the piston, connecting rod, main and big-end bearing shells so as to install them back where they delong during subsequent reassembly. Tastell fixing tool 5 (Pig. 2-10), unscrew bolts 3, take off washer 4 and pull the flywheel from the crankshaft, Renove the front cover of the eluteh housing. Using renover tool 4.40006, take out the gearbox clutch shaft bearing trom its Dore in the crankshaft (Pig. 2-11). Renove the crankshaft gland holder. Unscrew the main bearing cep bolts, take out ‘the caps complete with the lower shells, renove ‘the crankshaft, the upper shells and the thrust half-ringe on the rear support. ENGINE ASSEMBLY Put @ washed and cleaned cylinder block on ‘the stand and screw in any missing stud Insert shells without grooves into the bed and cop of the middie bearing; inetall shells with grooves into the renaining bearing beds and cepe.™ ote. The engine cylinders, pistons and glands, bearing shells and thrust half-rings of the cranksbsft should be lubricated with engine of] before installation. esas ee EE Flace the crankshaft on the main bearings and insert two thrust helf-ringe into the sockets of ‘the rear support (Pig. 2-12); the half—ringe should be selected by thickness ae instructed Under "Crankshaft and Fiywhee1". Install the main bearing caps in accordance with their marke (Pig. 2-13). Caution Install the main bearing caps into the cylin~ der block where they belong. Por this purpose the eylinder block and ite bearing caps are marked with the same conventions) number (Pigs 2-13 and 2-24). Install the thrust helf-rings with their recesses facing the thrust surfaces of the crank abaft. the etecl-sluninium half-ring should be placed at the front side of the rear support and ‘the cerametallic (yellow) half-ring, at the rear aide, Put the gland holder gasket on the crankshaft flange and insert the clutch housing front cover Bolts into the holder holes (Pig. 2-14). Si4p the holder with the gland on mundrel 41.7853.4011, move it from the manirel onto the crankshaft flenge and fasten it to the cylinder block. Install clutch housing front cover 6 (Pig. 2-10) with the eid of two aligning bushings. Install the flywheel on the. crankshaft with ‘the mark (tapered hollow) near the rim facing the axis of the dig-end joumal of Ho. 4 cylinder, lock ‘the flywhee! with fixing tool 4.60330/R and bolt At up to the crankshaft flange. Using an inserter bushing from act 02.7854.9500, insert the pistons with connecting rods into the cylinders (Pig. 2-15). Set 02.7854.9500 comprises an inserter bushing for the standard-size pistons and bushings for the repair size pistons (04 and 0.8 un oversize). Therefore, select the inserter buahing corresponding to the aize of the piston being installed. Fig. 2-12. Installing Thrust Helf-2ings on Rear Support since 1966 lower shells of the main bearings ‘ithout grooves on the inner surface are used. 1 2 3 4&6 5 79908 lo} «I tl le 5 Yig. 2-13. Marke on Main Bearing Cape (bearings fare counted from engine front) and Cylinder Block Code umberPig, 2-14. Crankshaft Rear Gland Holder. Arrows Indicate Luge for Aligning Holder with Crankshaft Plange tg. 2-15. Installing Piston with Piston Rings into ylinder with Piston Inserter Bushing fron Set 2.7854.9500 216. Sequence of Tightening Cylinder Head Bolt on The hole for the pin in the piston is offeet 2mm, therefore the pistons should be installed to the-cylinder with the mark "II" facing the eine front. a Put the bearing ahelle into the connecting 4s and thetr cape. Join the connecting rode with 5 ig. 2-17. Aligunent of Timing Marke on Crankshart Sprocket and on cylinder Block Fig. 2-18. Sequonce of Tightening Camshaft Bearing Housing mute ‘the crankshaft Journals, inetall the capa and tighten the connecting rod bolts. Tnstall the sprocket on the crankshaft. Install the ofl pump drive shaft and fasten it by ‘the thrust flange. Using two aligning bushings install the cylin- der head on the cylinder block compete with the gasket, exhaust and intake manifolds. Tighten the fastening bolts in two steps in the sequence atom in Pig. 2-16: = tighten bolts 1 through 10 preliminarily with @ torque of 33.3 - 41.16 Nem (3.4 = 4.2 kgf.m); Hghten bolts 1 through 10 finally with a torque of 95.94 = 118.38 Ham (9.79 - 12 kgf.m) and dolt 11 with a torque of 31.36 — 39.1 ¥. (3.2 ~ 3.99 ge, um the flywheel so that the mark on the crankshaft sprocket registers with the mark on the cylinder block (Pig. 2-17). ‘Install the sprocket on the camshaft assenbi- 4 with the bearing housing and tum the shaft 50 that the mark