Section II ENGINE ‘he longitudinel and cross sections of the engine are show in Figo 2-1 and 2-2. Pig. 201. Bugine. Longitudinal section2-2. Bngine cross Section O) SS ROUBLE. soorDNG conta omue anedy cause Remedy Tagine Paite to Start 4. Hos fuel in ca burettor: (e) fuel pipes oF carburettor and ‘fuel pump filters clogged, (>) fuel pump foulty 2. Ignition aysten snoperative 3. Carburettor choke valve remaing closed when starting engine (e) wash and airblest fuel tank end pipe filters (>) examine fuel pump end replace faulty parte 2, See Chapter "Ignition systext 3+ Eliminate poor tieht- ess of cazburettor choke mechani ‘Rngine Runs Wnevenly or Stalle When Idling 1. Wrong 421ing edjustaent ‘Adjust 1€1ing speed 2. Ady inteakage ‘through damaged drain pipe 3. Ady inleakage ‘through damaged hoot leading from intake manifold to brake vacuum booster 4. Ade tmleakage through gaskets in jointa between intake menifold and carburet~ tor or cylinder head 5. Wrong clearances between valve rockers and camshaft cams 6. Carvurettor fault: (e) carburettor 2. Replace rein pipe 3. Replace damaged hose 4. tighten up muts or replace gaskets 5. Adjust clearance: (a) atzblast jets andconta conta cause Re ay cause aaets, Jets or chames (c) choke atm diaphragn Leaky Ignition aysten alty channels (2) remove water from car varetter, drain sediment froa fuel tenk (eo) replace diaphragm 7. See chapter "Ignition systea" ‘Bugine Jacks Power and Pickup + Carburetor throttle 1. Adjust throttle valve lve open incompletely control Linkages 2. Air cleener clogged )+ Ignition systen faulty 4. Fuel pump tauity 5+ Carburetor feulty (a) acceleration punp defective (0) main jets clogged (e) choke valve opens incospie- ely (a) wrong fuel level in float hander 6. wrong valve rocker tovcam clearances 1. Boor compression, bev 1 Ma (10 Ket /en? (a) desective eylinder head gasket (2) buming of pistons, breaking or sticking of piston rings (ce) poor seating of valves (@) excessive wear of cylinders and piston rings Grankahart 2. Replace cleaner 61 ent 3, See under "Ignition Syotea" 4. Check pump performance and replace damaged parts (a) check pump capactty, replace faulty parts (2) atrblast jet (e) adjust choke valve Linkage (4) adjust carburettor fost setting 6, Adjust clearances (a) replace gasket (2) decarbonize piston ‘grooves and ring! replace defective rings and pistons (e) seplace faulty valves, reface seste (@) repiece pistons, rebore and hone cylinders och Ae a rule thie knocking ts of dull metallic nature, detects when the throttle valve 19 1, Spark advance angle ‘too carly 2, O42 pressure too 1. Adjust ignition timing 2. See "011 Pressure Too low Low at Idling Speed” 3. Loosening of fly- 3. Tighten up to specified wheel bolts torque 4, Excessive clearance ‘Yetween main journals and their bearing abelle 5. Excessive clearance vetween thrust balf- rings and crankshaft 4. Grind journale and replace shells 5. Replace thrust half- rings by new sné thicker Bigcind Bearing mock: Usually mocking of big-end bearings to sharper than that of the main bearings. It ie heard fat engine idling speed when the throttle valve is sharply opened. the origin of imocking can be easily Adentified by dtacomecting spark plug wires one after another. 1. Insufficient oft pressure 2. Recessive clearance vetween big-end jour nals and shells 1. See "O11 Pressure Too Low at Téling speed" 2. Replace dhelis and grind journals Piston Sepa Ae a mule it ie a dull imocking caused by eleckness of piston in the cylinder. It is best audible at a low engine speed and under © losd. 1, Excessive piston-to- cylinder clearance 2. Bxceastve piston ring aide clearence 1. Replace pistons, rebore and hone cylinders 2. Replace ringe or pio~ tons with rings Talve Enocks Excessive clearances in valve gear cause characteristic Imocks, usually with regular inter vals. Knocking frequency is lower than that of any other engine knocks, aince the valves are operated by the camshaft which rotates at half the crank- shart speed. 1, Rxceneive valve-to= 1 rocker clearances 2, Valve epring broken 3. Excessive clearance Detwoen valve stem and guide Adjust cloarences 2. Replace pring 3. Replace worn parte sharply opened at idling speed. Grows with increase of crankshaft speed, Excessive crankshaft end pley causes a sharper sound with uneven intervals moat conspicuous during gradual throttling up and dow 4. Woer of camshaft cams 5. Loosening of adjust- Ang bolt lockmut 4, Replace camshaft and valve rockers 5. Adjust valve rocker-to- cam clearance an ‘tighten lockaut. Conta conta Less uate Drive chain Nol The camsbart drive chain noise becomes noti- conble against the background of general engine noie in case of excessive clearonces between the chain and sprockets and it is particularly loud et ow angine speed. 1. Chain Decomes slack 1. Tension chain’ ‘through naturel wear 2. Chain tensioner shoe 2. Heplace tensioner shoe or damper broken, or damper 3+ Chain tensioner plum~ 3, Eliminate jaming ger rod jamming 041 Pressure too Low et Idling Speed of wom Bngine 1. Poreign matter get- 1. Clean valve of foreign ‘ting uder reducing matter and burrs, wean valve of of1 pump out of] pump 2. 012 pump gears worm 2. Repair of pump 3+ Breessive clearance 3., Grind journals and between crenkehert main replace shelle Joumala and bearing shells 12 Pressure foo High in Ham Engine 041 pump reducing Replace valve valve jamming Excessive 011 Conmumption 1. 012 Leaking past ‘engine seals 1, Tighten fastenings or replace gaskets ond glance 2, Wear of piston 2. Rebore cylinders and rings, pistons or replace pistons and ringe cylinders 3. Broken piston + Replace rings rings 4+ Gummed slots in 012 control rings or cutouts in piston grooves 5. Valve oil-deflecting 5. Replace caps cape worn or damaged 6. Heavy wear of valve stens or guides 4+ Remove carbon deponite from slots and cutouts 6. Replace valve oylinder head Exo tion 1s Choke valve faile to open completely 2. High resistance to car motion 1. Adjust choke valve Linkage 2. Check and adjust tyze presmre, brake aysten, front wheel aliganent 2+ Adjust ignition tining 3. Wrong tgnition tia ang Cause Renedy 4.7 Replace vacuum timer or Agaition distributor 4.¥ rgnition distribu ‘tor vacuum spark timer foulty 5. Carburetor fuel level too high: (a) carburettor needle velve or ite gasket leaky (2) look tor foreign Particles between valve ‘sont and needie; replace gasket or valve, Af necessaxy (2) Joming or () examine float and friction interfer- replace it, if necessary Ang with normal notion of floaty float Leaky 6. corburettor air 6. Clear up Jets dete clogsed Engine overheat 1. stackening of pump and altemator érive vert 2. lack of coolant sn cooling ayster 3. Wrong ignition tiaing 4 Radiator bearity sotted an oute 5. thermostat faulty 61 befective valve in radintor oap [opening preemure belo 0.05, Mee (0.5 ket/ea*)] 1. Coolant pump 1. Adjust bert tension 2. Add coolant into cool~ ing aysten 3+ Adjuat ignition timing 4. Clean radiator with Jet of water 5. Replace themostat 6. Replace cap T. Check, replace or foulty repair coolent pump id Drop of Coolant Level in Expansion ‘Penk 1, Radiator damaged 1. Replace or repair mediator 2. Damaged hoses or 2. Replace damaged hoses Pipe joint gaskets oF gaakets 3 Coolant leaking 3s Replace cock ‘from heater cock 4s Loosening of hose 4. Tighten up clamps clamps 5. Coolant leaks 5. Replace gland ‘through coolant pump giana 6, Radiator cap or ite 6. Replace cap gasket damaged 7. cylinder head gas- 7. Replace gasket kot danaged Defects relating to the engines with carburettor 2107-1107010-20.GE Place the car on a lift or inspection pit. je the hood. Take away the spare wheel and move its supporting tube. Disconnect the wires from the storage battery 1d from the engine-nounted electrical devices, Drain the coolant fron the radiator, cylin yr block and heater; for this purpose unscrew the juga on the LH, aide of the cylinder block and 1 the radiator bottom tank; shift the heater mntrol upper lever to the right (this lever pens the heater cock) and take off the caps from ne expansion tank and the radiator. Sion fo avoid danaging the radiator, unscrew the pein plug with one wrench and hold the plug union Sldered into the radiator with another. Preferab- @ socket or box wrench not to mutilate the move the fan shroud, first disconnecting te halves. Discomect the coolant inlet and out- nt hoses from the engine and take off the radia or complete with the themostat and ho Renove the air clemer, first discomecting ne howea, reaoving the cover and the filter eli ante n WAL, AND INSTALLATION Unscrew the mute which hold the muffler inlet pipe to the exhaust manifold. Detach the inlet pipe from the bracket on the gearbox and ease it down Detach the throttle valve control rod and choke valve cable from the engine. Disconnect the fuel feed hose from the engine and detach the hoses leid to the heater and vacuum brake boosters Using articulated socket wrench 02.7812.9500, tmecrew the bolts which hold the starter to the clutch houeing. Unscrew the bolts which Zesten the clutch housing cover to the lower part of the housing. Using articulated socket wrench 4.55035, tum off the clutch housing-to-cylinder block vorta, Suspend croas bean 1C0~3/379 trom a lifting tackle and sling the engine by the shackle instal- Led on the exhaust manifold front fastening stud fat the R.H. side and by the clutch housing fa ing hole at the Lell side. Tension the tackle chain a little, unscrew ‘the muta whick fasten engine front mount pads 3 (Pig. 2-3) to the side brackets and uscrew the nuts and the bolt which fastens the front axle housing to the engine brackets. ‘Take out the engine, first moving it upward to withdre the mount pad bolts from the bracket holes, then shift it forward 20 sa to pull the fend of the gearbox clutch shaft out of the bear ing im the crankshaft flange. Fig. 203. Engine Mount: 1 = Ru. mount bracket with pady 2 ~ LH. mount bracket; 3 - pad; 4 - engine rear mount crosauen- der; 5 - engine rear mount bracket with supportRemove the heat-insulating shield of the starter, the starter proper and the bot air intake complete with the inlet hose. Renove two side pracketsfrom the cylinder block complete with the engine front mount padi Unscrew the clutch fastening bolts and xenore the clutch. ‘fo install the engine rover ‘the removal Wash the engine on the washing stand, put it on the disassembly dench end drain the ofl sump. Disconnect the hoses and throttle valve control rod from the carburettor and renove the latter. Remove the fuel pump and ignition distribu- ‘tor; unscrew the spark plugs and the coolant ten- pereture trenmmitter with wrench 67.7812.9514. eke off the altemstor and coolant pump drive belt, remove the alternator and its bracket. Resove the coolant pump, discomecting the heater pipe from the punp and exheust manifold. Detach the coolant outlet pipe and the pipe conducting coclent to the heater an¢ renove then from the cylinder head. Using renover tool 4.60312 usorew and take off the of} filter with the gasket (Pig. 24). ‘Unscrew the ofl pressure and of] pressure warming lamp tranauitters ant renove their unions. Take off the crankease breather cover, the ofl guap and the ofl pump. Take off the retainer of the of] separator drain pipe and take out the crankease breathing of1 separetor. Remove the crankshaft pulley securing the ‘flywheel with fixing tool A.60330/R (Pig. 2-10) fend unscrewing the crankshaft starting Jono with wrench 4.50121 (Pig. 2-5)+ Renove the cylinder head cover and the cover of the camshaft chain drive, Unscrew the bolts of ‘the camshaft and oil pump drive shaft sprockets. 2c4, Removing O11 Filter with Reuover Tool 4.60312 by RB operations. Pay particular attention to the con- nection of the engine with the gearbox: the clutch uaft should enter accurately into the splines of ‘the clutch driven diac. Besides, for proper Alignment of the engine with the transfer cave, ‘the aligning washers of the engine front mount pede mst enter the corresponding holes in the side brackets. Pig. 2-5. Unscrewing Crankuhett Starting Jew with Wrench 4.50121 Pig. 2-6. Removing Chain Tensioner and Dampe: 1 = tensioner cap mut; 2 - tensioner boty; 3 = tensioner fastening nut; 4 ~ tmsioner shoe: 5 = ahoe bolt; 6 - camshaft drive (timing) chains 7 = of1 pump rive sbatt aprocket bolt; & - damper volte Loosen cap nut 1 (Pig. 2-6) of the chain ‘tensioner, mscrew nuts 3 which bold it to the oylinder head, remove the tensioner end, unscrewing volt 5, take off chain tensioner shoe 4.Pig. 2-10. Renoving Flywheel: + Removing Camshaft Thrust Plange: yt Flange; 2 - comshaft; 3 - bearing hous tarust flange fastening stud ~ thrust flange; 2 - flange bolt; 3 - of] pump avant; 4 = wrench Figs 2-9. Removing Crankshaft Sprocket with General-Purpose Remover Tool 4.40005/1/T 1 = wrench; 2 -flywheel; 3 - flywheel bolt; 4 = washer; 5 - fixing tool 4.60330/R to prevent ‘tuming of flywheel; 6 ~ clutch housing front cover Fig. 2-11. Pressing Out Gearbox Shart Bearing from Crankshaft with Reaover Tool 4.40006 Unscrew the chain limiting pin, take off the rive sprockets of the oil pump and camshaft and ‘take out the chain. Looten the nuts of studs 4 (Pig. 2-7). Take off the canshaft bearing housing. Unocrew the mute of etude 4, remove thrust flange 1 and take out the comshart taking care not to danage the surfaces of ‘the Dearing housing supports. Unscrew the cylinder head bolts and take off ‘the head complete with the exhaust and intake manifolds. Remove thrust flange 1 (Pig. 2-8) of the of1 Pump drive shaft and take the shaft out of the cylinder block.Ueing general-puxpo from ve} 4.40005, renove the sprocket from the ormksbart (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. remover tool 4.40005/1/7 ote. When Givassonbling the engine, nark the piston, connecting rod, main ond big-end bearing shells go as to install thom back where they belong during subsequent reassenbly. Install fixing tool 5 (Pig. 2-10), screw bolts 3, toke off washer 4 and pull the flywheel from the crankshaft. Renove the front cover of the eluteh housing. Using remover tool 4.40006, take out the gearbox clutch sbatt bearing from its bore in the erankebaft (Pig. 2-11). Remove the crankshaft glend holder. Unscrew the main bearing cap bolt ‘the caps complete with the lower shell: ‘the crankshaft, the upper shells and the thrust hmalf-rings on the rear support. toxe out BUGINE ASSEMBLY Put @ washed and cleaned cylinder block on the etand and screw in any alesing studs, Insert shelis without grooves into the bed td oap of the middle bearing; install shelte with grvoven into the romaining bearing beds and ca} ‘Hote. The engine cylinders, pistons and glends, Dearing sbelie and thrust helf-rings of ‘the crankshaft should be lubricated with engine ofl before installation. Flace the crankahaft on the main bearings and insert two thrust half-rings into the sockets of ‘the rear support (Pig. 2-12); the half-rings should be selected by thickness ae instracted under "Crankebatt and Flywheel", Install the main Dearing cape in accordance with their marke (Pig. 2013). ‘Contin Install the main bearing cops into the cylin der block where they belong. For this puxpose the Pig. 2-12. Installing Thrust ‘Support * Since 1966 lower shells of the main bearings without grooves on the inner surface are used. cylinder block and its bearing cops are marked with the same conventional number (Pige 2-13 and 2024). Instell the thrust helf-rings with their recesses facing the thrust surfaces of the crank- batt, the cteel-eluminius half-ring should be placed at the front aide of the rear aupport and ‘the ceremetallic (yellow) half-ring, at the rear nade. Put the gland holder gesket on the erankshatt ‘flange and insert the clutch housing front cover bolts into the holder holes (Pig. 2-14). Siip the holder with the gland on mandrel 41.78534011, ove it zon the mandrel onto the crunkshart Flange and fasten it to the cylinder block Insteli clutch housing front cover 6 (ig. 2-10) with the aid of two aligning bushings. Instell the flywheel on the. crankshaft with ‘the mark (tapered hollow) near the rim facing the ‘axis of the big-end joumml of Ho. 4 cylinder, lock the flywheel with fixing tool A.60330/R and bolt At up to the crankshaft flange. Using en inserter bushing from set 02.7854.9500, insert the pistons with comecting rote 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 (0.4 and 0.8 me oversize). Therefore, select the inserter bushing corresponding to the size of the piston being installed. 1 2 3 4 5 e| {a QC A lo) lo 2 i) \o) Yige 2-13. Marks on Main Bearing Cape (Dearings ‘are counted from engine front) and Cylinder Block Code Sumber2-15. Installing Piston with Piston Rings into yiinder with Piston Inserter Bushing from Set 2.7854-9500 + 2-16, Sequence of Tightening Cylinder Head Bolt See caution ‘he hole for the pin in the piston is offe / 2am, therefore the pistons ehould be installed to the-oylinder with the mark "Il" facing the eine trent. $e Put the bearing ahelle into the comecting ds and their caps. Join the connecting rods with 5 Pig. 2-17. ALigment of Timing Marke on Crankshaft Sprocket end on Cylinder Block Figs 2-18. Sequance of Tightening Camshaft Bearing Housing mite ‘the crankshaft journals, install the caps and tighten the comecting rod bolts. Install the sprocket on the crankshaft. Install the of1 pump drive shart and fasten it by ‘the thrust flang Using two aligning bushings install the cyline der head on the cylinder block compete with the gasket, exhaust and intake manifolds. Tighten the fastening bolts in two steps in the sequence shom in Pig. 2-16: ~ Hghten bolts 1 through 10 preliminarily with @ torque of 33.3 - 41.16 Nam (3.4 = 6.2 ke. ‘tighten bolta 1 through 10 finally with a torque of 95.94 ~ 118.38 Mm (9.79 = 12 kgfem) and bolt 11 with e torque of 31.36 = 39.1 me (3.2 ~ 3.99 gta). ‘um the flywheel so that the mark on the erankabaft sprocket registers with the mark on the cylinder block (Pig. 2-17). Install the sprocket on the canshaft aesenbi~ ed with the bearing housing and tum the shaft fo that the mark on the sprocket faces the mark on the bearing housing (Fig. 2-19). Remove the sprocket and, without changing the position of theZiss 2019. Aldgment of timing warts on canshart Sprocket and on Bearing Housing: Ts mark on sprocket; 2 - mark on bearing housing censhatt, Snetel the bearing housing on the gvlinder hea and fasten it by tightening the mute in the sequence shom in Pig. 2-18. Instell the chain damper on the cylinter head. 7 Put the chain on the camshaft eprocket ena Gove it into the drive space, seeing that the sark on the sprocket Lines up with the mark on the Dearing housing (Pig. 2-19). Do not tighten the sprocket bolt all the way hone, ~ anstall the sprocket on the of1 puap drive Saft, also without tightening the fastening bors completely; + install the tensioner ahoe and the ten stoner proper, without tightening the cap mut to allow the tunes: rag aoe, PE> B17) and on the Dearing housing (Pig. 2-19); = af the marks are in alignment, lock the penne) Tit Fixing tool 4.60330/m (Pig. 2-10), Lighien up finally the sprocket belts, the chasn Sentimer cap ut and 1ock the aproctet belts by Hee lock masberas 42 the marks f4i1 to coincide, Fepent the chain installation operations, Adjust the valve rocker-to-cen clearance: Mithout tightening the festening bolts ant mute st he way. Using mandrel 41.7853.4010, align the 16 cover relative to the end of the ora: Hghten up ite fastening bolts and m Inetell the crankshatt pulley az starting Jans, Install the of1 titer, soreming cylinder block union handtight. Insta separator of the crankcase breathing the breather cover and secure the ret 082 separator drain pipe. Tastell the of1 pump and the 0:2 ite gasket. Inetell the coolant pump, alter and altemator, Run the belt over the adjust ite tension. Anstall the heater radiator inlet ‘the outlet connection on the cylinder the heater radiator outlet pipe to the Pump end exheuet mini fold, Tnetell the gouge tranmeitters. Tnstell the of1 pump and ignition ative gear. Install the ignition distr: sdjust Sgnition tiaing. Screw in theo) and tighten then with torque-indicating 61.7812.9515, ‘Install the fuel pump as inetructe "Puel syetea", Install the carburettor and comec hoi Install the cylinder head cover wi: Ket and ruel line bracket, Install the air cleaner; for this; secure the hoses on the air cleaner body cleaner body with the gasket on the cost ametall the supporting plate and fasten with mts. Put in the filter element end the cleaner co PALI the engine with of2 through th ‘throat on the cylinder head cover. FAG: 2-20. Canshatt Drive Cover. Arrows Sh for Aligning cover with Crankshart Pulley 1nnn en rie rr lo le ee ES ee ENGINE STAND pES73 A repaired engine shall be subjected to stand tests (running-in) at no-load in accortance mith the following program: 2 min at 850 - 900 rpm 3 min at 1000 2pm 4 min at 1500 rpm, and 5 min at 2000 xpm. Walle rmning-in @ repaired engine do not operate it at miximm speed. Mount the engine on the stand, start 1t and check £0: = water and fuel leaks between the mating fron the pize Joints and past the gaskets; parta, If off leaks are detected past the gasket between the cylinder head and cover or past the gaskets between the engine of] sump, cylinder block and covers, tighten the corresponding bolts with the recomezded torque. If leakage persia check for correct installation of the gaskets and replace then, if necessary. ‘A repaired engine 19 not yet run-in, therefore friction of the working surfaces of new parte offers a considerable resistance to rotation; con- sequently, « certain working-in period ia required. Taio applies particularly to the engines where pistons, big-end and main bearings wore replaced, the crankshaft journals were ground and ‘the cylindere honed. Therefore, the rumming-in progres should always end on the car driven at the = abnormal mocking. speede recomended for the early stages of car In case of atnomal Imocking or other defects, operation. stop the engine, correct the defects and resume te sests BUGINE CHECKOVER OB CAR After installing the engine on the car check {t carefully for correct mounting. Bun tho engine for sone tine end check the following = oaks of coolant and fuel at the pipe Joints; tighten the joints, if necessary; = ofl Leeks; = see thet the carburettor contre) Linkage ensures complete closing and opening of the throttle and choke valves and adjust the Linkage, 4 necessary; = altemstor drive belt tension; adjust, if necessary; = see that the wire contacts of electrical equipment are in good condition; = check to see thet the waming lamps on the instrument penel function as they should. Caution Do not check the engine and the car on a stand with mumning druna without additional rol- lers under the front wheels ‘SeLTMDER sTocK the min dimensions of the cylinder block are dhe. im Pigs 2-21. Pig. 2-21. Main Dimensions of Cylinder Block GEWERAL CLEANING AND INSPECTION wh the oylinder block thoroughly and clean ‘the of] channels. Airblast and dry the cylinder Block, particularly its of1 channels. Bxamine the cylinder block and replace it, if cracked in the supports or elsowhere. ‘YLIMDER BLOCK TIGH®HESS CHECK If there 1s « suspicion that the coolant penetrates into the crankcase, the cylinder block can be checked for tightess on a special stant. Por thts purpose plug the holes in the cooling jacket and deliver water at room temperature under pressure of 0.3 MPa (3 kef/on’). ‘Mere should de uo water leaks from the cylinder Block in the course of 2 mine If off gots into the coolant, defore proceed~ ing to disnssenbling the engine check the oylinder bleck for cracks in the ofl chanel zones. Por this apurpose Grain the coolant from the cooling systen, remove the cylinder head, £112 the cylinder bleck cooling Jacket with water and deliver compressed sir Gato the vertical of1 channel in the cylinder Dieck. If air bubbles appear in the water filling ‘the cooling Jacket, replace the cylinder block. cylindere Check the cylinders for wear which should not exceed 0.15 mm (the maxim tolerable value). The cylinder bore is meamured with on inter~ nel gauge (Fig. 2-22) in four sones, both along and across the engine (Pig. 2-23). Ring gauge 67-8125.950149 used to set the intemal gauge to Figs 2-22. Measuring Cylinders with Internal aug! 1.~ internal gauge; 2 ~ seroing internal gauge by check gauge ‘he cylinders in the block are divided into five diameter ¢ 4, B,C, Dand Ein steps of 0.01 mm. The class of the cylinder 19 marked on the lower face of the block (Fig. 2-24). The same face and the main bearing cops bear a conventional number of the cylinder block which indicates that the bearing cepe belong to this particuler block. ee In zone Wo. 1 the cylindera practically do not wear, so this zone may de used as 0 reference one for determining cylinder wear in other three Fig. 2-23. Cylinder Measurement Diagram: 4 and B ~ directions of monsurements; 1, 2, 3, 4 ~ sone mmbere Pig. 2-24. Cylinder Block Marked with Cylinder ‘Size Group (Waite Arrows) and Cylinder Block Code Musber (Black 4z708) If the maximum wear exceeds 0.15 mm, b—~ the oylinders to natch the nearest repair size u. the Piston (0.4 oF 0.8 m= oversize) with an 0.03 am Llowance in dianeter for honing. Then hone the cylinders to the diameter providing the designed clearance between the piston of the selected. repair sise and the cylinder equal to 0.06 ~ 0.08 CYLDIER HEAD JonNENG SURFACE ‘The upper face of the cylinder block may be Atetorted. therefore, check this murface with straightedge and a vet of fecler gauges. Place the straightedge on the diagonals of the cylinder block fand in the middie, both lengthwine and crosewise. If the surface 18 out-of-true by more than 0.1 mm, Feplace the cylinder block.1S_ AND CONNEC! Ds The main dimensions of the comecting rod end piston group are given in Pig. 2-25. as fas) (ae iis) (1835) (8 E Lee by the dinmeter of the piston pin hole. the ott of the piston (letter) and the category of the pi: ie r lO Te Te 51339 eaee ee Pig. 2-25. uain Dimensions of Piston, Comecting Rod, Piston Pin and Piston Rings PRESSING OUP PISTON FDI ‘The piston pin should be removed on « prei using driver 4.60308 and a support with @ cylin- drical hollow to receive the piston. Take care to renoe the piston rings before driving out the piston pin. ‘The removed parts can bo reused if they are but slightly worn and wdamaged. Therefore, mark the parts during disassenbly 20 as to reassenble then in the original sets. cumasrss Renove' carbon deposite from the piston crom nd ring grooves and clean the lubricating channels f the piston and connecting rod from all deposite. Baamine the parts thoroughly for probable mage. Cracks of any nature on the piston, piston ings, pin, comecting rod and its cap are imper- igetiie and call for immediate replacement of @_ Replace the bearing shells if they ore eeply sorstched or heavily wom. PISTON-T0-CYLINDER MATCHING The designed clearance between the piston and ylinder (for now parts) 18 0.06 - 0.08 mm. The learance is determined by measuring the cylinders na pistons and fitting the pistons and cylinders longing to the sane class. The maximum clearance caused by wear) should not exceed 0.15 mm. ‘Wate. the diameter of the pistol tv checks he plane pexpendicular to the piston pin at a Setance of 52.4 mm from the piston crom Pig. 2-25). ‘The pistons are divided into five classes (A, , C, D and 8) by the outside dianeter, in 0.01 mm tepa and into three categories, in 0.004 mm steps 19 ton pin hole (figure) are indented on the piston Tf the clearance in « used engine exceeds 0415 um, select the pistons to the cylinders to provide the clearance aa close to the designed value as possible, Delivered for spares are pistons of classes 4, Cand Z. These classes pemit matching the piston to any cylinder as both the pistons and cylindera are divided into classes with a certain overlapping of dimensions. ‘Tho piston pin i pre end of the connecting rod with an interference and ia free to rotate in the piston bo: Hote. With respect to the outside diameter the piston pins are divided into three categories in ¥ig. 2-26. Pieton Pin Should Go in Under Thumb PressureFig. 