What is the repair of the car engine. Engine overhaul. General Engine Repair Concepts

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One sentence of service workers who are so afraid to hear drivers - "will have to make the engine overhaul." This verdict is perceived normally when the car has already drove a solid number of kilometers and its parts were extended during the long-term operation. And when this talks about a relatively "young" motor, this phrase sounds like a deadly sentence. First of all, because most drivers do not know what is a major overhaul of the engine. Today we will tell you in detail about this procedure of cardinal "treatment" of the power unit.

Overhaul The engine is a procedure that can be compared with dental prosthetics in humans. As a person, at a certain age, it is necessary to install new jaws in order to correctly and fully process food and the engine needs to be updated the nodes and parts so that it can in normal "to digest" fuel, develop optimal power, in a word, fully function. Causes that can lead to motor overhaul, several:

- "aging" of nodes and aggregates in the process of long-term operation;

Non-compliance with the operating conditions of the motor (untimely, air and oil filters, refueling the car is poor and so on);

The operation of the power unit at the maximum loads in adverse conditions.

To understand that the engine of your car has already needed overhaul, you should pay attention to one of the symptoms testifying to serious malfunctions power plant. These include:

The sound of the engine, which appears when they come into disrepair of liners and crankshaft crankshafts, sliding bearings located in a crank-connecting mechanism. This feature can also be diagnosed, measuring oil pressure. If it is low - there is no depreciation of the specified parts;

Increased oil consumption and exhaust of the SIZAL color, which are talking about the maximum wear of the elements of the cylindroporto group;

Engine jamming, which occurs due to the destruction of elements piston group, crankshaft or cliff rolling.

If one of the listed features is observed, the driver should immediately apply to the service station, where its car is served and carry out a full diagnosis of the power unit. Based on these diagnostics, experts will determine the specific cause of the engine breakdown and will carry out the operation of the engine overhaul in this case. Independently repairing the engine, of course, it is possible, but for this you need to have special knowledge and remember that only the owner of the car will be responsible for operations with the motor, and not a manufacturer or dealer who sold you.

Now let's talk about what, in fact, is the overhaul of the car engine. First of all, the engine is extracted from the workpiece. For these purposes, there are necessary equipment in workshops, with which you can disconnect all the power systems and cooling the motor controlling its electronics, unscrew it from the island, remove hinged equipment, raise and move to a special machine (mounted stapel), where the unit is cleaning from the accumulated dirt, complete disassembly and flushing parts.

The first stage of major repairs is to determine the degree of wear of engine parts. Motorist studies in detail the crankshaft state, measuring the diameters of the jackets on the cervix. Then follows the procedure for measuring the neck, the flywheel with the crankshaft, and in the cylinder block - the axial backlash of the shaft. Also, a specialist by measuring the diameters of cylinders in the longitudinal and transverse plane at three levels establishes whether there is a deviation in their sizes and geometry. The next measurement is the determination of the magnitude of the gaps between friction pairs (camshaft, valves and guide sleeves and so on). The engine parts of the engine are not ignored, which are carefully inspected in the search for cracks - the crimping equipment helps in this. Having determined how worn all the listed components of the motor and comparing the diagnostics obtained as a result of the diagnostics with normal, the specialists determine which overhaul operations should be carried out. As a rule, repairing such engine nodes as a block of cylinders, a cylinder head, crankshaft is a crankshaft. Consider them separately.

Operations for repairing the cylinder block include replacement of removable sleeves, reassurance and honing cylinders. There are engines in which removable sleeves are not provided, in this case, the locksmith sets the so-called repair sleeve. To do this, he mounted a cylinder on the machine, and in the resulting slot inserts the repair sleeve, then it processes it in order to obtain a size with other cylinders. The Honing Procedure is an application to the surface of the cylinder strips with a specific profile that helps to delay the oil here, which allows you to lubricate piston rings and skirts pistons. The cylinder is processed to the so-called repair size so that it corresponds to the diameter of the repair piston, while take into account the amount thermal clearance (The value between the piston skirt and the cylinder wall). Also, the repair of the cylinder block includes such operations as a recovery of the bed of crankshaft, the elimination of cracks in the block itself, the milling of the aircraft plane before its subsequent alignment.