on the sprocket £1 ‘the bearing housing (Pig. 2-19).Fig. 2-19. artgnment Sprocket and on ie Bearing Housing: mark on sprocket; 2 - censheft, install the bearing housing on the cylinder head and featen nuts in the it by tightening the jequence show in Pig. 2-18, Install the chain damper on the cylinder head, bearing housing (Pig. ‘sioner proper, 2419). sprocket bolt 411 the way home; ~ inetell the sprocket on the of2 pump arive Saft, also without tightening the fastening bolt completely; 7 install the tensioner shoe and the ten= Do not tighten the without tightening the cap nut to allow the tensioner spring to press down the ‘sorew the chain @er block; = fim the crankabart tro revolutions in ite Reuter direction thereby ensuring the required chain tension; check to sprockets are aligned with the marks der block (Pig. see that the marks on the 2-17) end on the bearing housing (Pig. 2-19); ‘the lock washers; repeat the chain mark on bearing housing limiting pin into the cylin= on the oyline 16 Gover relative to the end of the orm ‘tighten up its fastening bolts and tm Install the crankshatt pulley ar starting jore. Inetell the oi1 titer, screwing cylinder block union handtight. Insta separator of the crankcase breathing ‘the breather cover and secure the ret of separator drain pipe. Tastell the of1 pump and the oi2 ite gasket, Install the coolant pump, alter: and altemator. Run the belt over the agjust tte tension. Install the heater rediator inlet he outlet comection on the cylinder ‘the heater radiator outlet pipe to the Pump end exhsuet manifold. Install the gauge trananitters. Install the of1 pump and ignition ative gear. Install the ignition dist: sdjust ignition timing, Screw in the sf fané tighten then with torque-indicating 67.7812.9515, ‘Tastall the fuel pump ae inetructe "Puel syaten", ‘Install the carburettor and comes hoa Tnstsll the cylinder head cover wi ket and uel 1ine bracket. Install the air cleaner; for this secure the hoses on the air clemer body Gleaner body with the gasket on the cart anstall the supporting plate and fasten with nuts. Put in the riiter elenent and ‘the cleaner cover, FALL the engine with of] through th throat on the cylinder head cover, 748+ 2-20. Canshatt Drive Cover. Arrows Sh Tor Aligning Cover with crankshaft Pulley 1BICRE ‘A repaired engine shall be subjected to otend teste (running-in) at no-load in accordance with the following program: 2 min at 850 - 900 xpm 3 min at 1000 xpm 4 min at 1500 rpm, and 5 min at 2000 rpm. While running-in a repaired ongine do not operate it at maxim epeed. Mount the engine on the stand, start it and check for: = water and fuel leaks between the mating fron the pipe Joints ané past the gasket ofl pressure; ignition timing; dling speed; abnormal imocking. In stop the engine, correct the defects and resume ta eats. parta, ¢ of abnormal imocking or other defects, stp tes78 If of] leaks are detected past the gasket between the cylinder head and cover or past the gaskets between the engine ofl sump, cylinder Dlock and covers, tighten the corresponding bolts with the recomended torque. If leakage persists, check for correct installation of the gaskets and .ce them, 4f necessary. A repaired engine is not yet mm-in, therefore friction of the working surfaces of new parte offers a considerable resistence to rotation; con- sequently, @ certain working~in period 1s required. Tale applies particularly to the engines where pistons, big-end and main bearings wore replaced, the crankshaft journala were ground and the cylindere honed. Therefore, the mmning-in program should always ond on the car driven at the speeds recomended for the early stages of car operation. ENGINE CHECKOVER OW CAR After installing the engine on the cer check tt carefully for correct mounting. Run the engine for some time and check the following = Yeaks of coolant and fuel at the pipe Joints; tighten the joints, if necessary; = off leaks; ~ see that the carburettor control Linkage ensures complete closing and opening of the throttle and choke valves and adjust the Linkss: 4 necessary =~ altemator drive belt tensior adjust, if that the mire contacts of electrical equipment are in good condition; = check to see that the waming lamps on the instrument pane) function ae they should. on Do not check the engine and the car on a etend with ruming drums without additional rol~ ers under the front wheels. CHLTNDER BLOCK ~—"he main dimensions of the cylinder block are sho. in Pigs 2-21. } yn raat Py Ts 200 sem ES io A GENERAL CLEANING AND INSPECTION