Contents: Removal ↡ Installation ↡ Boring of cylinder block liners ↡ Lapping and polishing of cylinders ↡
Removal
1. Press out the sleeves (figure 2.47).
2. Clean the cartridge holes thoroughly.
3. Measure the diameters of the holes for the cylinder liners in the cylinder block. If the measured value is greater than the permissible value, replace the cylinder block.
Diameter of the hole for the cylinder liner in the cylinder block: 91.500-91.535 mm.
Figure 2.47. Pressing out the sleeve.
Installation
4. Place the cylinder block on the press and secure it.
5. Install the new sleeve 2 into the hole at the required angle (figure 2.48).
Figure 2.48. Installing the sleeve: 1 - Cylinder block; 2 - Sleeve.
6. Press the sleeve into the cylinder block,
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7. Grind the contact surfaces of the cylinder block with the chain drive cover. The amount of material to be removed should be minimal.
8. Wipe the cylinder block 1.
9. Lapping and polishing of the cylinders.
Boring of cylinder block liners
10. Bore the diameter D2 of the sleeve (Fig. 2.49).
Figure 2.49. Boring of cylinder block liners: D - Diameter of the sleeve flange; D1 - Sleeve flange diameter; D2 - Sleeve diameter; T - Length of the sleeve; T1 - Sleeve seating depth.
11. Bore out the diameters D and D1 of the sleeve flange.
12. Mill the chamfers of the liners between the cylinders.
13. Remove burrs from the cylinder block chamfers using a polishing stone. Dimensions for boring sleeves are given in Table 2.8.
14. Thoroughly wipe the cylinder block.
Table 2.8. Dimensions for boring sleeves
| Parameters | Engines 602.984/985 |
| Diameter D2 of the sleeve, mm | 91.500-91535 |
| Diameter D1 of the sleeve flange, mm | 92.05-9.15 |
| Diameter D of the sleeve flange, mm | 94.15-94.25 |
| Sleeve seating distance T.mm | 231.0-231.2 |
| Depth of T1 sleeve seating, mm | 1.0-1.2 |
| Chamfer width M, mm | 50 |
| Change in height between cylinders after boring Rz, mm | 0.100 |
Lapping and polishing of cylinders
15. Measure the cylinder diameters D (rice, 2.50a).
Figure 2.50a. Lapping and polishing of cylinders: D - Cylinder diameter after honing; D1 - Cylinder diameter.
16. Determine the cylinder diameter D1 and select the lapping and polishing tools. The diameter D1 corresponds to the diameter D with a reserve of material for honing. The stock of material for honing should be no more than 0.5 mm in each sleeve.
17. Hone and chamfer the sleeves.
Checking the cylinder sizes is shown in the figure 2.506, and the dimensions themselves are given in table 2.9.
Figure 2.506. Checking cylinder diameters: 1, 2, 3 - Measurement points; A - Longitudinal dimension; B - Transverse dimension; a - Upper position of the upper compression ring; b - piston BDC; c - Lower position of the oil scraper ring.
Table 2.9. Cylinder dimensions
| Parameters | Engines 602.984/985 | |
| Cylinder diameter, mm | Standard | 89.0 |
| Group A | 89.000-89.006 | |
| Group X | 89.006-89.012 | |
| Group B | 89.012-89.018 | |
| Deviation from the roundness of the cylinder, mm | 0.07 | |
| Cylinder honing angle,° | 40-60 | |
| Cylinder surface roughness Rz, mm | 0.002-0.005 | |