Volkswagen Transporter 2.5 TDI Engine Cylinder Block Repair Grinding Boring Crimping Liner AXD BNZ

Traditional methods

So, closer to the topic. You can bore a cylinder block at home without special equipment using several traditional methods. They will require not only time, which goes without saying, but also patience.

Method 1

Although the method is “old-fashioned”, it also cannot do without a tool. A good electric drill set at low speed will work here. A worn piston with a gap in the liner (on the side) is also required. And you will also need a cylinder pin, as well as sandpaper with a different number of abrasive.

The piston in this case plays the role of the most significant element. It is the working fluid onto which the sandpaper is fixed. It is better to select an old piston that has expired, since after boring it will no longer be suitable for use.

In a car service, it is not paper that is used, but abrasive chips. Instead of a drill, as mentioned above, a special machine with a crank having the required diameter is used.

Repair process

• A hole is drilled in the middle of the piston for the cylinder pin.
• A nut is screwed onto the stud, and then the stud is inserted into the piston with its end up.
• The pin is tightened tightly.
• A cut is made on the piston with a metal hacksaw.
• The sandpaper is inserted into the resulting hole and then wrapped around the piston.
• This unique attachment is installed in the drill and tightened tightly.
• The cylinder is secured against turning.
• The drill turns on at low speed. Boring starts from top to bottom, and then from bottom to top.

Note. During this boring process, care must be taken to ensure that the skin does not come out of the piston. First, a large skin is used, then a finer one. At the final stage, grinding should be carried out with a zero.

Some experts also advise boring the cylinder block while using oil. Others do not agree with this opinion, because they believe that it bores well even dry. We are more impressed with the latter option, especially since you can feel the uniformity and smoothness with your hands if you have a certain skill.

A useful recommendation is: in order not to knock your hands off during grinding with an electric drill, it is recommended to firmly fix the cylinder, but try not to damage it in the process.

You may also find this video about honing helpful.

Method 2

In this case, a wooden mandrel will be used as the main tool. But you will have to contact a milling machine who will turn this very mandrel. The mandrel manufacturing technology is based on the following formula: if the cylinder being bored is 76, the bar mandrel should have a diameter of 74 mm. As for the length, it should be 200 mm larger than the size of the cylinder.

Preparing the fixture

• A hole is drilled in the mandrel.
• Using a hacksaw, a cut is cut along the mandrel, into which abrasive paper is inserted, as in the case described above.

Note. The approximate depth of the groove should be 10 mm. The skin, as in the first case, should be both large and small.

Let's get started

• The abrasive paper is wrapped around the mandrel.
• The skin is generously moistened with oil.
• The cylinder is bored by a mandrel. It is necessary to rotate the mandrel inside the cylinder with a large piece of sandpaper, trying to achieve free movement along the surface. Then change the paper to fine paper and continue.

Simple tips

The ideal option for boring cylinders that contain a car engine block:

The piston should sit tightly inside and not move downward due to its own weight.

The ideal option for boring cylinders that contain a motorcycle engine block:

The piston inside the cylinder should move easily, but not hang out too much, since when heated it will jam due to physical expansion.

Having learned how to carry out boring with your own hands correctly, you will no longer be concerned about the problem that arises for most owners of used cars. It is hardly possible to avoid low compression of internal combustion engines on used cars, but theoretically anyone can bore and increase compression.

Of course, as at the beginning of the article, we warn the reader. Most likely, it will not be possible to carry out boring correctly without the appropriate knowledge, but desire can overcome all doubts. Be sure to watch a few video instructions, study our recommendations and go ahead!

Why is a cylinder block liner needed?

When the engine is used for a long time, the use of low quality fuel, untimely maintenance, as well as unscrupulous repairs (piston pin failure), irregularities and abrasions appear on the cylinder walls in the block. Failure to properly handle can result in wear that is so large that boring to the maximum size will not remove the resulting bends. In such cases, “Honest Repair” copes with such damage only by installing repair liners in the cylinders. We bore the cylinder to a diameter equal to the outer diameter of the liner minus the amount of tension that is necessary to fix the liner in the cylinder block. We develop liner technology purely individually, based on the block material and cylinder wall thickness. To line the cast iron cylinder block, we use cast iron liners, which are obtained by centrifugal casting. This method is not suitable for aluminum cylinders.

In the event of a breakdown, the manufacturer often offers to replace the cylinder block, but this takes a long time. The only quick solution is to order a sleeve. For example, diesel engines on Volkswagen and Audi cars (BPD, BPE, AXE, AXD), in domestic conditions, often fail due to the destruction of ion-plasma spraying of the cylinder walls.

By ordering a cylinder block liner service from us, you will receive high-quality work done in a short time. After all, we have over 20 years of repair experience.

Sleeves as a method of repair

Boring and liner of the cylinder block
And in cast iron and aluminum blocks, there is such a thing as “SILER”, that is, special liners are installed - these are cylindrical (usually cast iron) hollow parts similar to a large piece of pipe.