2-27. checking Piston Pin Pit otepe of 0.004 ma. The category to marked by paint on the end of the pin: blue fer the tet category, green for the 2nd one and red for the 3ni category. The fit of the piston pin in the piston 12 checked by coating the pin with engine of1 and Aneerting it into the piston boss. the ft 18 con sidered correct if the pin enters the hole maér ‘tmumd pressure (Pig. 2-26) and does not fall out of ‘the boas (Pig. 2-27) of the piston held with the Pin positioned vertically. If the pin slides out of the boss, use 8 replacement pin of the next larger category. If, however, the pin belongs to the Int category, doth-the piston and the pin mst be replaced. (CHECKING PISTON-TO-RING CLEARANCE The side clearance of the piston ringe should be measured ae shows in Fig, 2-26, inetal- Ling the ring into the corresponding groove. The assenbly clearance should be 0.045 ~ 0.077 am for the upper compression ring, 0.025 = 0.057 mm for the 2nd compres Fig. 2-20. checking Piston Ring Side Clearanct 1 ~ piston ring; 2 - piston; 3 - set of feeler enuges 20 ‘and 0,020 - 0.052 mm for the oil contrel ring. me wear Limit 16 0.15 mm. Mhe ring Joint gap should de checked with a set of focler gauges, inserting the rings into gauge whose inside diameter 1s equal to the nomi~ nal diameter of the ring, true to 0.003 mm. ‘Me gep should range from 0.25 to 0.45 mm for all rings. File off the jointing murfaces of the ring if the gap {0 insufficient and replace the Fing, if it fe too big. (CHECKING BEARING SHELL~T0-CRANKSHAPE cunARaNcES. ‘The clearence between the bearing shells and ‘the crankshaft Journals can be checked by caloule- ‘tions (by measuring the parts) or with a piece of calibrated plastic wire in the following onder: = clean thoroughly the working wurfaces of ‘the shell and big-end Jounal and install the con- necting rod with the piston on the big-end journal, im accordance with their numbera; = put a piece 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 Nam (5.2 kefem); = resove the cap and determine the flattening of the wire (Pig, 2429) against the scale on the wire packing, thus finding the clearenc If the clearance is within the tolerance 1i- inits (0.036 ~ 0.086 aa) or dove not exceed the wear Limit (0-10 mm), the shells may be used without changing the dianeter of the big-end journal. If the clearance exceeds the 0.10 ma wear Limit, use replacement shells (able 2-1) and grind the big-end journals to the repair size specified under "Crankshaft and Plywheel". Fig. 2-29. Measuring Width of Flattened Calibrat- ed Wire against Seale: 1 calibrated wire; 2- abel; 3 - big-end dear ing cap: 4 - scaleTable 2-1 Matclnese of Connecting Rod Bearing Shells, = Oversize Wominal 0.25 | 050 | 0.75 1.0 113 «1.048197 —«2.098 2.223 4.730 1.855 1.980 2.105 2.230 Figures 0.25, 0-50, etc. indicate the reduc ‘thon in the dianeter of the big-end journals after grinting. CHECKING PISTON MASS ‘he pistons in the engine should be of the seme mses, true to 42.5 g- If a aot of pistons Delonging to the sane nase group 42 not available, they can be adjusted for mass by removing some motal from the base of ‘2 deton pin bows as show by arrows in Pig. 2.30; However, the metal mat not be reaoved deeper than 4.5 mn relative to the nominal height of the piston (59.40 mm) while the removal of metal in width should be linitea by a diameter of 70.5 ma. e RS < Pig. 2-30. Points (Show by Arrows) Where Metal Can Be Removed to Equalize Piston Weights 59.4 34,9 ASSEMBLING COMIECEING ROD AND FISTON cRouR Qo provide for an interference fit of the piston pin in the mall end of the connecting rod, heat the latter to 240 °C for expanding ita mali end. Por this purpose place the connecting rods into an electric oven. Ie the oven has already been brought toa teaperature of 240 °C, hold the connecting rods there for 15 ain, Por correct jointing of the pin with the connecting rod, press in the pin as rapidly as possible, since the comecting rod cools quickly after which the position of the pin will be tmpoaidle to change. Jo prepare the piston pin for assembly put it on shaft 1 (Pig. 2-31) of tool 02.7853.9500. Pit guide 3 on the end of this shaft and secure it 2-31. Tool 02-7853.9500 for Prese-Pitting Piuton Pin into Piston and Connecting Rod Bnd: {= tool shart; 2 - piston pin; 3 - guide; 4 ~ thrust screw Vig. 2-32. Prese-Pitting Piston Pin into Connect- ing Rod Suall End: 1 = tool 02.7853.9500; 2 - piston pin. Te piston should rest on comecting rod end as shom by arrow with screw 4. Do not overtighten the sorew to avoid seizure due to heat expansion of the pin caused by contact with the hot comecting rod. Take the comnecting rod out of the oven and clamp it quickly ine vice. Put the piston on the connecting rod, aligning the pin hole in the piston with the hole in the anall end of the connecting rod, Using tool 02.7853.9500, push the piston pin into the piston bogs and into the connecting rod smell end (Pig. 2-32) until the shoulder of the tool cones in contact with the piston, During this operation the piston boss should be pressed against the mall end of the comecting rod in the direction of the force applied for prese-fitting the pin (show by arrow in Fig. 2-32). Tn thie way the piston pin will occupy ‘the correct position. Caution ‘The piston ond comecting rod should be Jointed so that the mark "II" on the piston is Located at the aide of the of] outlet hole in the connecting rod big end.Alow the comecting rod to cool dow and Aubricate the piston pin with engine of1 through ‘the holes tm the piston bos ‘When installing the piston rings, space their Jointe at 120°. te step on the onter surface of the 2nd (scraper) compression ring should be Airected dom and the chanfore on the outer gur- face of the oil control ring should face upward (rig. 2-25). The connecting rod is machined jointly with the cep and the caps are not interchangeable. In order not to confuse then during assembly, the con- necting rod and the corresponding cap are marked with the number of the oylinder they belong to. During assembly ee that the figures on the comnect- ing rod and cep are located on the eane aide. uECEING PrstoN FIN PIT After assembling the comnecting rod with the piston pin and piston check the pin fit with @ torque-indicating wrench and tester 4.95615 as fellows: = cleap tester base 4 (Fig. 2-53) ine vice land instal the piston pin-connecting rod assembly on Sty = lower indicator bracket 8, insert threaded spindle 3 into the pin hole and move it into the piston boss until spindle head 2 thrusts agsinet ‘he end of the pin; = serew mut 5 on the end of the spindle and draw up the nut against the support to take up the clearances, if any; = Lift indicator bracket @ to « horizontel Position, secure it by handle 7 and set dowel 1 of indicator 9 on heed 2 of the spindle inserted into the pin; a Fig. 2-33. Asseubled Pieton-Pin-comecting Rod Group Installed on Tester 4.95615 for Pin Pressing out test “1 = indicator dowel in contact with end of spindie; 2 ~ spindle head in contact with piston pin; 2 = threaded opindie with slot; 4 - dase; 5 - spindle mut; 6 - spindle atop; 7 - bracket Clamp handle; © ~ indicator bracket; 9 - indicator 2 ES ae oo = set the indicator to zero and insert etop 6 into the slot of the threaded spindle to keep the latter against tumings = using a torque-indicating wrench, tighten spindle nut 5 with a torque of 12.7 Nam (1.3 kgf. which corresponds to an axial loed of 3.92 iat (400 kee). The fit of the pin in the comecting rod ia correct 1f, after withdrawing the torque wrench and returning the mut to the initial position, ‘the indicator pointer retums to sero. It the pin lips in the comecting rod mall end, replace the connecting rod by a new one. CHECKING CONNECTING ROD BIG END AD PISTON PIN AXES POR PARALLELISM Before installing an asseabled connecting rod ané piston group on the engine, check their axes for parallel alignment (Pig. 2-34). ‘To check align the connecting red big end (without bearing shells) on exteneitie blades 2 and put gauge 4 on the piston crom. Using a set of feeler gauges check the clearance between the vertical plate of the jig and the vertical surface of the gouge at a distance of 124 mm from the corner or the upper end of the gauge, depending on whether it contacts the plete by the comer or the upper ena. Me clearance should not be over Ov4 ste Replace the connecting rod 1 the clearance is larger. Pig. 2-24. Checking Axes of Piston Pin and Con~ necting Rod Big End for Parallelian: 1 = anseabled comecting rot-pih-piston group; 2 = extensible blades; 3 - thrust bar; 4 - gouge‘The main dimensions of the crankshaft are ven 4m Pigs 2-35+ Au PLM) out-of-squarenese of the flange end surface relative to the crankshaft aris; with the crank- ea Pig. 2035. Main Dimensions of Crankahatt Main and Big-Bnd Joumels end Pillete CLEANING UJERICATING CHAMIBIS Remove the channel plugs. Run counterbore 1.94016/10 fitted on spindle 4.94016 through the piug sockets. Rash the channels thoroughly with gasoline and blow then with compressed air. Install new pluge with the aid of driver 4.86010 and lock-punch then at three points for higher reliability. CRANKSHAPY MAI AND BIO-END JOURIALS Checking, Put the crankshaft on two Y-blocks (Mix, 2-36) ond using & dial indicator, check: = mmout of the main journals which should not exceed 0.03 me: = nimout of the seating surfaces for the sprocket and the gearbox clutch shart bearing; the moximm permiesible runout 18 0.04 mm; = Gleplaceaent of the big-end joumel ex relative to the plane passing through the axes of ‘the Dig-end and main Joumale; the maxima permis atble Aisplacenent is 40.35 mm; Vig. 2-36. Permissible Runout of Crankshaft Basic Surta shaft rotated, the indicator installed at the side, 24 m from the shaft axis, should reed runout not exceeding 0.025 mm (Pig. 2-36)+ Mere eboulé be no cracks on the main and dig-end journals and webs of the crankshaft, otherwise the crankshaft. should be replaced. ‘The surfaces of the crankshaft mating with the active edgea of the glands should be free fron scratches, scores and nicks. Measure the diametere of the main and big-end Journala. Grind the journals if their wear exceeds 0.03 mm or out-of-roundness is greater then 0.03 mm ‘and alec if the Journals are scored or notched. Grinding. Grind the main and big-end journals reducing their size by 0.25 am to provide the Asanetere specified in Tables 2-2 and 2-3 and Journal fillet radii as shom tn Pig. 2-35. eble 2-2 aaa Uadersize 35 25 [050 [075 | 1-0 wrote 56h AT.B1h «4.064 46.014 47.834 41.584 47-334 47.004 46.834 a Atter grinding end finishing the joumals, wash ‘the cronkshazt thoroughly to renove the remaining abrasive particles. Wash the lubricating channels , several tines with gasoline under pressure first 23ae Ee mabe 2-3 Dimmeters of Main Joumale, m= aay Vadereize ‘The nominal designed clearance 12 0.050 - 0.095 mm. If the clearance is less than the maximum pernineibie limit (0.15 sm), the shelle say de used again. If the clearance exceeds the maximum permissible Limit, replace the shells on the [ees T oso | 0.75 [100 50.775 50.525 50.275 50.005. 49.775, 50.795 50.545 50.295 50.045 49.795, Femoving the channel plugs. Mazk Ke. 1 web of the crankshaft with the figure showing the reduction of he Joumal size (4 0.25; BB 0450). ‘The out-of-rouéness and taper of the main and Digrend joumals efter grinding should not be over 0.007 am. WAIN BEARING SHELLS The shell mst not be mubjected to any £it- ‘ting operstions. Tn case of acores, scratches and separations, they should be replaced. Check the shell-to-journal clearances as follows: = put a piece of calibrated plastic wire on ‘the journal ~ install the main bearing caps complete with the shelle and tighten the cap bolts with a torque of 00.36 Hm (8.2 kgf.m) 7 Fenove the caps, find the anount of flatten ing of the calibrated wire against the scale provide ed on ite packing (Pig. 2-37), thus determining the slearance. ‘The clearance between the main Journals and Donring shells can also be found by calculations, ‘measuring the dieneters of the main joumale and shell beds, and the thickness of the shells. Pig. 297. Monsuring Clearance with Seal 1 = scale; 2 - calibrated wire Journals with new ones. If the crankshaft journsis ‘are wom and regroud to a repair size, replace the shells with repair size ones (cf increased thick 1 08 Table 294). Unobstructed tuming of the crankshaft te an indication of correct assexbly and joumal-to-shell, aatebing. Table 2-4 Mhiciness of Main Bearing Shelle, =m ay Oversize 025 | 0.50 | 075 | 1.0 Tee 1.949 2.078 —2.199 ~~ 1.831 4.956 2,081 2.206 2.331 ‘The figures 0.25, 0.50, otc. denote the reduc tion in the diameter of the main Joumale after grinding. PIXEL Bsamine the teeth of the flywheel ring gear; replace the flywheel if they are damaged. ‘The flywhee! surfaces mating with the orank- shaft and the clutch driven diac should be perfectly flat and free from scratches and corse. If surface 3 (Pig. 2-38) of the flyweel mat- ing with the clutch driven dise is scratched, tum, it ona lathe, cutting off not more then 1 mn of metal. Then machine surface 2 to provide a size of (0.5401) am and parellelim of surfaces 2 and 3 relative to surface 1. the permissible non- parallelism is not over 0.1 mm as measured at ex- trese points of surfaces 2 and 3. Pig. 2-38. Plywhee! 