If you have to repair the head of the cylinder block, then the locksters are carried out with many small and labor-intensive operations. They consist in breach brewing, replacing the valve sleeves (if the degree of wear of the guides is not critical, they are restored, making the diameter of the hole under the valve rod less) and the champersion of the valve saddles. In addition, the repair of the cylinder head assumes the recovery (replacement) of the valves, the replacement of the camshaft and pushers, the restoration of the deformed stationary plane with the help of grinding, and another mandatory operation is the installation of new oil-challenged caps.

Another time-consuming operation, conducted during the overhaul of the motor - the recovery of the crankshaft to the optimal working condition. It is carried out like this: the washed and dried parts of the connecting rod and the root necks are first polished, and then polished, seeking the leveling of the surface of the surface of the neck and the edges of the oil channels. Also, the set of works on the repair of the crankshaft includes its editing and diagnosis of the surface, which is usually deformed by prolonged necks.

When these components of the engine are repaired, they are purified from the resulting chips ( special attention Channels for lubrication and cooling), wash, and then purged with air and dried. After drying, the process of assembling the elements of the power unit, which is performed on the mounting stapel, observing and controlling all the gaps in friction pairs. When the elements of the engine are installed, you need to make the pistons, piston fingers and connecting rods, adjust all the gaps and check the tension of all belts (chains).

The tightening of the bolts, fasten the enclosure parts of the engine, must be carried out sequentially to prevent the skew and subsequent deformation just repaired x items. Before installing collected engine In the open space, motorists hand check the work of the shafts, making sure that they rotate without effort. If a hitch occurs - it means that something is not established incorrectly, and, therefore, it will have to disassemble the element and again to perform measurements and re-installation.

One of important stages The overhaul of the car engine is its cold runoff. That is, even before installing the motor into the pumproom space and connecting to it all "feeding" systems (fuel, cooling and so on), it is necessary to pour oil and cooling fluid to the unit, connect the electric motor and arrange a so-called crankshaft run. The cold routine is needed so that the friction pairs and replaced (restored) engine parts fit under low load. Sometimes motorists spend cold running already installed in the engine compartment of the motor, giving him to work on idling Some time (up to 4 hours).

Finally, the final stage of the engine overhaul is the adjustment of the engine operation, which is carried out both on a special stand and directly by car. At this stage, Motorists check the coherence of the work of the cylindroporto group, the crank-connecting mechanism, fuel and other engine systems.

Remember that the overhaul of the power unit of the car allows you to increase the life of its operation and increase the engine life, which will naturally affect the quality of the engine and the total state of the car. Therefore, do not ignore the above signs, eloquently testify e about the nearby breakage of the power plant, and in a timely manner in preventive and procedures. Let the overhaul affair a long-term and costly business, but the "health" of your "iron horse" is definitely worth it.

In this case, both the nodes inside the block and the GBC are subjected to significant mechanical and temperature loads during engine operation.

It is not surprising that the damage to the cylinder block will not only break the performance, but also will be disrupted force aggregate. For this reason, the recovery of the block and its repair must be performed qualitatively and in a timely manner.

Read in this article

The main defects and malfunctions of the engine cylinder block

Let's start with the fact that there are two types of blocks of cylinders:

cast iron BC;
aluminum alloys blocks;

As a rule, the cast iron blocks are additionally strengthened using graphite, and lightweight products made from aluminum are carried out guylized (the lock is inserted into the unit). Also there are aluminum blocks of cylinders without sleeves. The alloy includes silicon, which significantly strengthens the block.

As for the guilized blocks, the sleeves are "wet" and "dry". In the first case, the coolant is directly in contact with the sleeve, whereas in the second sleeve tightly pressed into the body of the block during the manufacture.

Anyway, each solution has its pros and cons, as well as during operation there are various damage and defects of the cylinder block or defects of the block sleeve (depending on the type of BC).

Repair of the cylinder block must be started with establishing the cause of faults and defects. Often the main problem on motors with big mileage is the wear of the surface of the cylinder or the sleeve. On the surface (mirror) of the cylinder appear jackets, cracks, sinks, etc. can form.

The unexpected destruction of the piston rings and other unforeseen breakdowns becomes less likely to cause block defects. I also add that the bed of crankshaft bearings often occurs in the BC, etc.