They are pressed into the engine block under temperature and sit firmly in place. The main purpose is to make the motor stronger (in the case of the aluminum version), make the structure maintainable, and increase its service life. The sleeves can be made of high-strength alloy gray cast iron, as well as regular ones (it is worth noting that there are options with thin steel sleeves; this also exists, for example, ISUZU machines), there are also aluminum options, but they are not so common.

The big advantage is that when the liner wears out, it seems to take the entire blow upon itself. You simply pull it out (grind it out), install a repair one, or even one of the same size. Change the pistons and rings (most likely, repairs will be needed). And the engine runs normally again.

However, there are engines that are not “lined” from factories, both aluminum and cast iron. If we can bore a cast-iron block, and also “sleeve” it with a version of gray cast iron - install larger pistons (or the same ones) and roll on - because there is no difference in the thermal expansion of the metal. But aluminum, due to its complex manufacturing technology, is often not subject to this. A fair question arises - is it possible to put cartridges in it?

Cylinder block repair

All work on the repair and restoration of the cylinder block is carried out on modern high-precision equipment using advanced engine repair technologies. All technologies for restoring cylinder blocks meet the strict requirements of car engine manufacturers. The equipment of our repair shop allows us to provide a full range of BC repair services.

A comprehensive cylinder block repair includes:

• Boring BC
• Honingovka BC
• Gilzovka BC
• Restoring the geometry (flatness) of the BC
• Repair, restoration of crankshaft beds
• Sealing cracks

Any repair begins with washing the parts; without high-quality cleaning of the parts it is impossible to repair a modern engine. To clean parts, we use a Magido jet washer and a Tierra Tech MOT350 . After cleaning the parts, we determine its repairability; for this it is necessary to carry out pressure testing of the parts. Carmec PTR1600 leak testing stand .

Boring of cylinder blocks is carried out on a Berco ACP 160 . Thanks to CNC elements, the boring program can be set on the machine with maximum accuracy. The machine independently takes the necessary measurements and bores strictly according to the program without any deviations. A specialist who works on this machine can simultaneously work on several machines, which significantly reduces repair time in our service and technical center.

Another machine on which we bore cylinder blocks is AZ VB 182M . The machine has been used in our company for a long time and has established itself as a reliable and easy-to-use machine that allows you to quickly and efficiently repair the BC. For large parts longer than 2000 mm we use a high-precision machine AZ VB260.

For honing cylinder blocks, our service and technical center uses the AZ CH150 . Thanks to the use of smooth adjustments (changes) in the speed of the reciprocating movement of the spindle and its rotational speed, honing modes are optimized with both abrasive and diamond tools. The proven honing technology on this machine allows you to process the surface with the best results.

Restoration of the geometry (matting flatness) of the BC is carried out on an AZ SP1600 of the PLC series. This is a modern machine with CNC elements, which allows repairs to be carried out with high precision, cutting only to the required depth, which undoubtedly preserves the service life of the processed part.

Repair of crankshaft beds, as in the case of repair of camshaft beds in the cylinder head, is carried out on the AZ BAC 2000 . This machine is used by us and many of our clients to repair beds due to its high processing accuracy. Thanks to the smooth adjustment of spindle feed, spindle speed, chrome-plated boring bars and much more, this machine is the most successful among its kind.

We carry out other work on the repair and restoration of cylinder blocks using modern, technological equipment of domestic and imported production. For example, for spraying metals for various types of repairs, we use the domestic Dimet spraying installation. With this machine we can spray metals onto various surfaces quickly and efficiently.

Boring and lining of cylinder blocks at the Motortechnology technical center

Honing of cylinder blocks at the Motortechnology technical center

* Please note that this Internet site is for informational purposes only and under no circumstances constitutes a public offer as defined by the provisions of Article 437 of the Civil Code of the Russian Federation. For detailed information about the cost of services, please contact our managers.

Restoring engine cylinders

How to make a scissor lift with your own hands video

So, repairing the cylinder block and restoring the cylinders themselves involves:

• thorough cleaning of BC surfaces;
• then the cooling system channels in the block (cooling jacket) are checked for leaks;
• the oil channels are also washed and cleaned, and then checked;
• Next, the cylinders are inspected to identify various defects;
• then the block is bored/sleeved, surfaces are polished, etc.

For many engines, cylinder boring is a mandatory procedure as part of an engine overhaul. To perform the procedure, a special machine is used for boring engine cylinders. The boring of the block itself should be understood as the processing of the inner surface.

This treatment actually involves removing a layer of metal to level out unevenness, remove burrs, smooth out cavities, etc. The main task of processing is to give the cylinders a normal shape (cylindrical).

The next step after boring is honing. The application of hone to the internal surfaces of the cylinders is carried out using an abrasive fine-grained material (a honing bar on a honing head). The honing head itself is mounted in the spindle of the honing machine. This machine allows you to implement rotational and reciprocating movements.

Repairing the cylinder block may also involve liner re-lining or re-lining. In the first case, you should understand the installation of sleeves, although the factory design does not initially imply this. In the second, the worn sleeve is removed from the block, after which a new repair one is installed.