sh the cylinder block thoroughly and clean the of1 channels. Aizblast and dry the cylinder lock, partioularly its oil channels. Examine the cylinder block and replace it, if cracked in the supports or elsewhere. CYLINDER BIOCK TIGHTNESS CHECK If there 1a 0 suspicion that the coolant penetrates into the crankcase, the cylinder block can be checked for tightness on 8 special stand. Por this purpose plug the holes in the cooling Jacket and deliver water at © roo teapersture under 6 pressure of 0.3 MPa (3 kgf/cm). There should ve no water leaks from the eylinder block in the course of 2 mine If of gets into the coolant, before proceed- Pig. 2-21. usin Dimensions of Cylinder Block to Aeassenbling the engine check the cylinder block for cracks in the of1 channel zones. Por this ee eeepurpose drain the coolant from the cooling systen, remove the cylinder head, f111 the cylinder block cooling jacket with water and deliver compressed air dato the vertical of] chanel in the cylinder block. If air bubbles appear in the water filling ‘the cooling jacket, replace the cylinder block. cylindere Check the cylinders for wear which should hot exceed 0.15 mm (the maximn tolerable value). The cylinder bore is measured with an inter- Ral gauge (Fig. 2-22) in four zones, both along and across the engine (Pig. 2-23). Ring gauge 61-8125,950148 used to set the internal gauge to Fig. 2-22, Measuring Cylinders with Internal Gauge: 1 = intemal gauge; 2 - eroing internal gauge by check gauge Hote. The cylinders im the block are divided into five diameter classes 4, B,C, D and B in steps of 0.01 mm. the class of the cylinder t9 marked on the lower face of the block (Pig. 2-24). ‘The same face and the main bearing caps bear a conventional number of the cylinder block which indicates that the bearing caps belong to this particular block. even en nn ne NEE EE In zone Yo. 1 the oylindere practically do mot wear, 90 this zone may be used as a reference one for determining cylinder woar in other three Fig. 2023. cylinder Meamurenent Diagraa: 4 end 3 - directions of measurements; 1, 2, 3, 4 — ‘sone mumbera Fig. 2024. cylinder Block Marked with Cylinder ‘Size Group (Waite Arrows) end Cylinder Block Code Humber (Black Arrow) If the maximum weer exceeds 0.15 mm, b—~ the cylinéers to match the nearest repair size .. the Piston (0.4 oF 0.8 mm oversize) with en 0.03 me allowance in dianeter for honing. Then hone the cylinders to the dianeter providing the designed clearance between tho piston of the selected: repair size and the cylinder equal to 0.06 - 0.08 CYLDWORR HEAD JOINTING SURPACE he upper face of the cylinder block may de Aistorted. Therefore, check thie surface with a straightedge and a set of fecler gauges. Place the straightedge on the diagonals of the cylinder block and in the middle, both lengthwise and crosswise. If the surface 1a out-of-tmue by more than 0.1 ma, replace the cylinder block. 18ZISTONS AND CoNMBoTENG RODS The main dimensions of the comecting rod and piston group are given in Pig. 2-25. i ry iz dy the diameter of the piston pin hole. the class of the piston (letter) and the category of the pi: TE ial bs Vig. 2-25. uain Dimensions of Piston, Comnecting od, Piston Pin and Piston Rings PRESSING OUT PISTON PIE ‘The piston pin should be removed on a pre using driver 4.60308 and a support with a oylin= drical hollow to receive the piston. Take care to renove the piston rings before driving out the piston pin. ‘The removed parts can be reused if they are but slightly worn and undamaged. Therefore, mark the parts during disassenbly 20 as to reassemble thea in the original seta. crEANING Renove carbon deposits from the piston crow. nd ring grooves and clean the lubricating cbannels f the piston and connecting rod from all deposits. Bxamine the parta thoroughly for probable anage. Cracks of any nature on the piston, piston ings, pin, comecting rod and its cap are imper- igethle and call for imnediate replacement of Replace the bearing ahelis if they are eeply scratched or heavily worn. ‘PISTON-T0-CYLINDER MATCHING ‘The designed clearance between the piston and. ylinder (for new parts) 1s 0.06 ~ 0.08 m. The learence is determined by measuring the cylinders nd pistons and fitting the pistons and cylinders Longing to the sane class. The maximum clearance by wear) should not exceed 0.15 am. ‘he dianeter of the pistol is checked im he plane perpendicular to the piston pin at 0 {stance of 52.4 mm fron the piston crom, Pig. 2-25). he pistons are divided into five classes (4, 1, C, Dand 8) dy the outside