As for the wear of the surfaces of the cylinders, in this case such wear is often "natural", that is, it becomes the result of the engine operation in normal operating modes. The reinforcement of cylinders in this case often implies boring and honing of the cylinder (applying Hon). This allows you to remove the ellipsence of the cylinder, remove scratches and jams on the mirror.
A more complex occasion can be considered the ripple of the rod,
Since damage is usually more serious. Also the cause of the defects of the block is and breaking, the destruction of the valve seat, etc. The result is the loops on the surface of the cylinder and other damage. Also in the list frequent faults It should be highlighted or sleeves.
We also add that there are so-called "hidden" problems, that is, to identify defects visually as part of the surface inspection may be difficult. At the same time, unqualified repairs, which is limited by a banal replacement of worn parts, will still lead to the fact that the engine will need to be disassembled after several hundred or thousand mileage kilometers.

To the specified "hidden" defects, first of all, should include deformation of the block of cylinders. Often, such deformation is a consequence of the violation of technology in the process of manufacturing the block. Simple wordsIf the block does not remove the internal voltage, the deformation will arise.

By the way, this problem is more inherent in cast iron blocks. Also for deformation of the block (both cast-iron and aluminum) can lead the engine overheating or its uneven heating during operation.

Restoration of engine cylinders

So, the repair of the cylinder block and the restoration of the cylinders themselves involves:

thorough cleaning of the surfaces of the BC;
then produced (cooling shirt);
also washed and cleaned, and then oil channels are checked;
next is carried out;
then there is a boring / block of block, grinding of surfaces, etc.

For many engines, cylinder canopy is a mandatory procedure within. To perform the procedure, a special machine cylinder boring machine is used. Under the boring unit itself, it is necessary to understand the processing of the inner surface.

Such treatment is actually a removal of a metal layer for leveling irregularities, removal of scaling, smoothing with shells, etc. The main processing task is to give the cylinders a normal form (cylindrical).

The next step after the boring is. Hano on the inner surfaces of the cylinders is performed by an abrasive fine-grained material (a choning bracer on the honing head). Honing head itself is attached to the spindle of the honing machine. Such a machine allows you to implement rotational and reciprocating movements.

Repair of the cylinder block can assume a sleeve or germination. In the first case, the installation of the sleeves should be understood, although the factory structure initially does not imply. In the second, the worn sleeve is removed from the block, after which the repair new one is installed.

As a rule, the block sleeve can be performed in two ways when the sleeve is cooled with liquid nitrogen or the response part is heated. In the first case, the cooled sleeve decreases in size and easily put (pressed) on the seat. The second method involves heating. Both presovation methods of the sleeve allows you to achieve the desired tension.

Finally, we note that as part of the block recovery, you may need to repair the bed of bearings. crankshaft. Also in some cases there is a need to eliminate block deformation. For this purpose, an artificial aging method is used when the block is heated to a certain temperature, after which the processing of various sections is processed.

That in the end

As you can see, there are quite a lot of faults of the cylinder block itself. Some can be considered small (for example, etc.), while others are quite serious (for example, wear of the walls of the cylinder, cracks, etc.)

It is important to understand that in each case the technology of repairing a block of cylinders may differ. Also, the complexity of the engine block repair will directly depend on the problem itself, from the overall state of the damaged part, on the design features, etc.

In practice, this means that in some cases it is possible to restore the cylinder block with their own hands, even in the conditions of the garage, whereas in others you will need a mandatory availability of special equipment (machines for boring block, honing, grinding). Also, a very important aspect is the experience and qualifications of the master itself.

Taking into account the above, it becomes clear that you should trust the implementation of such work follows only experienced specialists, and the engine itself is optimally repaired on such a hundred, where it is possible to produce all the necessary operations right on site. First of all, this will reduce the repair time, as well as it is often a guarantee of quality.

When does the engine require major repairs?

They drove away - suddenly the engine of his beloved iron horse was stuck. Here are not rushing immediately to grab the "Capital". I must first check everything.