As a rule, the block sleeve can be made in two ways, when the sleeve is cooled with liquid nitrogen or the mating part is heated. In the first case, the cooled sleeve decreases in size and is easily placed (pressed) into the seat. The second method involves heating. Both methods of pressing sleeves allow you to achieve the desired tension.

Finally, we note that also as part of restoring the block, it may be necessary to repair the crankshaft bearing bed. Also in some cases it becomes necessary to eliminate the deformation of the block. For this, the method of artificial aging is used, when the block is heated to a certain temperature, after which various areas are processed.

Some general information about electronic control units
ECU
:

The abbreviation ECU (read EK-U) in the automotive industry refers to an electronic control unit (ECU)

.
Literally, ECU
is Electronic Control Unit (
ECU
).
Modern cars contain a wide variety of ECUs. They relate to the engine, traction control and anti-lock brakes, automatic transmission, active suspension, standard security system, air conditioning, radio and navigation, etc. One of the most important components is the electronic engine control unit - ECU. For various automakers and in various thematic sources, it may correspond to the names ECU, DME, DDE, ECM
(Engine Control Module),
PCM
(Powertrain Control Module) and some other abbreviations ECM (Engine Control Module, often combined with the automatic transmission control unit -
control unit PCM
).
The names PMS
and
PLD
are used in some Mercedes engine control units manufactured by Bosch and Siemens.
Often, for many manufacturers, the engine control unit is combined with an automatic transmission control unit
(AT) in one housing.
In this design, it is most often called PCM
(Powertrain Control Module). Such solutions are used by Ford, Mazda, Toyota and some German and Korean manufacturers.

Let's give a simple example on
PCM
unit from a Toyota RAV4 1AZ-FE AT 2002, USA. As can be clearly seen in the figure below, the Toyota RAV4 PCM / ECM control unit has 2 central processors - each works independently (at the same time, constantly exchanging data with each other), issuing executive commands and processing signals from the automatic transmission and ENGINE sensors. The processors control the automatic transmission solenoid actuators and injectors through specialized driver chips.

In the photo: electronic
engine control unit and automatic transmission ECU (PCM / ECM) from a Toyota Rav 4
1AZ-FE 2002.
Toyota part number: 89661-42821. Electronic components for engine and automatic transmission control are combined in one housing on a single printed circuit board. We ECU PCM
control units for Toyota RAV 4 from 2000 to 2004 (shocks when shifting gears, solenoid errors) at a special price of
6,500 rubles
with a 6-month warranty.

To avoid confusion with many terms, we will stick to the standard ECU term - ECU "electronic control unit"

, if necessary, supplementing it with belonging to a particular group of blocks.

Please ask for a complete printout of diagnostic codes , and if this is not possible, then ask a diagnostician what specific function is lost or incorrectly performed by the ECU. Remember that the inability to answer this question, as a rule, means a poorly performed diagnosis and the corresponding level of knowledge of this “master”. Correct identification of a malfunction at the preliminary diagnostic stage, as a rule, reduces our time for its final search and elimination and the funds you spend on repairs by several times.

Below we will try to list the main reasons

, contributing to the occurrence of malfunctions in the electronic control units of the ECU ECU:

1. Unqualified intervention during car repairs. 2. “Lighting up” from a car with a running engine or from a charging and starting device. 3. Mixed terminals + and —

when connecting the battery. 4. Removing the battery terminals with the engine running. 5. Consequences of exposure to time and a harmful environment (oxidation of contacts in the block and unsuitability of the tracks - most apply to blocks installed in the engine compartment). 7. Water or other liquids have entered the ECU/PCM housing. 8. Malfunctions of the ignition system output circuits: coils, wires, distributor, spark plugs. The result is failure of components in the ECU.

What is a cylinder liner?

How to make a spray gun for whitewashing with your own hands How to make a spray gun with your own hands Types of paint spray guns

The cylinder liner is actually a removable insert into the engine block. Otherwise, the liner acts as the walls of the cylinder block, since it is in it that the piston moves. The working volume of the cylinder directly depends on the volume of the liner. Installing a liner into a cylinder is called lining (lining) the cylinder block. The process of installing such an insert is complex, as it requires a number of preparatory work, as well as the presence of special equipment.

Car engines can have two types of liners: so-called “dry” and “wet”. The first type is an insert into the cylinder block that does not have contact with the coolant. The second type is a sleeve, which on one side comes into contact with the coolant. Such liners additionally have sealing gaskets that prevent liquid from entering the cylinder from the cooling system, and also prevent gases from escaping from the cylinder liner with their subsequent entry into the cooling system. We also add that “wet” sleeves are the easiest to repair.