1 1 = flywheet-toncrunkshaft flange festening surface; 2 - clutch mounting surface; 3 - oluteh driven ive mpporting surface; B - point for checking runout of surface 2; © = point for checking runout of wurtace 3 ByInstall the flywheel on a mandrel, aligning it y the mounting hole until it bears againat aurtace (Pig. 2-38) and cheok the mout of surfaces 3 nd 2, The runout read by the indicator at pointa B nd © should not exceed 0.1 um. (CHECKING CRANKSHAPD END CLEARANCE ‘The ond play of the crankshaft 19 Limited by vo thrust half-ringe installed at both sides of no rear main bearing. The helf-ring at the front ide of the bearing i of the stool-aluminiun type, mile that at the reer aide is e ceranetallic yellow) one. The half-rings are available in sminal size (2.310 = 2.360 mm thick) and oversize 20437 = 2.487 ma thick). The end clearance between the thrust balf- ings and the thrust surfaces of the crankshaft can ¢ measured as follow: = Snatall an indicator on 2 magnetic support nd insert the blades of two scremdrivers as show nhs 2-394 shift the crankshaft with the sorewirivere nd note the indicator reading. It should be within .06 end 0.26 me If the clearance exceeds the maximum perati (ble Limit of 0.35 mn, replace the thrust balz- Inge by new ones 0.127 mz overaiz Fig. 2-39. checking Crankshaft Bnd Clearance Woke. the end clearence of the crankehatt can also be checked on the car-nounted engine using tool 67.8701.9510. In this case axial aisplecenent of the crankshaft to produced by pressing and releasing the clutch pedal, and the end clearence ie determined by measuring the dieplacenen? of the crankshart front end. CYLINDER HEAD AND VALVE GEAR ‘The main dimensions of the cylinder heed are iven in Fig. 2-40. Sy (ER) GS) BS RS ARR) ass 7 4s aS, “45°30"s 4s Fig. 2-40. Besto Dinensions of cylinder Heed, Valves and Valve Guides 5 REMOVAL AND INSTALLATION ON CAR-MOUNTED axCDE ‘The cylinder head should be removed from the ur-ounted engine 4f ite defects do not call for ne ronoval of the engine, also whon the maintenance ork 19 confined to decarbonization of the combu 28 ‘tion chamber and vaiv head, proceed = rezove the spare wneel; = drmin the coolant from the mediator and oylinder block end remove the air cleaner; = disconnect the wires from the storage battery, spark plugs and from the coolant tenpera- ture tranaaitter; discomect the choke valve con- trol cable from the carburettors = using wrench 67.7812.9514 unscrew the spark plugs and the coolant tenperature tranamitter; = @isconnect the throttle valve control rods from the intemediate lever on the cylinder head cover and take off the covers = tum the crankshaft to align the aark on ‘the pulley with the longer park on the valve goar cover (Pig. 7-19), end the mark on the comshatt sprocket with the mark on the camshaft bearing housing (Pig. 2-19); = dtacommect the howe from the heater inlet pipe and detach the heater outlet pipe bracket from ‘the exhaust manifolds = disconnect the hoses fron the carburettor, Intake manifold and from the cylinder head cooling Jacket outlet pipe; = dtecomect the starter protective ahteld and the muffler inlet pipe from the exhaust manifold; fo renove the cylinder 2 follows:ae ote. Tt de good practice to leave the ex aust and intake manifolds with the carburettor on ‘the cylinder head. They can be removed later, when Aseassea¥ling the cylinder head. = loosen the cap nut of the chain tensioner, force off the tensioner rod with a tyre iron and fix it with the cap nut; = remove the canshaft aprocket and the bes ing housing complete with the camshaft; = tum off the oylinder bead-to-block bolts and renove the cylinder head. To reinstall the cylinder head, reverse the removal operations, observing the following requirenents: = do not forget to install the gaskets of the cylinder head ond its covers = tenten the cylinder head bolts in the sequence shown in Pig, 2-16 and the nuts of the conshaft bearing housing studs, in the sequence show in Fig. 2-18. Tighten the cylinder head bolts in two steps: tat step ~ tighten bolts No. 1 through 10 (Pig. 2-16) with @ torque of 33.32 ~ 41.16 ¥. (3d = 402 keto; = 2nd atop - tighten bolts No.1 through 10 with a torque of 95.94 - 118.8 Ham (9.79 = 12 kgf.m) and bolt Wo. 11 with « torque of 31-36 = 39-1 Hem (3.2 = 3.99 ket). When installing the cylinder head cover with ite gaaket, tighten the cover nuts with a torque not over 8 Wm (0.8 kef-n) to avoid fracturing the gasket at the fastening holes and wraping the cover. It is recomended that the cover gasket should be replaced by a now one during engine re~ pairs. Having installed the cylinder head check and tine the Sgnttion. DISASSEXBLY AND ASSENBLY But the oylinder head on plate 4.60335. Disconnect the exhaust and intake manifolds complete with the carburettor (simltaneously the hot aiz intake is removed). Discamect the outlet pipe of the cooling Jacket. Disconnect the pipe conducting the coolant to ‘the heater. Remove valve rockere 11 (Pig. 2-41) and take off their springs 12. ‘Loosen locknuta 14, unecrew adjusting bolts 13 and their bushings 15. ‘astall tool £.60311/R compress the valve springs end Jocks. Portable tool 4.60311/R stationary Jig 02-7823-9505+ Remove the valve springs with retainers and boats. tum over the cylinder head and take out ‘the valves from ite underside. shown in Pig. 2-42, free the opring can be replaced by 2 Fig. 2-41. Valve Gear Parti 1 = valve; 2 = locking ring; 3 - valve guide; 4+ oitederiecting cap; 5 - outer spring seat; 6 - imer spring seat; 7 - imer spring; 8 - outer apring; 9 - spring reteiner; 10 - rocker spring Jocks; 11 - valve rocker; 12 - lever spring; 13 = adjusting bolt; 14 - adjusting bolt Lockmt 15 = adjusting bolt bushing; 16 ~ rocker spring docking plate Fig. 2-42. Renoving Valve Springs: 1+ tool £.60311/R; 2 ~ assembly plate 4.60335 Remove the ofl-deflecting cape from the valve guises Assenble the cylinder head by reversing the Ateassendiy operation: (CLEANING CYLINDER HEAD Install the cylinder head on support A.60353+ Decarbonize the combustion chambers and the surfaces of exhaust channels with a wire bruah clasped on en electric drill. Clean and exanine the 28ilet channels and the ofl channels leading to the ive rockers. CuBOKING xm GRODTNG YALE sEAns ‘The shape of the valve seat faces is 411us rated in Pige 2-43 and 2-44. ‘The seat faces (in the gone of contact with 1@ valves) should be zee from pin-point pita, yrrowion end dannge. winor danage can be corrected / grinding the seats. In 90 doing try to renove az ttle metal as possible. Grinding can be performed her manually or with @ grinding aachine. 1 I I= new goats II - refac i OU15-207 Pig. 2o44. Exhaust Valve Seat Contour: I= now seat; I - refaced seat Grind the seate Ae follows = put the cylinder head on support 4.60353, asert spindle 4.94059 into the valve guide and scarbonize the seat faceo with counterbores .94031, 4.94092 (exhaust valve seats) and 4.94003, .94101 (inlet valve seats). the couterbores mould be secured on spindle 4.94058 and aligned by Mot spindle 4.94059; ote. Spindles 4.94059 are available in tro ifferent Aianeters: 4.94059/1 for inlet valve sides and 4.94059/2 for exhaust valve guid = put spring 4.94069/5 on pilot spindle .94059, install tapered wheel 4.94078 (for exhaust Jive seata) oF wheel 4.94100 (for inlet valve sats) on spindle 4.94069, Hig. 245). 27 Pig. 2045. Valve Seat Refacing. Fig. 2-46. chantering Valve Seat Pace with Comter- bore Installed on Spindle 4.94058 At the moment of contact between the grinding wheel and the valve aeat the machine should be tumed off to avoid vibration which will distort ‘the seat face. Tt {9 recomended that the grinding wheel should be dressed frequently with diamond tools. Bring the width of the working face on the exhaust valve seats to the values specified in Pig. 2-44, using 20° comterbore A.94031 and com- ‘terbore 1.94092 which removes cold-morking on the Ameide diameter. the counterborea should de slipped fon spindle 4.94058 and, like during the grinding, aligned by spindle 4.94059. Bring the width of the working face of the Amlet valve seats to the valueo specified in Fig. 2-43, first auchining the internal face with counterbore 4.94003 (Pig. 2-46) to obtain a diene ter of 33 am, then the 20° face with comterbore A.94107 until the width of the working face 1 1.9 = 2 mmvawvas Renove carbon deposits from the valves. check to see that the valve stem ie not distorted and ‘the valve head is not cracked; replace the valve Af 1¢ de found to be damage Look for excessive wear and danage of the working face. When refacing the valve on the grinding machine, ensure a face angle of 45°30"45 and see that the eylinaricel part of the valve head 18 not thinner than ‘0.5 mm after grinding. Take care not to renove the hard alloy coating from the face of the exhaust value, VALVE GUIDES Check the clearance between the valve guides and the valve stem, measuring the dieneter of the ston and the hole in the valve guide. ‘The assenbly clearance for new guides ie 0.022 = 0.055 mm (inlet valves) and 0,029 - 0-062 mm (exhaust valves). The maximum wear lint 19 0.15 am. If the guide-towvalve clearance is too big and cernot be eliminated by replacing the valve, replace the valve guides with the aid of mandrel 4.60153/R (Pig. 2-47). Fig. 2-47. Pussing Out Valve Ouides: 1 = mandrel 4.60153/8 fo replace two guides of the inlet and ex- heust valves in cylindere No. 1 and Ko. 4, unscrew two stude of the censhaft bearing housing since ‘they interfere with the installation of the mandrel. Drive in the valve guides complete with the locking ring mtil the latter comee to bear against ‘the surface of the cylinder head. Having presset-in the guides, ream out their holes with reamora 4.90310/1 (inlet valve guides) fend 4,90310/2 (exhaust valve guides). Then grind ‘the valve seat and bring the width of the working face to the required dimensions specified above. YALVE, GUIDE OY1-DEPIECTING CAPS Im the ofl-deflecting caps there should be no parations of rubber from the metal,no cracks and heavy wear of the working edge. During engine repaire it 0 recomended that ‘the caps should always de replaced by new ones. Replace the danaged of1-deflecting caps hav- ing removed the cylinder head not to bend the valve atens. To press-fit « new cap use mandrel 41.7853.4016. VALVE ROCKERS Examine the active surfaces of the rocker which ore in contact with the valve stem, the can- shaft can and the sphericel end of the adjusting soren. Replace the rocker if these surfaces are scored or notched. If the rocker adjusting screw or its bushing is distorted or damaged, replace the faulty part. vauve sPRINeS. Make sure that the eprings are not cracked and have not lost their resilience. Por thie pur- pose check then for deformation under load (Pigs 2-48, 2-49, 2-50). Dimension A (Pig 2-50) of the rocker springs (non-compreaved) sbould be 35 mm and dimension B under a load of 51 = 73.5. (5.2 = 7.5 kef) should be 43 mm. {282 15 x96) 7 | s| 61223 K9F 33,2 29,1 si cy 26,12 4 xgf Wig. 2-49. bain Data for Checking Valve Inner Spris Wigs 2-50. Checking Valve Rocker Spring: A = free length; B- length under a loadCYLINDER HEAD GASKET ‘The surfaces of the gasket should be free rom any signs of danage. Taey should be amooth, ree of dents, cracks, swelling and fractures. eparation of the outer layers from the metal is spormiseibie. The edgings of the holes burns and separations, should have no rack CHBCIGNG VALVES FOR TIGHT SEATING Clean carefully the seats and valves and watall the cylinder head on support 4.60353 rg. 2-51). 