First, let's immediately decide that this is not a bulbing engine when he was disassembled, cleaned, changed the gaskets and collected. Here, the reasons are more serious. So, pay attention to the prerequisites:

How much is the car? How much did she run? Foreign car or domestic? If a car for more than 10 years, he is domestic, for example "Zhiguli" or "Moskvich", then its limit is 150 thousand kilometers. For foreign cars - up to 300. It is possible that the resource of your car has been exhausted, and for this reason the power decreased.
We look with oil. Yeah, the pressure fell again, despite the fact that the car shoves the oil godlessly - another reason for repair.
Check the compression, since this is the main parameter affecting the choice - you need or do not need a major overhaul. We take the compressometer from acquaintances, do measurements. For example, in our case, from four indicators in one instead of the eight of the eight of the first five, it means that the time of major repairs has come.

Where to begin?

Of course, with information. Give the manual in which it is reported in detail and with schemes. How to repair your car brand.We find the directory on the Internet in which there are spare parts for this car to immediately decide on the prices and, perhaps, make an order in the online store.

Preparing tools:

keys - ratchet, dynamometric;
mandrels for clutch pistons, caps;
calculator to valves;
micrometer;
heads;
valve adjustment device;
two-liter or three-year puller;
stethoscope;
tweezers;
reference rack;
hydraulic chain hoist;
set of puller.

Get to the engine

We chase the car into the garage. We remove the battery. Disconnect the hood so that it does not interfere.

We drag off all liquids: Tosol, oil. To do this, instead of bolts on the radiator and the cylinder block, you set the cranes - they are sold in any automata - and drain with the help of hoses into the cooked container.

Given the age of the car, very carefully disconnecting the wiring, connectors, tubes, hoses, and so on so that they do not scatter in their hands, nothing has occurred and did not fail. And then some craftsmen are still repaired wiring, cooling system.

We remove everything without a rush, everything that can interfere to get the engine: air filter, carburetor, fuel pump - do not forget to wind the bolt, oil separator, rubber, cylinder cover, camshaft, cylinder head studs, and then block head, crankcase protection, belt generator, fan, radiator. Unscrew the bolts that secure the engine. Now the engine can be removed.

Stages of engine overhaul on the example of the Zhiguli brand

Step number 1.

Before you get to the engine's indoors and begin to make a major overhaul, try, following the safety technique, remove it from the car. Call an assistant - one does not manage here.

Prepare four tires by folding them on each other. Put two wooden bars on top. On them then put the engine.

Step number 2.

Now fasten the talc, i.e. the lift, on the ceiling beam, it can be attached to the tripod, placing it over the hood.

Do you know how much engine weighs? How do you have an aggregative in 140 kilograms? Serious thing? It is clear that you do not raise her hands, but if you fall, you can not do without injury. So that this does not happen, be extremely careful, check the fastening of the talca, and only after that start the rise.

Step number 3.

Carefully, without excess of bustle Tighten the engine up, move to the tires stack, which have already posted in front of the machine, lower, turn the carter to be on top, on wooden bars.

When disassembling, remember or mark somewhere where you take off and where the item was originally located, so that you were not too extra, as in some self-dellic.

Start glowing the flywheel: first remove the clutch, then get to the Carter's anther. Go to K. oil filter. Sliding fastenings, remove the bolts and remove the crankcase, trying not to break the oilhead.

Step number 4.

Now remove the front and back cover covers. Cut the piglet as an asterisk, remove it using the puller. Go to the chain limiter and unscrew, remove the tensioner's shoe, and then the chain, the crankshaft.

Go to the crankshaft. With connecting rod caps, take the nuts, then the covers, carefully pull the pistons, get the liners, carefully inspect them for reuse. If you can not use it, take the sample and buy new in a specialized store or in the car market. Only first decide whether the roller is needed for the shek, and only then customize the liners. Get the crankshaft with stubborn half rings.

Step number 5.

Remove the piglet, oil pump and its drive gear. Turn over, putting sideways, get out of cylinders pistons with connecting rods. Piston system Buy new on the old sample. In the auto repair shop still need to contact.

Take new pistons, let them bore the block, and also cast the crankshaft and piston fingers will be pressed. Measure the crankshaft micrometer, look in the manual, what size should have inserts, buy them. If inserts you pick up correctly, you can rotate crankshaft by hand - This will be a test for fitting.

Step number 6.

Start the assembly with the removal of nagar. Remove the entire metal chips, rinse bed, lubricate them and liners motor OilInstall in place, focusing on management. On the back wall of the block, put the stubborn semiring so that the launches are rotated on the plane of the crankshaft.