The list of basic requirements for block bushings, regardless of their type, includes:

• corrosion resistance;
• resistance to mechanical and temperature loads;
• strength of the manufacturing material;

Also for liners that are installed with a seal, it is necessary to ensure the required characteristics in the place where the cylinder block meets the sleeve

During selection, attention is also paid to the shape of the product (ellipse and taper) and the wall thickness. It is also necessary to take into account the presence or absence of tolerance for additional boring of the liner after installation in the block

Cylinder liner blanks

High-quality cylinder liner blanks made from high-alloy cast iron using centrifugal casting. The high quality of the material is determined by the internal content of pearlite with some inclusion of graphite, the absence of internal pores and cavities, as well as appropriate heat treatment. These blanks will be indispensable in the process of engine overhaul when restoring cylinder blocks.

Motordetal-Konotop is the only enterprise in the CIS that carries out mass supplies to the Western market of liners according to the drawings of leading engine manufacturers Mercedes-Benz, MAN, Volvo, Zetor, Navistar, Daewoo-Avia, Peugeot.

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"To the beginningBack 1 ForwardTo the end"

Sleeving procedure

According to experts, lining an automobile engine block is possible for any internal combustion engine. That is, various motors are subject to such repairs.

Masters usually know which engines are initially lined at the auto production stage, that is, lined from the factory, and which are positioned as unrepairable. Since we have figured out that all types of internal combustion engines can be repaired, the presence or absence of liners from the factory does not play a decisive role.

If the block was lined at the factory, then most often we are talking about wet sleeves. The repair consists of replacing the worn bushing with a new one. This is the simplest sleeve option among all existing ones. In some cases, work is carried out manually. To do this, it is enough to select the necessary and suitable repair sleeves.

It is also a mistake to assume that when lining, absolutely all bushings must be replaced. This directly depends on which of them are worn out. Only those that have already used up their resource can be replaced. The rest remain in their places and are used until they become scuffed and damaged.

If you have an unlined block in front of you, that is, the engine from the factory does not provide for the use of sleeves in its design, and dry sleeves should be selected for it, this task becomes noticeably more difficult.

• Bushings made from alloy cast iron are mounted in cast iron blocks;
• If the block is made of aluminum alloy, then aluminum bushings should be used.

We must not forget that alloys for BC can have various additives and additional components. Also, special reinforcing materials are applied to the walls themselves, which provides improved resistance to damage and scuffing. Therefore, it will be better if a qualified specialist undertakes the selection of cartridges.

Sleeving can be divided into the pressing process and hot sleeving.

Press-fitting is used in situations where it is necessary to replace old liners with new bushings. Here it is necessary to pre-bore the cylinders in order to create a perfectly even and correct geometry for seating new liners. Even the slightest deviation during boring is not allowed. Otherwise, the pistons and their rings will not be able to function normally. After boring, the bushings are pressed in, the corresponding pistons are installed, and the engine is assembled.

In the case of hot sleeves, when a dry sleeve is mounted, the process looks like this:

• The BC is heated to approximately 150 degrees Celsius;
• before installation, the selected sleeve is cooled using liquid nitrogen;
• a solution is applied to the sleeve to prevent condensation from forming during the installation of the cold sleeve inside the hot block;
• the sleeve is inserted into its prepared place.

This method of restoring the BC is optimal in terms of quality, since the technology makes it possible to create a tight fit and ensure tension in the areas where the bushing and block come into contact. The bushing itself easily slides into place, literally under its own weight. To completely install it in the socket, the master just needs to knock a little with a hammer. There is no need to use any extra force for pressing in the case of hot sleeves. Unlike the first method discussed, replacing the old bushing with a new one.

But there are some exceptions when the aluminum BC is not pre-bored. Then the bushing is installed by pressing. The procedure differs in that before installation the socket under the sleeve is lubricated with sealant. And then a new element is pressed in.

In practice, everything looks much more complicated. That is why lining should be trusted exclusively to highly qualified specialists with extensive experience, knowledge and relevant skills. It is not recommended to try to sleeve the BC with your own hands. Without special tools and equipment, it is almost impossible to do this efficiently.

If you follow the rules, follow all recommendations and strictly take into account all the technological features of the liner, the minimum service life of the internal combustion engine can be extended by 100 thousand kilometers. But in some cases, cars easily overcome marks of 150-200 thousand kilometers, while properly maintaining and operating the engine.

REPAIR OF ENGINE CONTROL UNITS Peugeot, Citroen

We repair the engine control unitPeugeot-Citroen
.

Peugeot - Citroen engine control unit repair, Peugeot - Citroen BSI unit repair.

We carry out diagnostics and REPAIR of ENGINE CONTROL UNITS, BSI, airbag, instrument panel, ABS, etc. on
Peugeot - Citroen
of all models. Repair of control units SID208, VICTEON DCU102 and others. Restoring BSI configuration, linking used units, repairing immobilizers and much more...

tel.
89096463839 SAO, Moscow. Directions
We also repair the engine control unit

on cars Audi, VW, Skoda, Seat, BMW, Mercedes Benz, Toyota, Lexus, Mitsubishi, Honda, Acura, Volvo, Saab, Opel, MINI, Rover, Range Rover, Mazda, Kia, Hyundai, Subaru, Nissan, Peugeot, Citroen, Renault, Ford, Isuzu, Jaguar, Infinity, Fiat, Alfa-Romeo and other manufacturers.