2051. Checking Valves for Tight Seating: = Bolder A.60041/2; 2 = tester 4.60148; 3 - sup- ort 4.60353; 4 ~ stopper 4.60018 for spark plug ells Inert the valves into the corresponding guides and stop the wells for the spark plugs with str—ere 4.60018. Set tester 4.60148 in the position shown in Pig. 2-51 and, pressing the lever hard, keep fore~ ing in the air with d rubber bulb until the pre: gure gauge reads 50 kPa (0.5 kgt/en"); there should pe no pressure drop within 10 5, Tf the valve faces fail to be in tight con tact with the seats, air leakage will be indicated dy the pointer moving tonards the sero division. If 80, grind again the valve face and the seat in the eylinder head with due care. Tight seating of the valves can also be check~ ed by pouring kerosene into the inlet and exhaust chambers of the cylinder head. There should be no kerosene leaks through the valves im the course of 3 mine CYLIWDER HEAD TLGENYESS TEST ‘% check the cylinder head cooling jacket for ‘tightness by water proceed a follows: = imetall the parts of tester 4.60334 (Pig. 2-52) on the cylinder heads = keep forcing water under a pressure of 0.5 MPa (5 kgt/on®) by the pump into the cylinder head. ‘There shall be no water Leaks from the cylin Ger head within two min, A cracked cylinder head ust be replaced. To check the cylinder head for tightness by ‘conpresced air proceed as follow = install the parts froa the act of tester 4.60334 on the cylinder head; = dip the cylinder head in water heated to 60 ~ 80 °C and let the hoad warn up for 5 min; = deliver conpressed air at a preamire of 0.15 = 0.2 MPa (1.5 - 2 ket/em®) into the cylinder head. Mere should be no air escape from the head during 1-145 aim. Fig. 2-52. Checking Cylinder Head for Tghtness on ‘Tester 1.60334: 1, 2, 4 = blank plugs; 3 - tester plate; with water inlet unton 5 ~ flange ‘SAMSHAPS AND DRIVE, me main dimensions of the camshaft and cen shaft bearing housing are given in Pig. 2-53, while Pig. 2-54 {llustzates @ section through the cylinder head and block across the inlet valve. ADJUSTING CAM-TO-ROCKER CLEARANCE Adjust the clearances on @ cold engine, having first adjusted the timing chain tension. after ‘adjustment the clearance should be"0.14 to 0.47 mm o-008/ 006 “ + 29 Proceed as follows: = tum the crankshaft clockwise until the mark on the camshaft sprocket gete in line with ‘the mark on the Dearing housing which will corres pond to the end of the compression stroke in Ho. 4 cylinder. Im this poattion adjust the clearance of ‘the exhaust valve in Ho. 4 cylinder (8th can) and fm the inlet valve of Yo. 3 cylinder (6th cam);00] 8005] Feg7o0 lab Th s] fas 5.35 las 0 6 s—L A I 7 4 8 Fig. 2-54. Cylinder Block ant Head. Section Through Inlet Valve: 4 = oylinder head; 2 - valve; 3 - spring; 4 ~ valve lever; 5 - bearing housing; 6 — camshaft; 7 ~ adjusting bolt; 8 = belt lockmut A = rockex-to.can clearance = loosen the locknut of the rocker adjusting Borts = insert flat feoler gouge 4.95111, 0-15 mm thick, detween the rocker and the camshaft cam and tum the bolt in o out with © wrench, securing Table 2-5 Sequence of Valve Clearance Adjuetment Gramkanart | nd of compression [umber of edjue rotation, | stroke in cylinder | od valves deg. (cane) ° Band 6 160 4nd 7 360 4 and 3 540 5 end 2 30 in Camshaft Bearing Housing Pig. 2055. Checking Rocker-to-Cam Clearance, 1 = feoler gauge 4.95111; 2 ~ adjusting bolt; 3 = adjueting bolt lockmat ‘the bolt by the loclmut until, with the lockmut Hghtened, the feeler gouge goes in with @ alight areg (Pig. 2-55); ~ having adjusted the clearance in the ex- oust valve of No. 4 cylinder and inlet valve of No. 3 oylinder, tum the crankshaft each tine through 160° and adjust the clearances in the sequence specified in Table 2-5. ADJUSTING CHAIN TENSION Loosen tensioner nut 1 (Pig. 2-56). Thia will free spindle 3 and the chain will be tensioned by shoe 7 (Pig. 2-57) which ie acted upon by spring 8 (Pig. 2-56). ‘tum the crumkshart 1-1.5 revolutions in the nomnl direction. The tensioner opring which actuates the hoe will automatically set the prope chain tension. Tighten tensloner mut 1; ao a result, spindle 3 will be clamped by the collete of retainer 9 05 = plunger spring; 6 - washer; > plunger; 8 - spring; 9 - retainer; 10 - spring 6 Vig. 2-57. Camshaft ond Accessory Drive Disgran, 1 = cansbatt sprocket; 2~ chain; 3 - chain damper; 4 - of pump drive sprocket; 5 - crankshaft sprocket; 6 ~ liniting pin; 7 - teneloner shoe; 8 ~ chain tensioner that on the runing engine plunger 7 will be loade y spring 5 alone. This spring forces the plunger ff the head of spindle 3 and the clearance between the two is filled with ofl on the muming engine, this ofl functioning as « shock-absorbing medium uring chain ispacts, Due to a guaranteed clearance of 0.2 - 0.5 mm etwoen spindle 3 and plunger 7, in case of strong bain impacts spring 6 starts functioning too. CHECKING CAMSHAP? nicka, seratehes and aluminium galling fron the bearing housings are not tolerable on the canshart journals. Wear exceeding 0.5 am on the working surfaces of the cams, and scored and faceting are not tolerable. Put the conshaft with ite extreme journal on ‘two Y=blocks placed on a surface plate and check radial runout of the middle joumals with an indi- Gator. The rmout should not exceed 0.04 mm, other- wine the canshaft should be trued up on & otrmightening press. ‘Tote. the care tumed out before 1962 were fumtshed with camshafts whose cams were induction hardened. Since april 1962 the camsbafte with nitrided cons aro inetalled. Since 1984 each shaft bears the mark of the year of its manufacture. Since 1985 sone cars are furnished with the cam shafts with chilled cena. These canshafts are dis~ tinguished by @ nex belt between the To. 3 and Not CHECKING CAMSHAPD BEARTNG HOUSING Wash and clean the canshaft bearing housing and the of2 chamels. Check the dieneter of holes in the oupports. Ig the clearance between the camshaft journals and aupporte exceeds the 0.2 mm wear limit, the bearing housing should be replaced. The internal supporting surfaces should be smooth and free of scores. Replace the housing i these surfaces are danaged. Examine the housing for cracks and replace it, sf oxmcked. CHAIN TENSIONER Dissssenbly and assenbly. To disassenble the chain tensioner renove cap nut 1 (Pig. 2-56), retainer 9 ond spring ring 4, then take out plun- ger 7, spring 5 and spindle 3 complete with ‘spring 8 and washer 6. ‘Zo reaaseable reverse the disassenbly procedure. Inspection. See that retainers 9 and spindle 3 are not scored end the mating surface: of the shoe and plimger are free of deep notches. Replace any damaged part: “a Pig. 2-58. Main Data for Checking Tensioner Spring 15206n98)Me resilience of the tensioner spring should be within the Limits indicated in Pig. 2058. Replace the spring if it is weak. Inopect the shoe and damper for heavy wear end replace then, if necessary. CAMSHAP? DRIVE CHATS Wash the chin in kerosene and exanine ite Links. The rollere and sideplates should be free ‘from chipping, cracks end other kinds of danage. The chain te apt to decane atretehed in sem vice. Tt te considered nerviceable if the tensioner is capsble of ensuring its adequate tension, i.e. when the chain is stretched by not more than 4 mms Check the stretching of the chain on a device equipped with two rollers 1 (Pig. 2-59) for in- stalling the chain, Stretch the chain with a force of 294 W (30 ket) then elacken it to 147 ¥ rig. 2-59. chain wear (stretching) Check Diagram: te roltere (15 wg), repent Doth operations and neamze datance 1 between the Peller axee, Por a new chain distance 1 detwoen the roller oxen $0 (495.3¢0:9) sms Replece the chain if 14 6 Htretohed to 49903 mms Before installing the chain on the engine coat it with engine ofl. ‘COOLING SrsrmN of the cooling aystem is shown in 0 $6 Pig. 2-60, Cooling Systea: 1 = body heater radiator inlet and outlet ho 2 = outlet connection; > ~ expansion tank; 4 = radiator top tank; 5 - radiator cooling fins; 6 = tans 7 ~ radiator bottom tank; 8 - pump drive belt; 9 = coolant pump; 10 ~ themontet CHECKING COOLANT IEVEL AMD SPECIFIC cRaviTE The quantity of coolant in the cooling syaten is checked by the Liquid level in the expansion tenk. On a cold engine (15 - 20°C) the level should be 3 - 4 cm above the "MIHY mark on the expansion tank. sion It 18 good practice to check the coolant level ono cold engine since the volume of heated coolant increases oo that its level ine hot engine may rise considerably. If necessary, check the specific gravity of coolant with « hydrometer, It should be 1.078 - 1.085 g/en? for TOCOE 440M Liquid used in the VAZ If the coolant level in the expansion tank is lower than prescribed and its specific gravity 1s too high, add sone distilled water. If the speck~ fie gravity 1s normal, add some coolant of the grade contained in the aystes Ie the specific gravity of the coolant 19 lower than prescribed for the oold season, take care to replace it with a proper grade. PILLING COOLING SYSTEM Asa mile, the cooling system is fi110d either when the coolant has to be changed, or after engine repairs. to £111 the eysten: = remove the radiator and expansion tank capa and open the heater cocks OQ ————————= pour 10.7 2 of coolant into the radiator; cep pouring until the liquid starts flowing from ne radiator throat; then replace the radiator cap; = pour the remaining coolant into the expan- ‘on tank end put in place its caps + mm the ongine idle for 1-2nin to enove any air pockets. Allow the engine to cool dow and recheck the polant level. If it drops below the preacribed ark and there are no leaks in the eysten, add up he required amount of coolant. ADJUSTING PIMP DRIVE BELT TENSION me tension of the belt should be checked by suring its deflection between the alternator and mp pulleys or between those of the pump and erank- naft. The tension is considered correct when flection A of the belt (Pig. 2-61) under a force t 98. (10 kgf) 19 within 10 - 15 mm and defiece jon Bis from 12 to 17 am. Zo tenston the belt loosen the altemator 1s” ag nuts, push the altemator away from the gine and retighten the nuts. Fig. 2-61. Checking Pimp Drive Belt Tension cooLame PUMP Disassenbly Mo Atsaezenble the pump: = detach the pump body from cover 2 (Pig.2-62) = secure the cover in a vice using gaskets and ake the impeller fron the shaft with remover tool 40026 (Pig. 2-63); = remove hub 2 (Pig. 2-64) of the fan pulley ron the sbaft with remover tool A+40005/1/55 = tum out lock screw 9 (Pig. 2-62) and take ut the bearing with the pump shaft; = pull gland 11 out of body cover 2. Inepection Check the end play of the bearing. mis opera fon 1s andatory when thy pump was very noisy in peration. The clearance should not exceed 0.13 am 89m 1 C OS 6 5 4 32 1 44201 Fig. 2-62. Coolant Pump. Longitudinal Section: 1 = bodys 2 ~ cover; 3 ~ fan shroud bracket; 4 = fans 5 ~ pulley bub; 6 ~ cover plate; 7 ~ shafts 8 - pulley; 9 - bearing lock screw; 10 = bearing; 11 - gland; 12 - impeller Fig. 2-63. Removing Pump Tapeller: 1 remover tool; 2 - impeller under @ load of 49 (5 kgf). Replace the bearing Af the clearance is larger. Tt is good practice to replace the pump gland ‘and the pump-to-cyLinder block gasket during repairs. ‘Examine the pump body and cove: be no distortions and cracks. Assembly ‘To aosenble the pump: = using @ mandrel install the gland without cocking into the body coversSimecteit Pig. 2-64. Removing Pulley Bub: 1 = pump body cover; 2 ~ pulley bub; 3 - remover toot Pig. 2-65. Installing Impeller on Pump Shaft with ‘Tool 4.60430: 1 = support; 2 - pump shaft; 3 ~ pump body cover; 4 = sleeve; 5 - setting screw = @rive in the bearing with the shaft into the cover, seeing that the lock screw socket i in line with the hole in the pump boty covers = tum dn the bearing lock screw and lock- punch the socket along the contour to prevent the sorew from working loose; = using installation tool 4.60430 (Pig.. 2-65) force the pulley hub on the shaft ensuring « dimen- sion (84.430.1) mm. Tf the hub ss made of ceranet, only @ new bub should be pressed on; = press-fit the impeller on the shaft with snotalletion tool 4.60430, ensuring « clearance of 0.9 - 1.3.mm between the impeller blades and ‘the pump body; = aseemble the pump boty with the cover, in~ stalling the gasket in between. 34 sumuosma? check the tenperature at which the themostet mein valve starte opening end meamure the travel of the w Yor this purpose place the thermostat on © 1o-106-000 tend, immersing it nto « tank with ater of coolant. ouch the indicator rod bracket ageinat the totton of mein valve 9 (Pig- 2-66). The initial teaperature of the Liquid in the tank should be 73 ~ 75 °C. Reise the liquid tem- perature gradually at the rate of 1 °C per minute toproxinately, etizring the 1ighi4 constantly 20 to obtain inifom temperature throughout ite vote. ‘he tenporature at which the valve starte opening 4a the texperature at which the travel of the main valve reaches 0.1 ax. Replace the thermostat if the temperature of the beginning of opening of the main valve ts otner than (0042) °C [(8242) °C for the velve of PM production)], or the valve travel 1a shorter than 6.0 mm. the winplest check of the thermostat can be rade directly on the oar. Haring started « cold engine, handafee1 the radiator; if the themostat ia in omer, the bottom tenk of the redistor should start getting wamer wien the pointer of ‘ihe coolant temperature gnige i sbout = 4 ma from the red zone on the scale, which corresponds ‘to 80 - 85% \ 8 2 109 67 Pig. 2-66. Thenostat: 1 = Anlet comection (from engine); 2 - bypass valve; 3 - bypass valve spring; 4 - sleeve; 5 - rubber insert; 6 - outlet conection; 7 - main valve epring; 8 ~ main valve 9 = main valve; 10 = holder; 11 - adjusting mut; 12 ~ pistons 13 = Amlet comsction (from radiator); 14 - filler; 15 - case; D ~ coolant from engine; P - coolant from radiator; H - coolant to PumpRADIATOR Removal from car To reaove the radiator from the car: = take away the spas supporting tub = drain the radiator and the cylinder block by removing the drain plugs from the radiator botton tank and the cylinder block; open the heater cock and remove the radiator filler cap; wheel and rezove its on, To avoid danaging the radiator, unscrew the drain plug of the botton tank with one wrench, applying another one to the plug union acldered into the radiator. Unscrew the plug with a socket or box wrench to prevent mutilation of the plug f = Atscomect the coolant hoses fron the radiate = remove the fan shroud, first separating its halve: unscrew the radiator-to-ear body bolts end take the mediator out of the engine compartaent. Mahtese Tost ‘The radiator can be checked for tightness in a water bath. Flug the radiator comections, feed in air at 8 pressure of 0.1 MPa (1 kgf/ca®) and dip the radia. ‘tor into the water bath for at least 30 5. There should be no air bubbles, Minor leaks can be corrected by soft-solder- ing; a heavily danaged radiator should be replaced by a new one. WBRICATING syssmx ‘the design of the lubricating oystea t6 wom in Pig. 2-67. Wig. 2-67. Lubricating systen: 1 = chanel to fe0d of1 to main bearings 2 ~ chamel to feed of] from main bearing to big-end Dearing: 3 ofl pump by-pase valve; 4 - paper filter e: ment; 