1980 SKODA 120 LS Workshop Manual

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CYLINDER HEAD ASSEMBLY
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2.2-2.3
threods. Fill the etrgine with oil ond the cooling
systenr with on ontifreeze, ond
bleed them.
2.3 REASSEMBLING THE ENGINE
The reossembly procedure depends
on the
extent to which the engine hos been
dis-
rnontled. For better understonditrg, o
reossembly
of o conrpletely disnrontled
engine is described
in the following
porogrophs.
lnspection of
Cylinder Block
1. Clomp the thoroughly cleoned
cylinder
block into the MP 9-101 stond with the engine
corrier type MP 1-101 ond check it for complete-
ness -
see Chopter 2.6. Fit the
block with its
lugs on the engine corrier pins
ond use the side
bolt for ltolding it down.
DK 1188
Fig.2311- Cylinder Block Fostened on the
Assenrbly Stond by lVleons of the MP 1-10-l
Corrier
2. Rernove the pressure
relief volve, moke
sure thot the boll contoct {oces ore cleon,
ond
refit the cleoned volve. Forr
f itting o new volve
see Chopter 2.6.
3. Remove the cronkshoft beoring
covers ond
tlre i;ylinder block reor cover.
To Refit the Cronkshoft
4. Force the beoring shell lrolves with the
fingers into the cronkshoft beoring bores so thot
the shell lip snops home into the slot (cut-out)
in the block ond so thot the shells do not pro'
trude over the beoring surfoces for the beoring
covers, ond lubricote them with engine oil. Be
r;ure to fit shells motching the cronkshoft
i":urnols -
see Chopter 2.7.
5. Slip the oiled guide
ring on the cronkshcft
"vith oil grooves
pointing
toword the cronkshoft
'.veb ond {it the cronkshoft with the pressed-on
boll beoring (see
Chopter 2.7)
into the shell. 6.
Inscrt the
beoring shell
holf ir-rto
the cover
of the beoring No.-l
os described in
porogroph
4,
ond fit the cover with the
recess for the guide
ring turned outword. Proceeding from
the front
of lhe block, slip
on the next guide ring with
the oil grooves pointing
owoy from the block so
thot itJ
lip engoges ogoin into
the slot in the
cover. Coot the ring
with oil ond slip on the
thrust ring. Fit the MP -1'112
thrust collor on the
cronkshofi ond
tighten the
beoring slightly
using the belt
PrrlleY bolt.
7. Instoll the next
two beorirrg covers
corl'l'
plete with beoring shells
ond lightly
tighten l.he
cover nuts.
Press the cork
seol
into the
reo'r
cover moking
sure thot it
f its the groove
snugly
ond slightly bverlops the lower
seoting surfoce'
Before titting the cork seols,
compress them
for
o while in o vice to distort them. Insert the
distorted seols in the grooves
or gops between
the cover qnd
the cylinder block
where they
will expond onci provide
for perfect seoling.
lnsert tob woshers under
the nuts of the
beoring covers
ond while tightening the rruts
check their correct position so os
to enoble
o subsequent correct locking
of the nuts.
Fig.2.312 -
Meosuring Cronkshoft Ploy
1 -
Thrust collor, type
MP 1 112
2 -
Diol indicotor in o
speciolly mode yoke
8. Rotote the cronkshoft severol times ond
using o mollet top the covers ond both shoft
ends to ensure o correct bedding
of the covers
ond cronkshoft guide rings.
9. Tighten the belt pulley nut
to clomp the
thrust ring, ond
rotote ond force
off
the cronk-
shoft to
check its ploy. The
cronkshoft must
be
free to rotote but
without ony
noticeoble ploy.
lf there is o noticeoble ploy, recheck
its volue
ond odiust it by replocing the guide ring with
o new one. The
moximum ploy
should not ex-
ceed 0.10 mm, the recommended minimum ploy
being 0.04 mm. 10.
F
speciol
end onr Drive
suchr o
be turnr
cover. I
ever, tf
the cyl
speciol note in
11. Ti
the tigh
in the
covers. hoving
does no
must ro
Then lo,
woshers
ond nut
To Refil
12. R
greose i
it with i
o flywhr
engine,
with rec
under tt
Chopter
bending
shoft og
powl ins
For flyw
Fig.2.3l3
Using thr
Screw
holes, for
con be ur
further o1
the hondr
30

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Fig.2.3/6
-
Position of Cylinder Liners,
Pistons
ond Connecting Rods in Engine
1 -
Proiectlon of cylinder liners
obove the top
foce of the cylinder block (0.125 -
0.155 mm)
2 -
Connecting rod splosh hole
'3
- Arrow on the piston
heod pointlng
toword
the comshoft
4 -
Comshoft
Fig.2.317 -
Pilot Ring
for Piston Rings
Dimensions of pilot
ring to motch cylinder
liner diometer:
dio. 68 D:68 H 7
dio. 68.25 D :68.25
H 7
dio. 68.50 D :68.50
H 7
dia. 72 D:72 H7 14.
Hoving fitted the piston
rings ond con-
nectlng rods on the pistons,
turn the piston
ring
gops so thot they ore stoggered
through 120o.
Coot the entire surfoce of the piston
with the
fitted rings with oll ond insert the pistons
ossembled with the connecting rods into the
liners in the sequence of the corresponding
numbers of cylinders ond connecting rods. Moke
sure thot the
orrow in the piston
heod points
toword the morking
of the cylinder liners, l.e.
toward the comshoft, ofter the ossembly with
the cylinder block. This
is importont in thot it
does owoy with odditionol turning of the pis-
tons in the liner ond o posslble
displocement
of the piston
ring gops.
Smeor the top surfoce of the cylinder block
with point
or o seoling
compound before
instol-
ling the liners with the pistons
ond connectlng
rods into the cylinders in the order of their
numbering. It is odvisoble to prepore
o sheet sleeve or
o pilot
ring occording to Fig. 2.317
to com-
press the piston
rings when fitting
the piston
Into the cylinder liners. Force the piston
into
the sleeve or pilot
ring so
thot the piston
heod
is flush with its edge or protrudes
sllghtly
over it, locote the piston
on the liner, ond then
force down the piston
through the sleeve or
pilot ring into the liner.
15. Ploce suitoble ouxiliory devices over two
holes for
cylinder heod bolts, for exomple
lorge-diometer woshers, ond screw them down
Fig. 2.3/8 -
Fitting Piston into
Cylinder Liner
Using the Pilot Rlng
1 -
pilot ring
2 -
cylinder liner
32