diameter, in 0.01 am feps and into three categories, in 0.004 mm steps 19 ‘ton pin hole (figure) are indented on the piston If the clearance in a used engine exceeds 0415 um, select the pistone to the cylinders to Provide the clearance aa close to the designed value ag possible Delivered for spares are pistons of classes A, © and E. These classes pemit matching the piston to any cylinder as both the pistons and cylinder fare divided into classes with @ certain overlapping of dimension! (CHECKING PISTON-T0-PIN CLEARANCE The piston pin is prese-fitted into the mall end of the connecting rod with an interference and is free to rotate in the piston bos: Bote. With respect to the outeide diameter the piston pins are divided into turee categories in Fig. 2-26. Piston Pin Should Go in Under Thumb PressurePig. 2-27. Checking Piston Pin Pit steps of 0.004 mm. The category is marked by paint on the end of the pin: blue for the 1st category, green for the Qnd one and red for the 3rd category. The fit of the piston pin in the piston is checked by costing the pin with engine of2 and inserting it into the piston boss. The fit i8 con- sidered correct if the pin entere the hole umdér ‘thumb pressure (Pig. 2-26) and does not fal1 out of ‘the boss (Pig. 2-27) of the piston held with the pin positioned vertically. If the pin alides out of the bose, use a replacenent pin of the siext larger category. If, however, the pin belongs to the 3rd category, doth the piston and the pin must be replaced. GHBCKING PISTON-T0-RING CLEARANCE Moe side clearance of the piston rings should be measured as shown in Pig, 2-26, instal- Ling the ring into the corresponding groove. The assembly clearance should be 0.045 ~ 0.077 mm for the upper compression ring, 0.025 = 0.057 mm tor the 2nd compression ring 2-28. Checking Piston Ring Side Clearance: 1 ~ pieton ring; 2 - pistan; 3 - set of feeler gauges 20 and 0.020 ~ 0.052 am for The woar limit 10 0.15 mm The ring joint gap should de checked with @ yt of feeler gauges, inserting the rings into & gauge whose inside dianeter te equal to the noni- nei @iuneter of the ring, true to 30.003 m. he gap should range from 0.25 to 0.45 mm for all rings. Pile off the jointing surfaces of the ring if the gap 1s insufficient and replace the ring, 1f it ia too bige the of1 contre) ring. ‘CHECKING HEARING SHELL~T0-CRANKSHAPT ‘CURARANCES The clearance between the bearing shelle and ‘the crankshaft journals con be checked by caloule- tions (by measuring the parts) or with @ piece of calibrated plastic wire in the following orter: = clean thoroughly the working surfaces of ‘the shell and big-end journal and install the con necting rod with the piston on the big-end journal im accordance with their numbers; = put @ plece of calibrated plastic wire on ‘the big-end journal, install the connecting rod and its cap and tighten the nuts with a torque of 50-96 Ham (5.2 ket-n)s = remove the cap and determine the flettening of the wire (Pig. 2-29) against the ecele on the wire packing, this finding the clearance, If the clearence is within the tolerance 11- its (0.036 ~ 0.086 an) or does not exceed the wear Limit (0,10 mm), the shelle may be used without changing the @laneter of the big-end joumals. If the clearence exceeds the 0.10 mm wear Limit, use replacenent shells (Table 2-1) and grind the big-end joumals to the repair size specified under "Crenkshatt and Plywheel". Pig. 2-29. Measuring Width of Flattened calibret- ea Wire Againot Seale: 1 ~ calibrated wire; 2 ~ ahell; 3 - bigeend bear- ing cap; 4 ~ scaleTable 2-1 Thickness of Connecting Rod Bearing Shells, mm Oversize Womtnal 0.25 | 050 | 0.75 1-0 11 1.848 —«1973—~—«2.088 2.823 4.730 1.855 1.980 2.105 2.230 Figures 0.25, 0.50, ete. indicate the reduce ‘thon in the diameter of the big-end journals etter grinding. CHECKING PISTON Mass ‘The pistons in the engine should be of the sone nasa, true to 42.5 g. If a set of pistons belonging to the sane saase group is not available, they cen be adjusted for masa by removing some metal from the base of 4 daton pin boss as shown by arrows in Pig. 2-30; However, the metal mist not be renoved. deeper than 4.5 mm relative to the nominal height of the piston (59.40 mm) while the removal of metal in width ehould be limited by a dianeter of 70.5 ma OZ YS SB Pig. 2-30. Points (Shown by Arrows) Where Motel Can Be Removed to Rqualize Piston Weights ASSEMELING CONNECTING ROD AND PISTON ROP o provide for an interference fit of the piston pin in the mall end of the connecting rod, hoat the latter to 240 °C for expanding ite small end. Yor this purpose place the connecting rods into an electric oven. If the oven has already been brought to # temperature of 240 °c, hold the connecting rode there for 15 ain, Yor correct jointing of the pin with the connecting rod, presa in the pin as rapidly at poueible, since the connecting rod coole quickly after which the position of the pin will be Ampoasible to change. Jo prepare the piston pin for assembly put it om shaft 1 (Pig. 2-31) of tool 02.7853.9500. Pit guide 3 on the end of this batt and secure it Pig. 2-31. Tool 02-7853.9500 for Prese-Pitting Piston Pin into Piston and Connecting Rod Bnd: 1 = tool shaft; 2 ~ piston pin; 3 - guide; 4.~ thrust screw Pig. 2-32. Press-Pitting Piston Pin into Connect~ ng Red Saal Bnd, 1 = tool 02.7853.9500; 2 ~ piston pin. The piston should rest on connecting rod en¢ as shown by with screw 4. Do not overtighten the screw to avoid ‘seizure due to heat expansion of the pin caused by contact with the hot connecting rod. Take the comnecting rod out of the oven and clamp it quickly in a vice, Put the piston on the connecting rod, aligning the pin hole in the piston with the hole in the small end of the comnecting rod. Using tool 02.7853.9500, push the piston pin into the piston boss and into the connecting rod small end (Pig. 2-32) until the shoulder of the ‘tool comes in contact with the piaton. During thie operation the piston bose should be pressed againat the mall end of the connecting rod im the direction of the force applied for press-fitting the pin (show by arrow in Vig. 2-32). In this way the piston pin will occupy the correct position. ‘Gantion he piston end comecting rod should be Jointed so that the mark "I" on the piston ia Located at the side of the of] outlet hole in the connecting red big end.Allow the connecting rod to cool down and lubricate the piston pin with engine ofl through ‘the holes 4n the piston bosse: When installing the piston rings, apace their Joints at 120°. the step on the onter surface of ‘the 2nd (scraper) compression ring should be @irected dom and the chanfers on the outer sur face of the oll control ring should face upward (Pig. 2-25). Mhe connecting rod 18 machined jointly with ‘the cap and the caps are not interchangeable. In order not to confuse then during assembly, the con- necting rod snd the corresponding cap are marked with the number of the cylinder they belong to. During ascenbly see that the figures on the comect= ing rod and cap are located on the eame side, ‘OuECKING PISTON PIN PIT After assenbling the connecting rod with the piston pin and piston check the pin fit with a torque-indiceting wrench and tester 4.95615 as follow = clamp tester base 4 (Pig. 2-33) in a vice fand install the piston pin-connecting red assembly ont = lower indicator bracket 8, insert threaded spindle 3 into the pin hole and move it into the Piston boss until spindle head 2 thrusts against ‘the end of the pin; = screw mut 5 on the end of the spindle and draw up the aut against the mupport to teke up the clearances, if any; + lift indicator bracket 8 to @ horizontal position, secure it by handle 7 and set dowel 1 of indicator 9 on head 2 of the spindle inserted into the pin; Fig. 2-33. Assembled Piston-Pin-Connecting Rod Group Installed on Tester 4.95615 for Fin Preseing- out Tent: “1 = indicator dowel in contact with end of spinais 2 ~ spindle head in contact with piston pin; 2 ~ threaded spindle with slot; 4 - base; 5 = spindle nut; 6 ~ spindle stop; 7 - bracket clamp handle; 8 ~ indicator bracket; 9 - indicator 22 = set the indicator to sero and insert atop 6 Into the slot of the threaded spindle to keep the lntter against tumings = using a torque-indicating wrench, tighten, opindle nut 5 with a torque of 12.7 Nom (1.3 kgf-m) mhich corresponds to an axial load of 3.92 kX (400 ket). The fit of the pin in the connecting rod ta correct if, after withirering the torque wrench and returning the nut to the initial position, ‘the indicator pointer retume to sero. If the pin olipe in the connecting rot small end, replace the connecting rod by a new one. CHECKING CONNECTING ROD BIG END AND PISTON PIN ATES FOR PARALLELISM Before installing an assenbled connecting rod end piston group on the engine, check their exes for parallel alignnent (Pig. 2-34). To check align the connecting rod big end (without bearing shells) on extensible blades 2 and put gouge 4 on the piston crow. Using & set of feeler gauges check the clearance between the vertical plate of the Jig and the vertical surface