5 - antidrain valve; 6 ~ off pump; 7 - chennel ‘to feed of] from pump to filter; 8 - borisontal ‘hamnel in cylinder block to feed of} from filter 38 to main of] Line; 9 - chamed tn cylinder block to feed of to pump and ignition Q Atetributor drive gears 10 ~ channel to feed of to ofl pump and ignt~ ‘Hon distributor drive abatt; 11 ~ of] pump and Agaition distributor drive shaft; 12 - chamel in driven eprockst to feed off to chain; 13 - came shaft; 14 ~ ciroular groove on middle supporting journal of canshaft; 15 ~ channel in camshaft cam; 46 = channel in camshaft mupporting Journal; 17 = vertical channel in cylinder block to feed oft to valve goer 10 - main ofl Lines 19 ~ electric oft pressure trenmitter and of] presmure waming Leap trina tterREPLACING OIL Change the ofl while the engine is stil hot. Wait at east 10 min after opening the drain Bole to provide for complete drainage of ofl. Watle replacing the oil be sure to replace the of2 filter too. Tt con be renoved with the aid of remover 4.60312 (Pig. 2-4). Install the filter by screwing 4¢ in hand ‘tient. very 30000 in of nm wash the lubricating 2; ten with BHWIHN-6] of1 in the following order: = stop the engine, drain the used of} ana, without removing the oil filter, pour in the deter gent of2 BHIIHN-@ to the "MEH" nark on the of] @ipetick (2.9 1); = start the engine and mm it at the minimum dle speed for 10 min; + drmin all detergent o11 and remove the old of fiiter; = install © new of1 filter end pour in fresh lubricating of1 of the grade muited to the season. or: PUM The main @imensions of the of] pump and its artve are given in Pig. 2-68. ae) [ay im] (el (eaner | em tion} Lea rao] [Aa ‘hose| [aso Disassembly ond Assembly Clamp the pusp in a vice taking care not to Ganage the body and do the following: = unscrew the bolte and renove the intake con- nection complete with the ofl reducing valve; = renove pump body cover 3 (Pig. 2-69) and ‘take the pusp shaft with the drive gear, then the ariven gear, out of the body. ‘to assenble clanp the pusp cautiously in & vice and proceed as follows: = metal the drive gear with the shart into ‘the pump body and slip the driven gear on the axle in the bodys = install the body cover, the reducing valve with the spring and fasten the intake conection to the pump body. Tote, The gears im the assembled pump shoulé rotate moothly and without jaming when the rive shart 49 being tumed by band. ‘Ghecking Pump Pi Wash 11 parts of the dissesendled pump in Kerosene or gasoline and blow the with compressed P= i [isove | mt He = te (ee) ian Ragu Pig. 2-68, Basie Dimensions of O11 Pump and Drive Renova) end Instalietion If the of] pump alone has to be repaired, renove the engine from the car (aee "Engine Removal"), mouit it ona tumover stand, drein of from the engine sump, tum over the engine and remove the of1 emp. Then unscrew the of pump fastening bolts and take off the pump complete with the intake conection, % install the puap reverse the removal opera tone. 36 air; tien examine the pump body and cover; replace any cracked parts Using © set of feeler gauges, check the clearances between the gear teeth, also between the gear tips (outeide dtmeters of the gears) and the pump body walls (Fig. 2-70) which should be, respectively, 0-15 xm (maximm permissible 0.25 m) and 0-11 ~ 0.18 mm (maximum permissible 0.25 mn). If the clearances exceed the permissible lintt: replace the geara or, if necessary, the pump body tooe EEE2-69. Dionasembling O11 Pump: Mdueing valve; 2 ~ spring; 5 - Shatt Pigs 270. Guecking Radial Clearance in OL1 Pump Using a feeler gauge and a straightedge (rig. 2-1), check the clearance between the gear faces and the surface of the body; this clearance snould be 0.066 - 0.161 sm (maximum permissible 0.2 mm). Tf the clearance is larger than 0.2 mm, replace the gears or the pump body, depending on whichever is wom heavier. Measure the parts to detemine the clearance detween the driven gear and its axle. It should be (0.017 = 0.057 am (wear Limit being 0-1 mm). Besides, measure the clearance between the pump shaft and the bore in the body. This clearance sould be 0.016 = 0.055 mm (maximum pernissible ‘0.1 mm). If the clearances cxosed the limits, replace the wor parts. 37 Pig, 2-71. Checking Axial Clearance tn Of} Pump Checking Redueing Valve Then repairing the of} pump, tal examine the reducing valve. Pay attention to the condition of the valve and body surfaces since dirt or deposits on the mating surfaces may cause jan ming. The mating surfaces of the valve should be free fron nicks and burre which may decrease pres- sure in the system. Check the valve spring for resilience against ‘the date given in Pig. 2-72. care to Fig. 2-12. Basic Date for Checking Reducing Valve Spring OTL PUMP DRIVE SUAP? AND GEARS ‘The shaft joumala and the active surface of ccomtric should be free fron denta and notches. me teeth of the ofl pump and ignition aistri~ butor drive gears should not be chipped, otherwise replace the defective shaft or the gear. the OTL PUMP DRIVE SHAFT BUSHES check the inside @iemeter of the bushes, their f4t in the bores and alignnent of the ofl hole in ‘the front bush with the chamel in the cylinder dlock (tuming of the bush). Te inside surface of the bushes should be mooth and free of scores. Measure the diemeters of the chaft and bushes and determine the clearances betwoen the bushes and ‘the bearing surfaces of the shaft. If the clearancethe shaft bushes, rea both of then jointly with the aid of reaner 4.90353. OTL PUMP DRIVE GEAR BUSH Check the bush for reliable prese-fitting in ‘the bore. Replace the bush if ite inside surface 48 rough and scored. ‘to foree the bush in or out use driver 4,60326/R (Pig. 2-74). After prese-fitting ream out the bush to 16.016 = 16.037 mm ¥1g. 2-73, Renova and Installetion of of) Pump Drive Shaft Bushes: 1 = driver 4.60333/1/2 exceeds the 0.15 mm wear Lint fare damaged on the aurface replace them by new one: Both installation end renovel of the bushes should be performed with driver A.60333/1/2 (Pine 2412), observing the following requirenenta: = the bushes must be preso-fitted into their Dores so that the oi2 hole in the front bush is Lined up with the lubrication channel in the cyline Aer blocks leo if the bushes jooue in the bores, er press-fitting the bushes must be Fig. 2-74. Pressing Out Of1 Pump and Tenition Dis- finished to the exact inside Ainneter (for dimensions tributor Drive Gees Bush: see Pig. 2-69). fo ensure perfect exial alignnent of 1 = driver A,60326/R CRMNKCASE BREATHING syst WaSEIKG wash the systen disccnnect breathing Roses 4 and 8 (Pig. 2-75) trom the connections, teke flane arrester 5 out of hose 4, remove breather cover 3 and wach then with gasoline oF kerosene. Tt te elo necessary to wash the cerburettor — Fig. 2075. Crankcase Breathing System: A end B ~ operation of carburettor fune val\ ‘at low (A) and high (3) crankshaft apecda; 1 = of1 separator drain pipe; 2 - of2 separators 3 = breather cover; 4 - gas dramout hose; 5 ~ flame arrester; 6 - drawout manifold; 7 - air cleaner filtering element; 8 - crankcase fume recirculation 9 = primary throttle valve shaft; 10 - fume 11 = fume vaive groove; 12 - calibrated unitfuse valve and the air cleaner spaces end connec tions which conduct the aram-out gaat Since 1967, crankcase fune rectreulation hose 8 is laid to reach of separator 2. USL sysre ATR CLEANER fo remove the air cleaner take off its cover, Lift out the filter element, ungcrew the fastening nute (Pig. 2-77) and remove the cleaner body with the gasket. Yow discomect the hoses. Yuen installing the air cleaner take care to position ite cover properly. In sumer (at tem peratures above +15 °C) put the cover ao thet blue mark A (Pig. 2-76) ts in line with black arrow 3. In winter (at temperatures below +15 °c) set the cover to align ved mark B with the arrow. Fig. 2-77. Renoving Aix Cleaner. Arrows Show Cleaner-to-carburnttor Pastening mute 39 FUEL PM ‘The design of the fuel pump appears in Fig. 2-78. check: Insufficent mupply of gascline to the car- durettor may be caused by come fault of the fuel Pump oF by clogging or danage of the fuel lines. o identity the cause of the trouble aiscon~ nect the hose from discharge connection 1 and work hand-priming lever 8 to see whether the fuel to igs 2-76. Aix Cleaner: 1 = nut; 2 - cleaner cover; 3 - indicating arrow; 4.- mumer oir intake; 5 ~ cleaner body; 6 - winter warm air feed hoses A ~ biue mark SUIOMR (ETO); B - red mark WINTER (SIDA) aupplied at all. If not, atsconnect the hose from suction conection 4 ant check for vacuum built up at the outlet of this comection. If vacuum 1s created, the trouble should be traced to damaged Line; 42 not, the pump {2 at foult. Disassembly, Inspection and checking of Parte %o disassenble the pump unscrew the bolt of cover 5, ronove the cover and filter 2. Ten tum, out the screws fastening the body to the lower cover, detach these parts froa each other, take out ‘the @iaphraga unt and the spring Wash ali parts in gasoline end blow then with compressed air. check the condition of the pump springs. Look for probable jeming of the valves. Bxa- mine the diephragas. Tey ahould be free from cracks and age-hartening. Attor inspection replace all worn or damaged parte by new ones. The punp gaskets mst always be16 15 O Oo 13 rs 9 Mes 2-78. Fuel Pump: 1 10 1 = dtocharge comection; 2 - filter; 3 - boty; 10 = eccentrics 11 = rocker; 12 - operating lever; 4-= suction comection; 5 ~ cover; 6 ~ suction 13 = lower cover; 14 ~ inner spacer; 15 -outer epacery valve; 7 ~ rod; 8 - hand-prining lever; 9- spring; 16 - aiecharge valve replaced by new ones; before installation, coat then Pump. Using fixture 67.7834.9506 meamure distance ¢ with @ thin layer of lubricant. (the minimum protrusion of the pump pushrod deter mined by slowly tuming the crankshaft). If distance Installation of Pum @ ie withsn 0.8 - 1.3 mm, secure the pump on the engine; if it Se meller then 0.8 m, replace Correct installation of the fuel pump will be ensured by using two of the following three gaskets; S#SHS* B BY Gaskes A; if Giswnce @ is larger Shan emer aes aae 1.3 my, replace gasket B by gusket C. Recheck aist- Sr oite 1 ole an mien ‘ance d and secure the pump on the engine. Reaember eae 2450 an mnie, ‘tet the cylinder block and the heat-inmlating ee faieeeta ca vaee aastee cg str ea spacer should alwaye be separated by gasket A. proceed as follows. we, Install the heat-ineuleting spacer on the ae cylinder block, putting gasket A in detwoen, and Repoval end Installation Place gasket B on the spacer surface contacting the ‘% remove the fuel tank from the car: = unscrew cap 6 (Pig. 2-80) of filler pipe 9 and drain gasoline; = remove the reer seat, tum off the fastening screws of the R-H. and I.H. Linings of the wheel arches and remove the R.H. Linings = tum off the fastening screws and resove the cover of the fuel tank compartment; = remove the hoses which comect the fuel tenk with the filler pipe, éiscomect the wires ‘and hose from the fuel level trananitter, unscrew the fastening bolts and remove the tank. Yo install reverse the removal operations. Cleaning and Inspection Pigs 2-19. Dingrem for Checking and Adjusting Remove the fuel level tranmitter, wash the travel of Pump Drive Pushrod: tank with geaoline to remove sedinente, Then wash A= gasket 0.27 - 0.33 ma thick; B- gasket it with @ stream of hot water end stean-treat it 0.70 = 0.80 mm thick; 4 ~ pushrod travel to renove remmants of gasoline. 401g. 80. Puel Tank and Piping: = fuel tank; 2 ~ hoses 3 = fuel level transmitters = fuel pipes 5 ~ fuel pump; 6 — caps 7 - gaskets ~ filler pipe seal; 9 = tiller pipe; 10 ~ connec ng hoses; 11 = vent hoses; 12 ~ seal ‘Bxamine the fuel tank closely along the joint ake sure there are no leaka and, if necessary, rt-aolder the leaky point. cantion Soldering 1 permitted only on a thoroughly shed tank containing no gasoline fumes which may {9 nite during soldering. 8 1 ‘caRBURE?IOR te 1980 the YAz-2121 cars had been equipped th varburettors 2106~1107010. This mumber 1s at on the lower flange of the carburettor body. Beginning from 1960 the VAz~2121 cars are tted with carburetors 2107-1107010-20 jointly ch the ignition distributer type 30.3706-02 121=3706010-10) which incorporates a vacuum ark timer, However, sone of the cara may be ovided with carburettor 2107-1107010-10 Jointly th a conventional igition distributor (without e vacuum spark timer). On these carburetors the ber 1s given on the nameplate secured to the xburettor cover. . : Me carburettor 2106-1107Q10 19 of the emul- on double-barre! downdraft type. It incorporates balanced float chaaber end a systen for drawing ¢ exankeaoe gaoee into the after-throttle space rankease fume recirculation systea) (Pig. 2-81). @ idling syston bas heated zone of the rottle valves and an electromagnetic valve of the a 1615 14 y 13 12 Fig. 2-81. Carburetor Main Metering Systen and Beonostat (econostat atomizer 18 in carburettor secondary barrel. In this disgran it is show being located in primary barrel) 1 = econostat emision Jet™ 2 - oconcatat emulsion channel”; 3 ~ main metering systea air Jet; 4 = econostat air Jet; 5 - econostat fuel Je, 6 = needle vaive; 7 - Float pivot; 8 - needle ball; 9 = float; 10 - float chamber; 11 - main fuel Jet; 42 = equleion well; 13 ~ emision tube; 14 - prinary ‘throttle valve shaft; 15 ~ fume valve groove; 16 ~ fume valve; 17 ~ larger venturi; 18 - maller venturi; 19 - atomizer at ™ yot provided on carburettor 2106-1107010 SSS)9 6 7 6 § Pig. 2-62. Idling Systen of Carburetor 2106-1107010: 1 = atr jet; 2 - sbutofr valve; 3 - fuel chamels 4.