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Nowadays, a car is not a luxury, but a common means of transportation for everyone. As a result, the number of motorists who prefer to carry out repairs on their vehicles themselves is growing. This is explained by the rather high prices for service stations.
That is why the question of how to assemble an engine is quite relevant. Why overpay if you can diagnose or repair the engine yourself? These skills can be useful not only when repairing your car, but also if you want to assemble the car yourself. This is a fairly common practice, especially among car enthusiasts who have a lot of free time and resources. You can learn more about assembling a car yourself in the article How to assemble a car.
If there are not enough funds and resources, or there is not enough practical experience, you can start small and try to assemble a moped from a bicycle. You can learn more about this in the article How to make a moped.
Engine overhaul. Where to begin?
Engine overhaul - general information
Sometimes it is so difficult to determine when the moment comes that you need to carry out a complete overhaul of the engine of your favorite VAZ. And should it be produced at all? There are a lot of factors to consider here.
Significant mileage, as many are accustomed to believe, is by no means a sign of the need for major repairs. Conversely, low mileage also does not guarantee the normal condition of the engine. An important role in this matter is played by the frequency and quality of various procedures for related vehicle maintenance. Thus, an engine in which the oil and filters were changed with enviable regularity, and other maintenance procedures were also conscientiously carried out, is likely to last for many thousands of kilometers. On the contrary, careless or complete failure to carry out such procedures for routine maintenance of the machine will force a major engine overhaul after a very short period of time.
If you notice excessive oil consumption, pay attention to the condition of the piston rings, oil seals, and guide bushings. But before you blame all these components and make the main verdict, check whether the oil loss is simply due to a leak. As a rule, oil loss occurs as a result of impacts from the bottom of the car, as well as constant high-speed driving. In both cases, we can say that the driver is not experienced, and it is quite possible that he will not only quickly destroy the car, but will also receive a fine and confiscation of his driver’s license. It’s good that for unfortunate drivers there is a special service for returning a license from Andrey Aleksandrovich Sychev, otherwise you could forget about driving a vehicle.
The first thing to do is check the compression pressure in the cylinders. This will give useful information about the condition of the piston. You can check the pressure yourself by installing a pressure gauge instead of a pressure sensor. The measurement result is compared with the requirements from the specifications. Low pressure indicates possible wear of the bearings or hydraulic pump (or maybe both of them :).
Instability in engine operation, “incomprehensible” noise, knocking, increased fuel consumption, loss of power - all this may be a sign that an engine overhaul is necessary, especially (!) if several of them are observed at the same time. You can try an engine tune-up, but if this does not help, routine mechanical work will be required to restore the various engine components to proper operation.
Performing a full overhaul involves restoring engine performance to the operating values specified in the specifications of the new units. During the repair, the piston rings are replaced and the cylinder mirrors are grooved and fine-tuned (usually honing). Grooving is usually done in a car repair shop, since it is impossible to do it yourself efficiently. Pistons of the required size are also installed there. If necessary, the crankshaft journals are restored. Main and connecting rod bearings are replaced. A set of works to service the valve mechanism is being carried out. Usually, when engine repairs are needed, valves, bearing plates, return springs and other components are in terrible condition.
Together with the overhaul of the VAZ, you can check the condition and replace the starter, distributor and generator.
As a result of all the work, the restored engine should work with the characteristics of a new one and serve reliably for 100-150 thousand km.
If you intend to do most of the work yourself, before deciding what to entrust to specialists, disassemble the engine and carefully check their condition yourself.
Never purchase spare parts in advance and do not machine any of its parts (before you have analyzed ALL components), because the engine may be in such a state that it is cheaper, and most importantly, it will be easier to buy a new one or one that has already been restored. In addition to monetary costs, engine overhaul takes a fairly large amount of time, so there is no need to save money and install low-quality or non-standard parts. It will cost more.
In conclusion, in order to get the maximum lifespan from a rebuilt engine, the engine must be assembled in very clean conditions!
PS After repairs, it is necessary to “break in” the engine. It should be noted that only after 1.5-2 thousand km can you begin to gradually increase the load, and only after 10-15 thousand km can you “demand” from the engine to give everything it is capable of.
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What to do during a major overhaul
The first thing that needs to be done is boring the cylinders. During this procedure, the thickness of the liners decreases and the volume of the entire cylinder increases. If boring is not possible, then the sleeves must be replaced. After boring, the surface must be honed. Honing can be done in a grid or under a mirror. By making it into a grid, you will get an increase in power, but this will not be felt for long. After 4-5 thousand kilometers, the grid is erased and the power decreases.
Be sure to replace the main and connecting rod bearings. Carefully ensure that they fit tightly to the surface and that the holes intended for lubricant flow are not closed. If you are tuning the engine, then it is necessary to improve the lubrication system; for this you need to make an additional groove in the liners. It is impossible to do this manually, since not a single file will take hardened steel. Only competent specialists with good machines are able to perform this operation efficiently.