Why did the engine control unit fail?

The causes of unit failure, in 95% of cases, are related to external factors;
the engine control unit itself “never” breaks down
.
The most common causes of failure of the Peugeot - Citroen
:

1. Battery seating, improper lighting. 2. Carrying out welding work on a car. 3. Reversing the polarity of the terminals when connecting the battery. 4. Removing the battery terminals with the engine running. 5. Oxidation of contacts in the block or short circuit of the wiring. 6. Water or other liquids getting inside the engine control housing. 7. Malfunctions of the output circuits of the ignition or injection system - short circuit of the ignition coils, short circuit of the injection nozzles, sensors or wiring in their circuits. 8. Unskilled intervention.

On Peugeot Boxer, Citroen Jumper cars

We repair engine control units on Peugeot Boxer, Citroen Jamper and others. Repair and cloning of Continental SID208

, Visteon
DCU102
, Bosch
EDC15.
Malfunctions of the engine control unit Peugeot - Citroen

The symptoms are similar to many other malfunctions and, often, conclusions about a unit malfunction may be erroneous.
Approximately every fifth engine control unit that comes to us for repair turns out to be in good working order. We and the client are wasting time, but the fault remains in the car... Before making a verdict that the engine control unit is faulty ,
a thorough diagnosis of the operation of the unit in the car is required.
Correct identification of a malfunction at this diagnostic stage significantly reduces the time required to repair the engine control unit in a hospital
. When handing over the engine control unit for repair, do not forget to provide us with complete information about the car - year of manufacture, engine size, engine type and the results of diagnosing the operation of the unit in the car.

If the diagnosis is carried out correctly, in its results we should find answers to the following questions:

1. Does the suspected unit come up for diagnostics - yes or no, if so, what errors does it produce? Does the unit see the signal from the crankshaft sensor, camshaft sensor, coolant temperature in the current diagnostic parameters? 2. Is there or is there no spark on the spark plugs when the starter rotates? a. When you turn the ignition on, is there power to the ignition coils (from the main relay)? b. When the starter rotates, is there a control minus on the ignition coils from the engine control unit? 3. Are the injection nozzles working? a. When you turn on the ignition, is there power to the injectors (from the main relay)? b. When turning the starter, is there a control minus on the injectors on the engine control side? 4. When you turn on the ignition, does the main relay turn on? (is there power, is there a control minus from the engine control unit or not?) 5. When you turn on the ignition, does the fuel pump relay turn on? (is there power, is there a control minus from the engine control unit or not?) 6. Does the immobilizer respond to diagnostics? If so, what errors does it give? 7. During the diagnostic process, the diagnostic electrician must check the connection of the suspected unit according to the diagram, make sure that the required supply voltages and grounds are available, as well as the integrity of the CAN digital data exchange buses, etc.

Diagnostics are good in their results

!!!
Request from the car service centers that ordered the unit for repair detailed diagnostic results, which would clearly describe on what basis the decision was made that the engine control unit is faulty
.

If the diagnostics were not carried out or did not answer the above questions, we recommend that you bring the engine control unit for repair

along with the car. In this case, we ourselves will carry out the work to diagnose the causes of the malfunction and, if the engine control unit is to blame, we will begin to repair it. Some faults in the engine control unit cannot be detected without the vehicle being present. Therefore, in some cases, to speed up diagnosis and repair, it is better to provide the entire car.

When submitting the engine control unit for repair, please provide us with detailed diagnostic results in which we could find answers to the questions stated above. Require diagnosticians to provide detailed information about diagnostic results. We recommend that clients contact competent diagnosticians, and we recommend that diagnosticians have a diagnostic scanner and engine control circuit diagrams

and the ability to work with them.

We provide support to car services that cooperate with us

. We practice interaction with car service centers at all stages of car repair. We advise by phone, suggest diagnostic methods, help with diagrams and advice. We advise colleagues on the nuances of diagnosing various car models, help with pinouts of engine control units, immobilizers, etc. This approach allows us to minimize the likelihood of incorrectly diagnosing a fault at the initial stages.

In some cases, in addition to the engine control unit, other units may be required for repair, such as an immobilizer control unit, ignition keys, immobilizer antenna, etc. You can find out which units need to be provided for repairs in your case by calling. 8(909)6463839 Repair of the engine control unit is performed in a hospital; usually, the repair time for the control unit ranges from several hours to several days, depending on the complexity of the defect and the availability of spare parts.

Engine control unit repair

involves connecting the unit on a stand, supplying it with all operating voltages, monitoring the operation of the unit’s actuators, followed by troubleshooting of faults identified at the previous diagnostic stages. Finding faulty electronic components and replacing them. In cases where the motherboard of the engine control unit is damaged, as a rule, the unit cannot be repaired... In such cases, you can use a used engine control unit. or new. We carry out programming and binding of B.U. blocks. for cars from almost all manufacturers.