~ emilaion well; 5 - throttle valve housings 6 ~ primazy throttle valve; 7 - screw-adjusted hole; 8 ~ progression holes; 9 - throttle valve housing nesting channel; 10 - adjusting screw; 11 - emulsion channel; 12 - additional air adjusting screw; 13 ~ carburettor upper body 4 2 3 4557 8 a 8 ar 0 i 4 fe 6% 8 2 Tt Pig. 2-83. Choke Mechaniem ond Linkage of Carburet= ‘tore 2106-1107010, Diagramatic: 1 = choke control levers 2 - choke valve; 3 = carburettor primary barrel air hora; 4 - rod; 5 ~ choke mechanian red; 6 - diaphrege; 7 - adjust ing screw; 8 - space commmicating with after ‘Yhrottle space; 9 - telescopic link; 10 - primary throttle valve adjusting screw; 11 - throttle valve opereting lever; 12 - sector; 13 - primary throttle valve shaft; 14 - lever on primary throttle valve daft; 15 - secondary throttle valve shaft; 16 ~ necondary throttle valve; 17 - lever: 18 - carburettor body; 19 - levers 20 - rod Pig. 2-64. Acceleration Pump. Diegramatic: 1 = delivery ball valve; 2 ~ atomizer; 3 - fuel enamel; 4 - bypaas jet; 5 - flost chamber; 6 = acceleration pump operating sector; 7 - operat ing lever; @ ~ pump retum spring; 9 - diapbregs cups 10 = pump diaphragn; 11 ~ inlet ball valves 12 = gasoline vapour chamber Pig. 2-85. Secondary Throttle Valve Operating Mechaniam of Carburetors 2107-1107010-10 and 2107=1107010~20: 1 = pneumatic actuator Jet in primary barrel venturi; 2 - throttle valve operating levers 3 = lever rigidly linked with primary throttle Yeave shaft; 4 - secondary throttle valve opening Limiting levers 5 - pneumatic actuator jet in secondary venturi; 6 - lever spring-connected witt lever 9; 7 - secondary throttle valve shaft; 8 - pneumatic actuator rod; 9 - secondary throttl: valve operating lever; 10 - vacuum channel to pneumatic actuator; 11 - xod bushings 12 - second: ‘throttle pmoumatic actuatorignition distributor (without vacuum spark timer) must be replaced by the ignition distributor type 30-3706-02 with such timer. ‘The calibration date of carburettors are tabulated below. Adjustaent of Bagine tale speed a yi 1 9 2 ret 1 1s 8 i a a % gi! 7 WUT 6 coe oa Ps 2-06, Idling System of Carburetors 210)~1107010~10 ana 2107-1107010-20: 1 ~ throttle valve housing; 2 - prinary throttle valve; 3 ~ progression holes; 4 - screw-adjusted hole; 5 - air inlet channel; 6 - idle speed adju ing screw; 7 ~ idle mixture adjusting screw; 8 = idling system emulsion channel; 9 - additional air adjusting screw*; 10 ~ carburettor upper body; 11 ~ dling system air jet; 12 - shutoff valves 13 = 4aling system fuel channel; 14 - emulsion well * mstalied on sone carburettor sduing sot im the primary barrel (Pg. 2-82). A ayaten of levers envures the suscensive opening of ie tarettie velven; the choke valve bea @ Scaphraga-type mechanisn for starting © cold exr'ne (Fig. 2-29). A Aaphonga-type mechanseai2y- o; sted acceleration pump (Pig. 2-04) supplies fel snto the prinary Darvel. Bis carburettor 2167=1107010-19 is dtstin~ gutsued by dizzerent celibretion data (aoe Zable 2-6), provision of an enrichment device (econoetat), pneunatically-cperated secondary throttle valve (tg. 2-85) and a nodssied idling aysten (Pig 2.06). tere 19 no heating of the throttle zone tn these carburettors. ‘the carhurettor zi07-1107010-10 ie fully dnterebangeabie with the 2106-1107010 model end can be installed on the cars manufactured before 1900, She carburettor 2007=1107010-00 ateters free the 21OT-MOTO10-10 noded by éizterent dienctere of sone Jets and a provision of pipe for feed- ing vacuum to the iguition distributer vacuum spark tiner. Mie carburettor cen be used instead of 2106-11070%0 carburetors on the care tumad out before 1960. However, in thie case the conventional ve 4. The Ldle speed adjuating elenents (Pigs 2-87 and 2-88) include air-fuel ratio (idle mixture) adjusting screw 2 and mixture quantity (idle speed) najusting screw 1. To prevent the Omer fron interfering with the factory setting of the carburettor, serena 1 and 2 of carburetors 2107-1107010=10 and 2107-1107070-20 (only serew 2 of carburettor 2106-1107010) are provided with pressed-on limiting Plastic bushings which allow the screws to be tum fed through half a revolution only. If the CO con- Fig. 2-87. Téling System Adjusting Screws in Carburetors 2106-10701 1 = 4€le speed adjusting screw; 2 - t4le mixture adjuoting screw Fig. 2-68. Idling System Adjusting Screws in carburettors 2107-1107010=10 and 2107-1107010~20: 1 = dle apeed adjusting screw; 2 - idle mixture adjusting screwable 2-6 carburettor Calibration Data Froriofowe | BOT=TweTOI0-10 | Bas TTOTOTO=TG protaiioToie-20 | 2tes-ieTore-20 peranetere Tat] mea] tet mt | tot me verret | varren | barren | varret | terzer | barred Janat diate a izing chamber diaaeter, a 2 ew dixture etoniser celitretion number e 8 Gs ts Us Diemeter of main fuel jet, mm 1430 1640 112 1.50 1.07 1.62, Dinmeter of main air fots ma 150 1150504107070 Eecleten tube celfbretion wuaber re o9e re re ru Pe Dianeter of idling and progression systen fuel jet, m 0.45 0.60 0.50 0-60-0450 0.60 Dinneter of ddling eat progression systen air Jet, mm 1.70 0.70 1.70 0.10. 1s70——0.70 Dinoeter of orifice of acceleration pusp eteuieer, mn O00 = OMDt | OMD Diameter of acceleration pump bypass Jet, me cao Sa Capacity of acceleration pap per 10 full etrokes, ox) Ts25% - 9 Ts H > aes Dineeter of econostat fuel Jety aa ee ae 0 Dineeter of ccmortat ais Jet, ma re) Diameter of sooncetat emlsien Jet, mm 7. ee So tls0 Dinneter of chete nechanien alr Jet, ma ono >On Dinneter of secondary throttle pneumatic actuator ie = = 50 e202 1.00 Dietence fron float to carburettor upper body with uate (Dineneten A, Pig. 2-85), ma 6.50.25 6500.25 Glecrencan at valves fer edusting choke mechantin (ig. 2-100), choke valve (clearance 3) 199.25 520.5 threttie vaive (clearance ©) 0585-0495 onr-0.8 % 4:15 mm for carburettor 2107=1107010-10; 1.09 mm for tent in the exhaust gases camnot be adjusted with ‘these bushings in position, turn the screws util ‘the bushing heads are broken, remove the sorens, take off their busbings end tum the screws back into the carburettor. Toke. Me bushings installed at the Manufactur ing lant are blue, while those installed at Ser- vice Stations, red. The 1Aling speed should be adjusied on a warm ‘engine (coolant temperature 90 - 95 °C or of1 tex perature 75 - 90 °c) with well-sdjusted valve clearances and a correct ignition advance angle. ‘Zo adjust proceed as follow 2106-1107010 caxdurettore Using screw 1 (Fig, 2-87) set a crankshaft peed of 720 - 600 min"! ee read by the stand tachoneter. Rotating screw 2 bring the concentration of Co an the exhauat gases to 1.5 - 2.5% at the given position of the throttle valve. * reduced to 20 °C and 1013 apa (760 mm He), carburettor 2105-1107010-10, Using screw 1 bring the erankehaft speed again to 720 = 800 min", If necessary, restore the concentration of CO to 1.5 - 2.5 % with screw 2. Frese the plastic liniting bushing on screw 1 85 shown in Pig. 2-89 b. Garburettors 2107-1107010-10 and 2107-1107010-: Using ‘screw 1 (Pig, 2-88) bring the erankehart speed to 850 - 900 min”! as read by the stand tacho- meter, Rotating screw 2 bring the concentration of COM gn the exaust gases to 0.5 - 1.2% at the giver posttion of screw 1. Rotate screw 1 to restore the crankshaft speed to 850 ~ 900 min“. If necessary, rotate screw 2 to reetore the concentration of CO to 0.5 = 1.2 £. Press the plastic limiting bushings on the screws, orientating the bushing slots relative to the locating projections as show in Pig. 2-89. Adjustuent of Pus) Love; ber ‘The fuel level required for nome fmetioning of the carburettor 18 ensured by correct setting of SEEs+ 2-89. Inetallation of Limiting Bushings on (Ling System Adjusting Screws: ~ on idle apeed adjusting screw; > - on idle mix- sre adjusting acrow Ne oerviceable elements of its shut-off device rig 2-90). The distance between the float and guaket 10 antacting the carburettor upper body (dimension 4) mould be (6520.25) may this distance cen be adjust t by Dending tongue 8. the bearing surface of the sngue should de pexpendiculer to the needle valve Hod should be free from Jags and dents. so check thia distance use gauge 67.8151.9505- 914 the upper body vertically, with float tongue 8 ouching lightly upon Dall 5 of needle valve 4 {thout making it sink. The maxima travel of the float [(610.25) =m] an be gijustod by bending stop 3. Heedle valve vtum Yoke 6 should not interfere with free nove- ext of the float. Install the carburettor upper body and aks sure that the float aoves clear of the float banter walla. Hote. The setting of the float mst be checked henever the float or the nesdle valve {8 replaced; n the letter case the valve sealing gasket mst Iso be replaced. Ag. 2-91. Carburetor control Linkage: = cfoss Link; 2 - longitudinal Link; 3 - Link astening shackle; 4 - choke valve control cable; and 7 ~ sedis; 6 - cable mob; 8 - lockwasher; ~ accelerator pedal; 10 - zetum spring; 1 = lever; 12 - shaft; 13-shatt bracket; 4 = lover; 15 - intermedia Pig. 2-90. Plost Chamber Pusl level djusthent: 1 = carburettor upper bodys 2 - needle valve 3 = stop; 4 - needie valve; 5 - needie ball; 6 - valve neodie retum yoke; 7 - float am; 8 = tongue; 9 - float; 10 - gasket went of Carburetor Control Linkage With accelerator pedal 9 fully depre (Pig. 2-91) the primary throttle valve should be wide open and the throttle valve lever should have no additional travel. When the pedal is released ‘the throttle valve should be tightly closed. Ifthese requirenents are not satisfied, the position of the pedal and throttle valve can be coordinated ‘by changing the length of Link 2 which ie done by screwing its head on or off. Simultaneously check and, if necessary, adjust the length of link 1. The centre-to-centre distance of its heads should be 80 mm. ‘The cable and {te casing should be positioned 60 that the choke valve is fully closed when knob 6 iw pulled all the way out and fully open when the mob i pushed in. Romovel end Installation of carburettor Renove the sir cleaner. Disconnect 1ink 1 (Pig. 2-91) ond retum spring 17 from the throttle valve operating lever. Detach choke valve control cable 4 from the car vurettor. ‘Disconnect the hoses from the carburettor. Stop the ende of the fuel ant coolant hoves to mule out Leakage of fuel and coolant. Remove the carburettor. Stop the inlet hole of the intake manifold with a plug. ‘To install the carburettor reverse the removal operetions. After installation adjust the throttle control Linkage end the idle speed of the engine, Disassembly of Corburettor Remove Yoturn spring 7 (Pig- 2-92) of the lever Limiting the opening of secondary throttle valve. ‘Undo end detach ink 8 from the throttle valve ever. Disconnect pneunatic actustor rod 9 from the secondary throttle valve operating lever™. Compress the spring of telescopic link 4 and Aisconnect it from three-am lever 3. Detach the upper body with the gasket from the carburettor body, trying not to danage the upper dody and the Float. urn out the fastening screws, Giscommect the throttie valve housing from the carburettor body, taxing care not to danage the air-fuel passage adopter bushings pressed into the carburettor body, and the bushing sockets. Detach cautiously the heat- Anmulating gasket. ‘the carmrettor upper body = using @ ariver, carefully push flost pivot 16 out of the brackets (in the direction of the bracket with cut-out) and pull out the pivot with unserrated flet-nove pliers. Renove the float and needle valve 15 taking care not to damage the float tongue! = remove upper body gasket 11, unscrew needle ‘t 14, unecrew plug 13 and take out fuel valve site 12; ™ carburetors 2107-1107010-10 and 2107-1107010-20. 6 Figs 2-92. Carburetor 2107-1107010-20 Viewed from ‘Throttle Control Linkage: 1 = choke valve; 2 - choke mechanism; 3 - choke valve control lever; 4 - telesoopte ink; 5 = pri- mary throttle valve operating lever: 6 - secondary throttle valve opening Limiting lever; 7 ~ return spring; 8 ~ link connecting primary throttle valve with choke mechanien control linkage; 9 - pneumatic actuator rod; 10 - pneumatic actuator = Giscomect telescopic Link 7 and choke mecha niea Link 19 from the lever of choke valve shaft 8; = tum out two screws of choke mechani boty 6 fend reaove the latter; = tum out three screws of choke mechanism cover 2 and take off the cover with adjusting screw end spring 3; = tum out idle mixture adjusting screw 10; = remove the fastening screws of idle epeed ‘adjusting sore bushing 17 (Pig. 2-95) and take st off complete with screw 16 5 ‘= wnbend the tab of lockwasher 2 (Fig. 2-93) and unscrew mit 1 which fastens the levers on the primary throttle valve abatt; = remove the lockwasher, levere 2, 5, 8 end 21 with washers 7 and bushing 6 from the primary throttle valve shaft, then take off spring 20 and fume valve 19; ‘= userew nut 9 which fastens lever 10 on the secondary throttle valve shaft ond remove the lever with the washers, ‘on carburettors 2107-1107010-10 and 2107-1107010-20 remove two levers with washers and a opring from the secondary throttle valve ahaft (rig. 2-95).eg -93. Carburetor Upper Body Parts: Durettor upper body; 11 ~ gaake wujuating screw; 2 - choke mechantim cover; 1 = filter plug; 14 ~ needie vaive | = spring; 4 - diephrogn; 5 - diaphroge rod; 15 ~ noedie vaives 16 - float pivot: 17 - float; choke mechanism body; 7 = telescopic Linky 18 = gasket; 19 - choke mechanimm Link } = choke valve shaft; 9 - choke valve; 10 ~ car~ oo valve shaft; 10 - secondary throttle valve leve: 2-94. Throttle Valve Housing Parts of Car 11 = throttle valve housing; 12 ~ primary throttle marettors 2106-1107010; valve retum spring; 13 - secondary throttle valve | = mut for fastening levers on prinary throttle shart; 14 - aecontary throttle valve; 15 - primary jalve shaft; 2 ~ lockwasher; 3 - throttle valve ‘throttle valve; 16 - primary throttle valve shaft; yrating lever; 4- washer; 5 - secondary throttle 17 ~ screw limiting bushing; 18 - ile mixture yalve operating lever; 6 = bushing; 7 - spring adjusting screw with sealing ring; 19 ~ fume valve; masher; 8 ~ lever Linked with choke mechan‘en; 20 = spring; 21 - primary throttle valve shaft J - nut for fastening lever on secondary throttle lever; 22 ~ washer aPig. 2-95. Throttle Valve Housing Parts of Cam purettore 2107-1107010-10 and 2107~1107010~2 1 = throttle valve operating eve: ing acondary throttle valve opening: 3 - bushing; 4-= lever Linked with choke valve; 5 - lever on secondary throttle valve shaft; 6 - springs 7 = lover Linked with pneumatic actuator; 8 - throttle valve-bousing; 9 ~ primary throttle valve retum spring; 10 ~ secondary throttle valve muaft; 11 ~ throttle valves; 12 ~ primary throttle valve shaft; 13 - limiting bushing; 14 ~ idle mix- Pig. 2-96. Body Farts of Carburettera 2106-1107010: 1/= choke valve control cable sheathing screw: 2 = cable sheathing bracket; 3 - cable fastening screw; 4 - choke valve operating lever retum wr sate ts en tn 5 3 8 ~ acceleration pump atontzer; 9 - acceleration pump valve-serew; 10 - secondary barrel main air dety 11, 13 = emulsion tubes; 12 - primary barrel main air Jet; 14 - acceleration pump adjusting sorew; 15, 16 - eecondary and primary barrels main ‘fuel Jeta; 17 - acceleration punp retum spring: = lever Limtt= ture adjusting screw; 15 - sealing ring; 16 - 42 speed adjusting screw; 17 - idle speed adjusting screw bushing; 18 - mizing bushing; 19 - time valve; 20 - fume valve spring; 21 - primary throttle valve shart lever 89 NS 16 ~ acceleration pusp disphragn; 19 - accelera- ‘tion pump cover; 20 - shutoff valve; 21 - idle fuel jet in shutoff valve; 22 - carburettor body; 23 ~ throttle valve opening adjusting screw; 24 = lock spring; 25 - throttle valve operating 96 = choke valve operating lever; 27 - levexig. 