In this subsection, instructions and working procedures of basic operations are given which are to be carried out both in the case of operations contained in technological instructions of various subsections of this manual and in the case of routine servicing.
Following instructions are included in this section:
1. Instruction for assembling and disassembling the manifold 2. Instruction for mounting packing of joints and drives 3. Instruction for securing joints by means of locking devices
1. Instruction for assembling and disassembling the manifold
a) Wash the manifold, brackets and holders with lacquer petroleum and dry them before disassembling.
b) As soon as the manifold has been disassembled inspect visually its surface and contact faces. Look especially for scratches, vibration dents and other damages that might cause defects in further operation. Contact surface of flanges and cones must not be battered, distorted or scratched. Close the inspected manifold by suitable caps (plastic foil and rubber bands) and store it up. Do not insert blinding plugs inside the openings. They can be overlooked easily and the manifold, when mounted, becomes clogged.
To facilitate future assembling, using appropriate means, mark the location of brackets and holders.
c) When assembling the original manifold, remove the caps and fit the manifold to the demanded position. Take care that no dust, dirt, binding wire, nuts, washers or other foreign objects get into the engine. Should any foreign object fall in the engine, work must be discontinued until these objects are found and removed even at the cost of long time losses.
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d) When replacing damaged manifold by a new one, remove the blinding caps from the new pipes, rinse the pipes in petrol and blow with compressed air. Inspect the contact surfaces of cones and flanges. Place the manifold to the pipe union to which it should be mounted and check whether contact surfaces bear together without strain. If the parts of the manifold are not aligned, or - there is a gap or overlap in axial direction less than 1 mm, the manifold can be mounted on. If the gap or overlap exceeds 1 mm, the manifold should be adapted by bending. The manifold of outside diameter 12 mm can be bent by 10 mm, the manifold of outside diameter 14 to 22 mm by 5 mm, compared with its original shape.
The manifold must be bent at a distance greater than 25 mm from welds and soldered joints and greater distance than 10 mm from nipples. Manifolds of outside diameter less than 10 mm can be bent when fitted on the engine, their one end, however, must be loose.
Adjusted must also be that manifold whose gap between the pipe and other part of the engine is less than 3 mm. Also in passages through air baffles, alignment tolerance of the manifold and openings in the air baffles is 1 mm.
If the above dimensions cannot be measured, perform visual estimates.
2. Instruction for mounting packings of joints and drives
a) All packings and rubber packing rings removed in the course of disassembling should be replaced by the new ones. Original packings can only be used if undamaged, free of apparent defects and without changes in their mechanical properties.
b) Only prescribed parts can be used for replacement. Especially in the case of rubber packing rings it is easy to mistake parts made of different material and of different dimensions. New part must not be damaged in storing.
c) Before dismantling, check the functional surfaces for placing packings.
d) In assembling, do not use hardened tools with sharp edges.
e) Smear bearing surfaces of packings with the engine oil or with the sealing agent shown in the instructions for assembling. Apply smearing and sealing agents in thin, even layers. Remove excessive quantity to prevent contamination of surfaces, clogging of channels or nozzles.
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3. Instruction for securing joints by means of locking devicesa) Locking wire, lock washers, tab washers, spring washers and split pins can be used once only. Bushings and plugs must be secured on lugs or the body. Never secure plugs to the bushing with a binding wire.
Insert the split pins so that their heads will fit into the nut slots. Bend one end over the bolt and the other over the nut.
b) When bending the tab washers, do not use tools with sharp ends. These tools could damage the material of tab washers causing thus their breaking and, moreover, fall into the engine.
c) Proper alignment of holes used for securing bolts and nuts should never be reached through exceeding the prescribed torque (see tables 301 and 302). If proper alignment can only be achieved either by exceeding the prescribed torque or by incomplete tightening, select another part that would make it possible.
d) When securing joints by means of binding wire, adhere to the following basic rules:
- locking wire must be tight after installation,
- it should be bound in a such way as to act in the sense of tightening and hold the joint in secured position,
- it must not be exposed to excessive strain caused by twist, - its ends must be bent towards the engine or the part concerned,
- when twisting the wire, hold it in pliers by its ends that should then be cut off, - the wire should be cut off so that three complete turns were left out of the loop, - hook the ends of the wire.
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1. Adjust proper position of the hole for securing wire.
2. Draw the binding wire through the securing holes.
3. Bend the wire upper ends around the bolt head.
4. Twist the wire as close to the hole in the other bolt as possible.
5. Pull the wire and simultaneously continue to twist it till complete tightening. The twisted wire should have approximately 3 to 4 turns per 10 mm.
WORKING PROCEDURE FOR SECURING BY BINDING WIRE Fig. 301
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6. Draw the upper wire through the opening in thesecond bolt. Seize the end of the wire with pliers and draw it tight.
7. Hold the free end in your hand, bend it around the bolt head and, together with the other end protruding from the hole drilled in the bolt, twist it counterclockwise.
8. Seize the twisted end of the wire with pliers and twist it tight.
9. Bend the twisted end under the bolt head.
10. Cut off the excess wire and hook the ends of wire.
WORKING PROCEDURE FOR SECURING BY BINDING WIRE Fig. 302
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Tightening Torque
Thread Size Nm lb.in
TIGHTENING TORQUE LIMITS FOR STUDS WITH STANDARD THREAD Table 301
Tightening Torque
Thread Size Nm lb.in
TIGHTENING TORQUE LIMITS FOR STUDS WITH FINE THREAD Table 302