Repaired engine control units come with a WARRANTY. PS The warranty does not apply

for those cases when the unit fails again due to the initial causes of the unit failure in the car not being eliminated. To avoid repeated failure of the engine control unit, we recommend that you pay increased attention to finding and eliminating the causes that caused its failure. Those. in other words, if the control unit fails, in 95% of cases this indicates that there is a reason in the car that caused its breakdown. Before installing the repaired unit back into the car, make sure that the original cause of the engine control side failure has been eliminated, otherwise you risk burning out the repaired unit again. In such cases, we do not provide warranty obligations. To avoid such developments, we try to tell our clients the most likely, initial causes of unit failure and recommend measures to eliminate them. Based on the nature of the malfunction detected in the engine control unit, the technician assumes the original cause of the unit’s failure. To avoid repeated failure of the unit, the technician gives the client recommendations for checking and eliminating possible malfunctions in the car that could cause such a malfunction of the engine control unit. For example, in cases where the control channel for the injector of the 3rd cylinder in the engine control unit has burned out, the recommendations will be as follows: carefully check the wiring section from the injector to the engine control unit and replace the injector of the 3rd cylinder.

STATIONARY REPAIR OF ENGINE CONTROL UNITS Peugeot - Citroen tel. 8(909)6463839

Road map

Engine control unit repair in Moscow. Tel. 8(909)6463839

If you decide to disable the Mitsubishi immobilizer, you have come to the right place.

Removing the immobilizer on Mercedes C202, E210, S140, G463 cars with infrared alarm.

Programming and linking of B.U. blocks Remove immobilizer.

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Further development and non-repairable units

Automakers did not stop there. The decision to abandon the use of cast iron and sleeves turned out to be correct. This ensured a simplified and cheaper production process. Eliminated the need to press sleeves, cast blocks around the so-called glasses, etc.

However, the solid aluminum block meant that there was no need to take into account the temperature parameters of different materials, that is, aluminum and cast iron. This allowed for better cooling.

But the problem of aluminum being soft remained unchanged. Since the pistons use strong steel rings, during active use they will quickly begin to destroy the aluminum cylinder itself. There was a need to give the cylinder mirrors additional strength. To achieve this, developers began to try different coatings based on ultra-durable materials.

As a result, the world saw the first sleeveless motors based on an aluminum block. They went into mass production in 1971. The base was made of aluminum, to which 17% silicon was added. Briefly described, the mirror of the working cylinder was subjected to sudden and strong cooling, which made it possible to crystallize silicon. Then the area was treated with various acids. They removed the remnants of existing aluminum at the molecular level.

As a result, a high-strength solid wall appeared inside the cylinder, along which pistons with steel rings moved quite freely and without the risk of causing damage. The technology seemed very promising, which led to its further development. The result was aluminum sleeves saturated with silicon.

Despite the apparent victory of aluminum over cast iron, in practice everything turned out to be not so rosy and promising. There remained the problem of poor resistance to mechanical stress, which caused scuffing. Indeed, despite the high-strength layer, it was thin, and underneath there was soft aluminum metal.

The next stage of development was a special technology, which involved compacting the walls through galvanic treatment using nickel and silicon carbide. This technology is well known to fans of Audi and BMW cars. The Bavarians went a little further, releasing a motor with improved aluminum liners, while making all other components based on a magnesium alloy. This significantly reduced the weight of the internal combustion engine.

Currently, engineers are actively working to make cylinder wall processing technology even stronger, more durable and more efficient. As a result, laser alloying, plasma deposition, titanium, etc. appeared.

All efforts of the developers were aimed at increasing the resource of the internal combustion engine and reducing its weight. In theory, everything looked rosy and promising. But in practice, a number of shortcomings have appeared in the so-called non-repairable cylinder blocks. Aluminum BCs could quickly fail and not be able to be restored in case of certain breakdowns. At the same time, replacing the entire unit cost a substantial amount, amounting to about 20-30% of the cost of the car, and in some places even more.

Aluminum blocks could not provide a solid service life, which on average for different automakers was 300 thousand kilometers. If we compare them with cast iron blocks, or with blocks made of aluminum, but lined with cast iron, then they covered 400-500 thousand kilometers without any problems. There are also legendary millionaires.

Considering the existing shortcomings due to the short service life and high cost of replacing the BC, the question arose regarding the repair of supposedly unrepairable units. And then the shell casings became a salvation. Experts have been practicing sleeving aluminum BCs for many years, despite the fact that they are officially not subject to restoration.

This procedure turned out to be not the cheapest or easiest, but compared to purchasing a new block or a complete engine, it still reduces the car owner’s costs. If everything is done correctly and in accordance with the technology, the resource of the internal combustion engine after lining will be no less than that of a contract engine or an old internal combustion engine with a new block. Therefore, the costs of sleeves are often completely justified.

At the moment, almost any motor can be lined. The main thing here is the presence of sufficient wall thickness, which will allow restoration with sleeves. If problems arise with the engine, you can select suitable sleeves for it and install them inside the block.