2-97. Body Parts of Carburetors 107-1107010=10 end 2107-1107010-20: + secondary throttle valve pneumatic actuator ods 2 - pneumatic actuator body; 3 ~ diaphragms = pneumatic actuator cover; 5 - secontary barrel rogression systen fuel jet; 6 - fuel Jet body; '~ mailer venturi; 8 ~ acceleration pump atont~ yr} 9 = acceleration pump valve-screw; 10,12 — econdary and primary barrels main air Jota; 1, 19 + secondary and primary barrels emulsion Disassemble the carburettor body (Pig. 2-96): = tum out screw 27 of choke valve operating ew-—26, remove the lever and spring 4, detach rod 5 um the Lever; = tum out the screws of acceleration pump over 19, reaove the cover with the lever and jeceleration pump Giaphraga 18 with return spring 17; = tum out mein air jots 10 and 12, overtum rhe body and, striking 4¢ gently, shake emulsion rubes 11 and 13 out of thetr well: = unscrew fuel Jot body 6 and take it out com ete with Jot 5; tum out shutof? valve 20; + renove valve-gerew 9 and take off atomizer 8 of the acceleration punp with gaskets and turn out \ceeleration pump adjusting screw 14; = tum out screw 23 which adjusts the opening of the throttle valve; = take out muller Yenturie 7; = unscrew main fuel jets 15 and 16; = tum out the screw and remove bracket 2 which golds the casing of the choke xalve control cable. om carburettors 2107-1107010-10 ana. 49 ‘tubes; 14, 15 - secondary and primary berrels main fuel jetes 16 - acceleration pump adjusting screw; 17 = primary barrel idling system fuel jet; 18 - stutof? valve; 19 - acceleration pump retum spring; 20 - acceleration pump dsephregay 21 = accelerator pump cover; 22 - primary barrel smaller venturi; 23 ~ choke valve lever retum ‘springs 24 = choke valve operating levers 25 ~ link for conection with throttle valve; 26 ~ throttle valve retum spring bracket 2107=1107010-20 renove the pneumatic actuator of tho secondary barrel throttle valve instesd of bracket 2. To dtoassenble the pneumatic actuator, tum out three fastening screws of cover 4 (Pig. 2-97) ‘and renove the cover, then the spring and diaphraga 3 with the rod. pn RS uel filter. Wash the filter in gasoline and blow 1t with compressed air. Exanine the filter and ‘the tapered sealing bend of the filter plug. Replace the filter or plug, if danaged. Bloat mechaniom, The float mst be neither Ganaged nor distorted. The aase of the float should be 11 ~ 13 g+ The contact surfaces of the needle valve and ite seat shall be free of defects inter fering with the valve tightness. The valve should be free to move in ite socket and its ball should move freely, without Jaming. Replace any faulty parts with new ones.‘garburet tor upper body. Clean the upper boty end all holes and passages of dirt end ofl. Wash the upper body in gasoline or acetone and blow it out with Compressed air. Examine the sealing sur- faces of the upper body. If the upper body is Ganaged, replace 1t by @ new one. ‘Ghoke mechanies. Clean ali the parts of the choke mechanion, wash them in gasoline and air- blast, Examine the parte closely ané replace any Aanaged ones, ‘Jets end emilsion tubes. Clean the jets and emioion tubes of dirt and gumy deposits. Wash then in acetone or gasoline end blow through with compressed air. : ‘Gaution do not clear up the Jets with metal tools or pieces of wire, nor wipe then and other carburettor parts with cotton wool, fabric or rags since the remaining Lints may obetmuct the fuel-emision path. In case of heavy obstruction, clean the jets with @ softwood needle wetted with acetone. eee Carburetor sbutoff valve (Pig. 2-98). In case of erratic valve functioning check for jaming of the valve needle and measure resistance of the coil mbich sbould be 150-160 2 at 20°. If it se other than nominal, replace the shutoff valve. Cerburettor body. Clean the body of dirt and oft. Wash the body and its passages with gasoline or acetone and blow out with compressed air. If necessary, cleen the passages and emulsion wells with special reamera. Examine the sealed surface: of the body and replace the body, if they are damaged. ‘Acceleration pump. Clean, wash and eirblest ‘the pump parte. check the ball for ease of motion tn valve-sorew 9 (Pig- 2-96) and the condition of ‘the sealed surfaces and gaskets. Check the movable elements of the pump (lever, roller, éiephrage parte) for ease of novenent. There should be no jamming. The diaphrage should be in- tact, without deformations. Replace any danaged parte by new ones. ig. 2-98. Corburettor Shutoff Valve 1 = ddie fuel Jet; 2 - needle; 3 ~ sealing ring; 4 = valve bodys 5 - contact plate; 6 - coil; 7 = cof housing; 8 = plug; 4 ~ jet calibrated orifice; B - fuel outlet hole into idling system equleion chame) 50 Secondary throttle valve pneumatic actuator. Clean, waah end airblast the parte. Examine the @iaphragn. It should be perfectly intact. Murottle valve housing, Clean the parts and wash then with gasoline or acetone. Inepect the parts and replace those danaged. Aspeably of Carburettor to asseable the carburettor, reverse the disai eembiy operations observing the following require- ments: = the float should rotate freely on ite pivot, without rubbing against the chamber wall = the needle valve «ould slide easily in ite socket, without cocking and jaming and the valve Qrive ink should not interfere with the movenent of the float tongue. ‘To avoid confusing the Jets of the primary end secondary barrels at aasenbly, take a note of ‘their markings end install then in conformity with the table of calibration data given at the begin- ning of this chapter. Main air Jets 3 (Fig. 2-81) are marked on the upper wurface of their heads (e.g. "150") which denotes the diameter of the Jet orifice (1.50 mn)+ Wain fuel jete 11 bear figures on the side surface ("130") which Likewine denote the dieneter of the Jet orifice (1.30 =n). Bmuleion tubes 13 are marked on the cylindrica surface in the lower part. The figures on the tubes (eegs "P15") stand for the tube calibration minber. ‘saailer Venturia 18 alo bear figures (e.g. nam) which denote the calibretion number of the atonizer orifice. ‘The {dle fuel jets have figures indented on the cylindrical band (e.g. "45" oF "60*); these figures denote the diameter of the orifice (0.45 oF 0.60 mn) allat: Pneumatic Actuator. To connect rod 8 (Pig. 2-85) tc lever 6 on the mecondary throttle valve sbatt = tum the secondary throttle vaive to @ ver~ teal position; = prea pneumatic actuator rod 8 all the way and, holding bushing 11 against turing, tum the rod in or out, thus adjusting ite length until the ole in the end of rod 6 gete in line with the pin on lever = elip rod 6 on the pin of lever 6 and secure At with @ Lockwasher; = fasten rod 8 with a locknut, uoing another wrench to keep bushing 11 ageinst tuming. Foat-sssenbly Adjustzent and checks of Garbure ttor Position of throttle valves in carburettor 2106-1107010. With lever 4 (Pig. 2-99) in a posit! where the upper lug of lever 3 contacts lever 2,24g. 2.99. Adjusting Pull ond Partiel opening of “sete Valves in carburettor 21061107010: 4 ~ adjusting partial opening of primary throttle valve; D - adjusting position of secondary 1 = lover on secondary throttle valve shaft; 2 ~ secontary throttle valve operating lever; 3 = lever rigidly linked with prinary throttle valve shatt; 4 - throttle valve operating lever; 5 ~ primary throttle valve; 6 - secondary throttle vere the prisary throttle valve should be partially open (720.25) m]. mio opening can bo adjusted by Dending the upper Iug of lever 3. Both throttle valves should be fully open when lever 4 1s fumed to the extreme position in which the Aug of lever 3 dears against a apecial boss on the throttle valve housing (Pig. 2-99 b). ‘This position of the throttle valves should be -fusted by bending the lower lug of lever 3. Rosttion of throttie valves of carburetors 2107=1107010-10 and 2107~1107010=20- cheek the ‘Yhrottle valves for full opening by tuming their operating levers all the way to stop. The maxima opening of the primary throttle vatve [(19 40.5) me] should be adjusted by bending she lower lug of lever 3 (Pig. 2-100). The maxim opening of the seccniary throttle vate [(170+5) ma] should be adjunted by screwing ‘the paeuaatic actuttor rod in oF out. Partial opening of the prinery throttle valve st which the upper lug of lever 3 contacts lever 2 (Pig. 2-101, ) should de (640.25) me. Tie diatance 4S adjusted by bending fhe upper Tug of lever 3. Ghoke mechanimm. when lever 1 (Pig. 2-101) 1 ‘tamed ell the way counterclockwise, the choke sr Fig. 2-100. Adjusting Position of Throttle Valves in Carburettors 2107-1107010-10 and 210T-1107010~20; a ~ primary throttle valve partially open; b= throttle valves fully open; 1 - lever on secondary throttle valve shaft; 2 - secondary throttle valve operating lever; 3 - lever rigidly connected with primary throttle valve shart; 4 - throttle valves operating lever; 5 - primary throttle valve; 6 - secondary throttle valve valve should bo tightly closed. In this posttion of the lever the end of Link 3 should be located in ‘the end of the slot of choke mechana rod 4, without moving the letter. this requirenent can be met by bending Link 3. When the choke valve is tightly closed, the primary throttie valve mist be partially open, 1.0. ‘through 0.85 - 0.95 mm (clearance ¢ ia the distance ‘and chamber wall at the progres- of the idling oysten). Thi clearance can be adjusted by bending Link 7. 4 completely closed choke valve should be open- ‘etughrough (720.25) m (clearance B) by choke mecha nim rod 4 when the letter 1s shifted by band oll the way to the right. Tis opening can be adjusted by screw 5. In carburetors 2107-1107010-10 and 2107-1107010-20 clearance B should be (5.540425) um and clearance 0, 0.9-~ 1.0 m. Acceleration pump capacity. Tis should be measured by ten complete strokes (tums) of throttle valve operating lever 4 (Pig. 2-100). Puel dtecharg- ed from the pump atomizer during these ten strokes should be collected into a neasuring glass. Ite Yolune should range from 5.25 to 8.75 cm?.Pig. 2-101. a sting Choke Wechantm Control Linkage: 1 = choke valve operating lever; 2 ~ choke valve: (~ 3 = choke mechaniem link; 4 - choke mechanism rod 5 ~ adjusting screw; 6 - primary throttle valve; 7 = tarottle valve operating link Before the checks make ten trial strokes of lever 4 im order to £121 up the acceleration pump passages. ‘Mghtness of needle valve should be checked on f@ stand which is cgpeble of delivering fuel to the carburettor underdh pressure of 30 Pa (3 m H,0). Atter the fuel level has settled in the test tubo of the stend, it must not drop for 10 - 15 s. If the evel drops, this should be attributed to the leakage of fuel through the needle valve EMAUsr sysmu Exhaust gases are dtecharged from the engine through the exhaust manifold, muffler inlet pipe 1 (Pig. 2-102), ouxiliary muffler 6 and main muffler 7. ‘The Joint between the exhsust manifold and muffler inlet pipe flanges in sealed by gasket 2. The muffler pipes are interconnected by clasps 5. ‘The mufflers and their pipi fron the car at three point: ‘The imlet pipe is fastened to bracket 4 which is mounted on the gearbox rear cover. The main muffler 18 fastened to the body floor by two streps while the tail pipe, by rubber pad 9. ‘The welded mufflers complete with pipes con- stitute inseparable unite and, in case of failure, ‘they should de replaced by new one Pig. 2-102. Rxhaust System: 1 = miffler inlet pipes 2 - gasket; 3 ~ inlet pipe~ togearbox clemp; 4 ~ inlet pipe-to-gearbox brackets 5 - muffler pipe comecting clamp; 6 - front uriliary muffler; 7 - main muffler; @ - main muff- ler fantening strap: 9 - tail pipe fastening ped z