of the gauge at a distance of 125 mm from the corner or the upper end of the gauge, depending on whether it contacts the plate by the comer or the upper end. The clearance should not be over 0.4 mm. Replace the connecting rod if the clearmce is larger. Fig. 2434. Checking axes of Piston Pin and Con~ necting Rod Big End for Parallelim: 1 = assembled connecting rod-pin-piston groups 2 = extensible diedes; 3 - thrust bar; 4 ~ gouge(CRANKSHAPT_AND_PLYWEBBL, ‘The main dimensions of the crankshaft are Wwen in Pig. 2-35. out-of-squareness of the flange end surface relative to the crankshaft axia; with the crank- Pig. 2-35. Main Dimensions of Crankshaft Main and Big-Bnd Journals and Pillets CUBAMING UJERICATING CHANNEIS Renove the channel plugs. Run counterbore 4.94016/10 fitted on spindle A.94016 through the plug sockets. Fash the channels thoroughly with gasoline and blow then with comprosged air. Install new pluga with the eid of driver 4.86010 and lock-punch thom at three points for higher reliebility. CRANKSHAPE MATH AND BIG-BND JOURNALS Ghocking. Put the crankshaft on two V-blocks (Pie. 2-36) end using a dial indicator, check: = mmout of the sain journals which should not exceed 0.03 am; = nmout of the seating surfaces for the sprocket end the gearbox clutch shaft bearing; the naximm permissible runout is 0.04 mm; = dieplaceaent of the big-end journal exes relative to the plane passing through the axes of ‘the big-end and main joumals; the maximum perais- sible displacement 4: Pig, 236, Permiesible Runout of Crankshaft Basic Surfaces sbaft rotated, the indicator installed at the ‘side, 34 mm from the shaft axis, should read runout not exceeding 0.025 mm (Fig. 2-36). ‘There should be no cracks on the mein and big-end joumale and webs of the crankshaft, othertiee the crankshaft. should be replaced. ‘The surfaces of the crankshaft mating with the active edges of the glands should be free fron scratches, scores and nick jasure the Aianeters of the main and big-end Journals. Grind the journals if their wear exceeds 0.03 mm oF out-of-roundness is greater then 0.03 am and also if the Journals ere scored or notched. ‘Grinding. Grind the main end big-end joumale reducing their eize by 0.25 mn to provide the Giemeters specified in Jebles 2-2 and 2-} and Journal fillet radif ao show in Pig. 2-35. able 2-2 Diemeter of Big-Snd Journals, om ——— =a Uadersize 0.85 [0050 | 0-75 | ‘1.0 a8 QT.56h—AT.316 47.064 «46.014 47.834 47.584 47.336 47.084 46.834 ee After grinding and finishing the journals, wash ‘the crenkshazt thoroughly to renove the remaining abrasive particles. Wash the lubricating channels , jeveral tines with gasoline under presmure firstable 2-3 Diameters of Main Joumals, mm ‘The nominal designed clearance 18 0.050 ~ 0.095 mm. If the clearence is lese than the ‘maximum permissible limit (0.15 mn), the ahelle ney again. If the clearance exceeds the maximn pemssible limit, replace the shells on the ——_ ek =i Undersize 0.25 | 0:50 | 0.75 | 1-0 50.775 50525 «50.275 50.025. 49.775 50.795 50.545 50.295 50.045 49.795 removing the channel plugs. Mark Ho. 1 web of the crankshaft with the figure showing the reduction of the Journal size (M 0.25; BE 0.50). The out-of-roundness and taper of the main end Digrend joumsle after grinding should not be over 0.007 mm. WAIN BEARDIG SHELES The shells must not be eudjected to any fit ting operations, In case of scores, scratches and separations, they should be replaced. Check the sheli-to-Journal clearances as follow = put e piece of calibrated plastic wire on ‘the Joume! = install the main bearing caps complete with ‘the shells and tighten the cap bolts with a torque of 80.36 Hom (8.2 kef.m); ~ renove the caps, find the anount of flatten- ing of the calibrated wire against the scale provid~ ed on its packing (Fig. 2-37), thus determining the clearance. ‘The clearance between the min joumsle end Dearing shells can also be found by calculations, measuring the Aieneters of the main journals and shell beds, and the thickness of the shell, 1 = scales 2 ~ calibrat 24 Journals with new ones. If the crankshaft journals fare worn and reground to « repair eize, replace the thick shells with repair size onee (of incre ness, nee Table 2-4). Unodstructed tuming of the crankshaft ie an indication of correct asseably end joumal-to-shell antching. Table 2-4 ‘Thiclness of Main Bearing Shells, mm = Oversize 0.25 [ 0.50 | 0.75 | 1.0 1824 1.989 2.07 ~—«199~—« Ew 1.831 1,956 2,081 2.208 2.331 The figures 0.25, 0.50, ote. denote the reduc ton in the disneter of the main