Engine block repair

5.1. Article 18 of the Law of the Russian Federation “On the Protection of Consumer Rights”. Consumer rights when defects are discovered in a product 1. If defects are discovered in a product, if they were not specified by the seller, the consumer has the right, at his own discretion, to: demand a replacement with a product of the same brand (same model and (or) article); demand replacement with the same product of another brand (model, article) with a corresponding recalculation of the purchase price; demand a proportionate reduction in the purchase price; demand immediate free elimination of defects in the goods or reimbursement of costs for their correction by the consumer or a third party; refuse to fulfill the purchase and sale agreement and demand a refund of the amount paid for the goods. At the request of the seller and at his expense, the consumer must return the defective product. In this case, the consumer also has the right to demand full compensation for losses caused to him as a result of the sale of goods of inadequate quality. Losses are compensated within the time limits established by this Law to satisfy the relevant consumer requirements. In relation to a technically complex product, if defects are discovered in it, the consumer has the right to refuse to fulfill the purchase and sale agreement and demand a refund of the amount paid for such a product or make a demand for its replacement with a product of the same brand (model, article) or with a different product. brand (model, article) with a corresponding recalculation of the purchase price within fifteen days from the date of transfer of such goods to the consumer. After this period, these requirements are subject to satisfaction in one of the following cases: detection of a significant defect in the goods; violation of the deadlines established by this Law for eliminating product defects; the impossibility of using the product during each year of the warranty period in total for more than thirty days due to repeated elimination of its various deficiencies. The list of technically complex goods is approved by the Government of the Russian Federation. 2. The requirements specified in paragraph 1 of this article are presented by the consumer to the seller or an authorized organization or an authorized individual entrepreneur. 3. The consumer has the right to present the requirements specified in paragraphs two and five of paragraph 1 of this article to the manufacturer, authorized organization or authorized individual entrepreneur, importer. Instead of presenting these demands, the consumer has the right to return goods of inadequate quality to the manufacturer or importer and demand a refund of the amount paid for it. 5. The consumer’s absence of a cash or sales receipt or other document certifying the fact and conditions of purchase of the goods is not a basis for refusal to satisfy his requirements. The seller (manufacturer), authorized organization or authorized individual entrepreneur, importer are obliged to accept goods of inadequate quality from the consumer and, if necessary, carry out a quality check of the goods. The consumer has the right to participate in checking the quality of the product. In the event of a dispute about the reasons for the occurrence of defects in the goods, the seller (manufacturer), an authorized organization or an authorized individual entrepreneur, or the importer are obliged to conduct an examination of the goods at their own expense. The examination of goods is carried out within the time limits established by Articles 20, 21 and 22 of this Law to satisfy the relevant consumer requirements. The consumer has the right to be present during the examination of the goods and, in case of disagreement with its results, to challenge the conclusion of such examination in court. If, as a result of the examination of the goods, it is established that its defects arose due to circumstances for which the seller (manufacturer) is not responsible, the consumer is obliged to reimburse the seller (manufacturer), an authorized organization or an authorized individual entrepreneur, the importer for the costs of conducting the examination, as well as those associated with its implementation. costs of storing and transporting goods. 6. The seller (manufacturer), authorized organization or authorized individual entrepreneur, importer is responsible for defects in goods for which there is no warranty period, if the consumer proves that they arose before the transfer of the goods to the consumer or for reasons that arose before that moment. In relation to goods for which a warranty period has been established, the seller (manufacturer), an authorized organization or an authorized individual entrepreneur, the importer is responsible for defects in the goods unless he proves that they arose after the goods were transferred to the consumer as a result of the consumer’s violation of the rules for use, storage or transportation of the goods, actions of third parties or force majeure.

The concept of a sleeve

To begin with, car enthusiasts should be introduced to such an element as the cylinder liner. At its core, it is a removable insert (bushing) that is installed in the cylinder block. So we can say that the task of the liner is to perform the functions of the block wall, since the piston will move inside it upon completion of the repair.

The volume of the liner used directly affects the working volume of the cylinders used. The process in which the liner is installed in the cylinder is called liner or block liner.

The installation process is quite complex. Here you can’t just take a sleeve, insert it inside the block, and put everything back together. Preliminary preparation is required. During the work, special equipment is used.

The liners used during major repairs are divided into 2 categories. These are wet and dry elements. Dry ones do not come into contact with the coolant. The wet type is designed so that one of its sides is in contact with the coolant. They have additional sealing gaskets that prevent antifreeze from penetrating into the cylinders. At the same time, they block the breakthrough of gases formed in the cylinders into the cooling system.

If we talk about repairs, then the advantage is on the side of wet sleeves. When choosing sleeves or bushings, a number of basic requirements should be presented to them. They should be:

• corrosion resistant;
• resistant to mechanical loads;
• resistant to temperature loads;
• made from high-strength materials.