Now you can return the crankshaft in place with liners and covers, checking the marking, places where castles are located. Watch them to be all on one side. Take the dynamometer key, tighten the bolts, the crankshaft twist - if it is spinning easily, then everything is in order. Otherwise, replace the liners on thinner.

Step number 7.

Ask in the workshop to assemble the piston, because you yourself can not heat up to more than 100 degrees of the rods head, and you need to warm up over 200. Control the process.

Now neatly wake through the openings piston fingers, sketch, not in a hurry, piston rings, make sure that the slots are preserved, holes, tighten the wreck key. Place the block on the side, insert the piston with the connecting rod, not forgetting about the marking.

Step number 8.

Take the wooden bar and, quietly picking up, shake into the cylinder piston. Turn over B. initial position Block, but do it so that the top is the crankshaft. Tighten the bolts.

Long begin to pull the rod to the necks. Then scroll through the crankshaft to make sure that everything is supplied correctly and the liners do not need to change. Now you can tighten the bolts.

Step number 9.

Put a new bowl on the cover, install it on the block, pre-wove the location of the docking sealant. Go to the installation of the coupling of the clutch and flywheel. Remember that the handwheel is necessary to deploy to the fourth knee of the crankshaft - it is important.

Now do the installation of the asterisk, the pig, the tensioner shoe, the front gland, oil pump, the clutch of the flywheel.

Step number 10.

Finally, you can install the engine and secure it with bolts. Tighten carefully, so as not to thread the thread and did not burst the details. Return to the previous places of the pump, the generator, the radiator, the fuel pump, attach the wires, hoses, terminals, check the mounting strength.

Cold running

As soon as the engine overhaul is complete, it is necessary to carry out a cold run before it is installed on the machine. This is done in order for the new parts to get to each other, and is carried out in passive, stand mode or on rigid tug when thanks to the movement of the wheels begins to spin the crankshaft and a cold runoff occurs.

So, in the garage connect the hoses air filter, cooling systems, oil supply, engine graduation. Install the plugs. Connect the unit to the electric motor.

Fill the coolant, which was drained during disassembly, heated it to 85 degrees, then heated to 80 degrees oil. On the low revolutions, From 600 to 1000, let the engine work for 2 minutes, high, from 1200 to 1400, - 5 minutes.

Engine Operating Tips after overhaul

Before the car runs two and a half thousand kilometers, do not sharply accelerate, dial the speed gradually, the engine does not overload.
After the first run, drain the oil, replacing it clean, but the same brand (preferably).

Now you made sure that the engine overhaul is possible and beneficial, because it costs three times cheaper. In addition, it will allow to exploit the car for several years as a result of the extension of the resource, will prevent an unexpected breakdown on the road, will help to avoid accidents.

About what parts are needed for the windmont of the VAZ 2103 engine, you will tell you the following video:

Take yourself, tell me friends!

Repair of aggregates in the system of heating, working in a pair with a network pump

The electric motor repair technology in this case is reduced to the following algorithm of action:

To begin with, it is required to remove the cooler impeller cover, located behind, it is fixed with fasteners, the number of which can vary, then throw off the impeller.

Take a test to accurately determine the free move in the bearings behind and in front, for this purpose, dramatically lift the motor and return it to the original position or move forward and backward, the bearings have developed immediately let yourself know.

An alternative diagnostic method is simple enough: just turn on the engine and listen, then you can hear the sound of the motor. To carry out such a pre-work - because it was decided to repair, in the diagnostic process you will become clear whether it is necessary to repair right now or the engine is still quite efficient.

Therefore, be sure to take on arms methods how to check the electric motor, such knowledge will never be superfluous. If during the diagnostics process you made sure that the bearings were loose, change them immediately to cost without unpleasant surprises on the road.

Disassembling motor

Repair of the electric motor with their own hands implies independent disassembly of the motor, which is carried out different ways. Sometimes it is enough to turn the engine where exactly it depends on the place where it is installed. There are cases when you need to disconnect the power cord, and it is necessary to mark the phase, otherwise you will have to guess which wire where to connect.

Use the puller to remove or pull the coupling.

Inspect the housing, pay attention to the state of the side covers, whether there is a leakage lubricant on them, while detected, remove them. If there are no traces, you can proceed to removal of covers, fasteners, as a rule, has from 3 to 5.