joumsle after grinding. PLYWRREL Examine the teeth of the flysheel ring gear; replace the flywheel if they are damaged. The flywheel surfaces mating with the erank- shaft end the clutch ériven disc should be perfectly flat and free from scratches and scores. If surface 3 (Pig. 2-38) of the flywheel mat~ ing with the clutch ariven disc ie scratched, tum it on @ lathe, cutting off not more than 1 mm of metal. then machine surface 2 to provide a size of (0,540.1) am and parelleliam of surfaces 2 and 3 relative to surface 1. the pemissible non- perallelin is not over 0.1 mm as measured at ox- ‘trene points of surfaces 2 and 3. Pig. 2-38. Plywneel: 1 1 = fywheel-to-crankshaft flange 2 ~ elutes mounting surface; 3 - clutch driven isc supporting surface; B - point for checking mmout of surface 2; © ~ point for checking runout of surface 3 206Install the flywiee! on a mandrel, aligning it y the mounting hole until it bears ageinet surface (Pig, 2-38) and check the rumout of surfaces 3 nd 2. The runout read by the indicator at points B nd C should not exceed 0-1 am. CHECKING CRANKSHAPE END CLEARANCE ‘The end play of the crankshaft is limited by ro thrust half-rings installed at both sides of ne rear main bearing, The half-ring at the front ide of the bearing is of the steel-aluniniun type, nile that at the rear side is a coranetallic yellow) one, The half-rings are available in ominal size (2.310 = 2.360 ma thick) and oversize 2.431 ~ 2.487 me thick). The end clearance between the thrust balf- ings and the thrust surfaces of the crankshazt can ¢ measured as follows: + install an indicator on a magnetic support nd insert the blades of two screwdrivers as shown n Pigs 2-39; shift the crankshaft with the screwirivers nd note the indicator reading. It should be within .06 and 0.26 am. If the clearance exceeds the maximum permis. {ble Limit of 0.35 ma, replace the thrust halt- Inge by new ones 0.127 am oversize. Pig, 2-39. Checking Crankshaft End Clearance Woke. The end clearance of the cramkabaft can also be checked on the car-nounted engine using ‘tool 67.8701.9510. In this case axial dieplacenent of the crankshaft 18 produced by pressing and releasing the clutch pedal, and the end clearence is determined by measuring the displacenent of the crankshaft front end. QULINDER HEAD AND VALVE GEAR ‘The main dimensions of the cylinder head are ven in Pig. 2-40. wel [tnt ovo} idaed 33 7 45 “45°30's8 49°30"5" ig. 2-40. Beste Dimensions of Cylinder Head, Valves and Valve Guides e REMOVAL AMD INSTALLATION OW CAR-MOTNTED ‘BuGIME ‘he cylinder head should be removed from the ar-mounted engine if ite defects do not call for ne removal of the engine, algo whon the maintenance ork is confined to decarbonization of the conbus~ 28 ‘tion chamber and valve: head, proceed aa follows; = remove the spare whee: = drain the coolant from the radiator and eylinder block and remove the air cleaner; = @iscomect the wires from the storage battery, spark plugs and from the coolant tempera- ture tranmaitter; discomect the choke valve con- trol cable from the carburettor; = using wrench 67-7812.9514 unscrew the spark plugs and the coolant tenperature trananitter; = @iscomect the throttle valve control rods from the intemediate lever on the cylinder head cover and take off the cover; = tum the crankshaft to align the mark on ‘the pulley with the longer mark on the valve gear cover (Pig. 7-19), and the mark on the canshart sprocket with the mark on the camshaft bearing housing (Pig. 2-19 = Atacomect the hose from the heater inlet pipe and detach the heater outlet pipe bracket fram ‘the exhauat manifold; ~ @iscomect the hoses from the carburettor, intake manifold and fron the cylinder head cooling Jacket outlet pipes = @tacomect the starter protective shield and the muffler inlet pipe from the exhaust manifold; To remove the cylinderTt de good practice to leave the ex- aust and intake manifolds with the carburettor on the cylinder head. They can do removed later, when @isassenBling the cylinder head. = loosen the cap mut of the chain tensioner, force off the tensioner rod with e tyre iron and fix it with the cap suts = remove the conshaft sprocket and the bear ing housing complete with the camshaft; = tum off the cylinder head-to-block bolts and resove the cylinder head. Jo reinstall the cylinder head, reverse the removal operations, observing the following ‘requirenent: = do not forget to imsteli the gaskets of the cylinder head end its cover; = tighten the cylinder head bolts in the sequence shown in Fig. 2-16 and