Unscrew the bolts on the lids, let's slightly knock on the lid on one side, while simultaneously providing another tension. Criticalizing accurately, so as not to break the "ears", which will inevitably entail additional costs. As you need to repair the engine, this is accuracy and skillful actions of the wizard.

Flip the covers to determine if you need to get a rotor from the housing, or all the repair work can be made in place. When the engine power is less than 17 kW, the rotor is simply pulled out and remove to the side, and if higher, then repairs are on the spot.

There are cases that the rotor of the large engine has to be taken, then the rotor tubes wear pipes with the appropriate dimensions and carefully remove it from the stator, it is important not to hurt windings.

After you figured out with the shaft, make it with the removal of bearings, remove the completely leaving lubricant using aviation kerosene. When the lubricant poured the winding, it will be necessary to wash and dry, 1 or 2 light bulbs or a canoriorifer are used for drying.

Views repair work The electric motor is divided into account with the type of malfunction, for example: "Checked" on the shaft bearing, speaking in other words, its landing has weakened, it is necessary to apply the shaft using the electrical welding and tweel it on the lathe. If the bearing has a number lower than 309, it is soldered by tin, this repair has enough good results.

Consider the engine with a power up to 100 kW, equipped with rolling bearings, when the engine works in a disaster, at a critical temperature, if the thermal protection does not work, the linking bursts.

Faced with a similar problem, follow these steps:

Remove the remnants of the winding.
Make a bandage again and apply a layer of varnish on it, then the link will stick to the windings, it will not hang out during the operation and last longer.

Motor assembly

The assembly is made in the exact opposite order:

Bearings are heated using a special transformer, and then planted, there is no need to buy a transformer - it can be made independently.
After installing the bearing, you put on the front cover, and then the bearing will go to the nest intended for it.
Heat the demummouft and plant, install the rotor back, plugging the key.
Put the second cover, tighten the bolts, taking carefully with a hammer or a small sledgehammer.
Turn the shaft of the hand to determine how free it is spinning, the shaft will slow down when the shaft is skewed.
If everything is fine, fasten the engine with bolts and tested by taking a test start, making sure that everything is leveled, give the engine to work for 15 minutes.

When the bearing is can, apply notches with core, chisel, perform copper with the welding machine.

Knowing how to repair an asynchronous electric motor, you can repair a durable electric motor of a variety of devices such as sharpening machines or mini-sillars. The easiest and most common faults include a blown fuse or triggered protection.

Photo of the process of repair of electric motors

Engine repair - an event, an extremely responsible and difficult, requiring car owner, if he decided to subordinate car Engine, knowledge and patience. To delay with the repair of a car engine, it is impossible under any circumstances: when even the slightest signs of problems appear, you should give a car into the reliable hands of professionals or make all the work independently, otherwise financial losses can be very serious.

Characteristic signals that the engine is time to repair is a high oil consumption, a significant reduction in power and the appearance of non-engine sounds. Also in the diagnosis of the automotive engine it is necessary to pay attention to the color exhaust gases. SIZY smoke of exhaust pipe The car may, for example, to testify that the oil gets and burns in the engine, so the engine repair is inevitable.

Any independent overhaul begins with a complete engine dismantling. This event is extremely responsible and painstaking, requiring care and increased caution, since at this stage there is the possibility of damage to tubes, hoses and electrical wiring connections. After the car engine is removed from the body of the car, proceed to its wash and subjected to the subsequent disassembly.

After the first stage, it is necessary to evaluate the parts of the engine, how seriously its components are damaged - the head of blocks and the cylinder block - whether there are cracks and other defects. The result of the analysis should be the conclusion - what needs to be done next? Replace the old elements with new or try to "save" existing ones - to do their boring and grinding. However, in the disassembly process, the piston rings, valve glands and liners have to be replaced. From this not going anywhere.

However, it should always be remembered that without adequate qualifications and due knowledge of the car, certain manipulations in the process of major repairs will not be carried out. In this case, you can always contact the services of a qualified specialist. If all work is successful, it will result in its result will increase the operation of the engine operation, an increase in work resources. Also, high-quality repairs will help prevent the premature engine breakdown and improve its technical parameters.