the nuts of the candhaft bearing housing studs, in the sequence show in Fig. 2-18. Mghten the cylinder head bolts in two step: tet step - tighten bolts No. 1 through 10 (Pig. 2-16) with a torque of 33.32 - 41.16 Nom Ge4 = 4.2 ketem)s = and step ~ tighten bolts No.1 through 10 with e torque of 95.94 - 118.38 Nem (9.79 = 12 kgf.m) and bolt Wo. 11 with a torque of 31-36 = 39-1 Rem (3.2 = 3.99 kef-m)- When installing the cylinder head cover with ite gasket, tighten the cover nuts with a torque not over @ Nem (0.8 kgf.) to avoid fracturing the gnaket at the fastening holes and wreping the cover, It 1s recomended thet the cover gasket should be replaced by a now one during engine re- paira. Having installed the cylinder head check nd time the ignition. DISASSEXBLY AND ASSENOLY put the cylinter head on plete A.60335- Disconnect the exhsust and intake manifolds complete with the carburettor (similtaneously the hot air inteke is removed). Disconnect the outlet pipe of the cooling Jacket. Disconnect the pipe conducting the coclant to the heater. Remove valve rockere 11 (Pig. 2-41) and take off their springs 12. ‘Looeen lockuuts 14, unscrew adjusting bolts 13 and their bushings 15. ‘Install tool £-60311/R compress the valve springs and Locks, Portable tool 4-60311/R stationary Jig 02.7823.9505+ Remove the valve springs with retainers and seats. Tum over the cylinder heed end take out ‘the valves from ite underaiae shown in Pig. 2-42, free the spring can be replaced by 264 Fig. 2-41. Valve Gear Parts: 1 = valve; 2+ locking ring; 3 - valve guide; 4 = oll-deflecting cap; 5 ~ outer spring 6 ~ tmer spring sont; 7 - inner spring; 8 - outer spring; 9 - spring retainer; 10 - rocker spring Jocks; 11 - valve rocker; 12 - lever spring; 413 = adjusting bolt; 14 - adjusting bolt lockmut; 15 ~ adjueting bolt bushing; 16 - rocker spring locking plate Pig. 2-42. Renoving Valve Springs: 1 = tool 4-60311/R; 2 - assembly plate 4.60335 Renove the oil-deflecting caps from the valve guides. Assemble the cylinder head by reversing the Aisanvendly operetions. CERANING CYLINDER HEAD Install the cylinder head on support 4.60353. Decarbonize the combustion chanbers and the surfaces of exhaust channels with a wire brush clamped on an electric @rill. Clesn and exanine the 26ilet channels and the of1 channele Ive rockers, nating to the CHRCKING AND GRINDING VALYE SEATS ‘The shape of the valve seat faces is {1]us~ mated in Piga 2-43 and 2-44. The seat faces (in the zone of contact with 1@ valves) should be free from pin-point pits, erosion and damage. Minor damage can be corrected ; grinding the seats. In so doing try to remove ag ‘ttle metal as possible. Grinding can be performed ‘ther manually or with a grinding machine. Pig. 2-43. Inlet Valve Seat Contour: I = new seat; II - refaced 0305 Pig. 2-44. Exhaust Valve Sest Contour: I = now seats II - refaced seat Grind the seats As follows: = put the cylinder head on support 4.60353, nsert spindle 4.94059 into the valve guide and scarbonize the seat faces with counterbores 194031, 4.94092 (exhaust valve seats) and 4.94003, .94101 (inlet valve seats) mould be secured on spindle 4.94058 and aligned by Hot spindle 4.940595 ‘the cousterbores Hote. Spindles 4.94059 are available in two ifferent dianeters: 4.94059/1 for inlet valve sides and 4.94059/2 for exhaust valve guides. = put spring 4.94069/5 on pilot epindie .94059, install tapered wheel 4.94078 (for exhaust ive seats) or wheel 4.94100 (for inlet valve sts) on spindle 4.94063, secure the spindle in 1¢ grinding machine and reface the valve seat Hee 2-45). 27 Pig. 2-45. Valve Seat Refacing Fig. 2-46. Chamfering Valve Seat Pace with Counter- bore Installed on spindle 4.94058 At the moment of contact between the grinding wheel and the valve seat the machine should be tumed off to avoid vibration which will distort ‘the oat face. Tt 12 recommended that the grinding wheel should be dressed frequently with diamond tool: Bring the width of the working face on the exhaust valve seats to the values specified in Pig. 2-44, using 20° coterbore 4.94031 and coun terbore 4.94092 which removes cold-norking on the inside diameter. The counterbores should be slipped on spindle 4.94058 and, like during the grinding, aligned by spindle 4.94053. Bring the width of the working face of the inlet valve seats to the values specified in Pig. 2-43, first muchining the internal face with counterbore 4.94003 (Pig. 2-46) to obtain a diane tor of 33m, then the 20° face with counterbore A.94101 until the width of the working face 1 1.9 - 2 mm.