If these are sleeves where additional seals are provided, then it is also important to take into account the place of contact between the block and the sleeve. Do not forget about the shape and thickness of the walls of the product

If necessary, specialists take into account the absence or presence of approval for additional boring of the liner itself after installation work. That is, the sleeve (sleeve) can be installed in the block, and then bored to the required parameters corresponding to the dimensions of the piston.

Types of sleeves

Today, there are 2 types of liners used in cars:

• “dry”: this type is mounted in the cylinder block itself during manufacturing.
• “wet”: the type most suitable for repairs. The outer side interacts with the coolant.

The main requirements for the performance properties of liners are:

• corrosion resistance,
• wear resistance of metal,
• strength.

The reliability of the seals of the repair bushings during sleeve must be ensured by high reliability of the seals at the junction of the bushing and the block.

Cylinder block lining technological process of lining

This technological operation is classified in two variations: during current or major repairs of the engine. If the format is current, we replace the head gaskets and adjust the thermal clearance of the valves present. Here, dismantling the unit is not required; the operation is performed in the garage. It is more difficult to act during a major overhaul. It is actually possible to remove the component, place the cylinder head, cylinder block. To carry out boring, honing of components, and “sleeving” of the block, you will need to use specialized equipment.

The liner is a removable insert (metal) for the cylinder block. This is where the engine piston moves and the cylinder volume is determined. It is the repair of the sleeve that involves the procedure of “sleeving” - the technological process is very complex. The procedures are carried out according to the recommendations of the manufacturers, and the service life (mileage) of the machine is assessed. It is necessary to take into account the brand of the block, the standard of the engine, and find out the wear of the cylinder.

On a modern car there are two types of liners:

• “wet” - interact with the cooling liquid, contain sealing gaskets that prevent liquid from entering;
• “dry” - mounted on the cylinder block (this design).

There are requirements for the operating properties of liners: these are anti-corrosion resistance, strength, and wear resistance of the metal. It is the reliable seals of the repair sleeves during the procedure that should ensure the reliability of the various seals at the joint areas with the block.

The shape of the sleeve determines the ellipse and taper of the product (parameter up to 0.02 millimeters). The surface of the part must correspond to accuracy class (8-10). By the way, the repair of liners is not necessarily accompanied by the replacement of parts. It is first worth diagnosing the condition of the components using a bore gauge. Then we decide to change the sleeve if necessary.

The repair procedure depends on the type of liners used. You can change “wet” sleeves manually. To replace “dry” elements you will need equipment.

The cylinder blocks are made of cast iron, they are lined with cast iron bushings made of alloy cast iron. If the blocks are aluminum, aluminum alloy components with coating additives are required. First we bore the cylinders. It is necessary to maintain the correct geometry of the nests present. The ellipse of this socket will then be reflected in the shape of the liner - the piston will also function.

The sockets are then honed to ensure an accurate surface. All that remains is to line the BC. The method of processing “dry” cartridges involves heating the block. Then an element cooled in liquid nitrogen is placed in the nest. We treat the sleeve with a compound in advance to prevent water condensation during installation. This method is the most successful, high-quality - optimal interference is achieved in the connections.

To carry out pressing, proceed as follows:

• first the response part (block) is heated;
• then the bushings are cooled;
• sealant is introduced into the hole;
• The bushing is pressed into the socket.

This is the procedure for lining the Central Bank. If the work is done accurately, following the parameters, the repaired “engine” will last a long time.

Lining of the cylinder block

There are two types of sleeves: dry and wet. Wet is when the liner is washed by coolant. Dry, respectively - no. When replacing wet liners, there are usually no difficulties. Replacement requires a special sleeve remover. When replacing dry liners, there are nuances due to a tighter fit when installed in a seat in the block. Before pressing a dry sleeve, it must be cooled. Liquid nitrogen is used for this.

Call, tel. Come for diagnostics and repairs!

Pressing the sleeve into the TRUCK-24 using liquid nitrogen

Also, when performing a major overhaul, the main connecting rod bearings are replaced, and the crankshaft is polished or ground, if necessary. The plane of the cylinder head is polished and the cylinder head is crimped. The edges and valve seats are edited. Change valve guides, if necessary. The camshaft and rocker arm rollers are also checked for wear and scoring, and replaced if necessary. When performing a major overhaul of an internal combustion engine, we recommend checking the fuel injectors on a test bench. Thus, improper operation of the fuel system can also lead to engine failure. The oil pump is diagnosed - this determines whether there will be the required oil pressure in the engine.

After all the work has been completed, the valves are adjusted and new oil is added. We at TRUCK-24 recommend that after running-in (3000 km) you change the oil and adjust the valves again.

Aluminum and cast iron

Before telling you about the process itself, it’s worth mentioning that there are different materials for making blocks. These are cast iron (it appeared first) and aluminum. I will have a separate article about them, but today I will simply tell you which ones can be SHARPENED AND WHICH NOT!

Cast iron is an almost ideal option, cheap, reliable, durable. They last for a long time, and often give in to grooving. We remove the required size, install new repair pistons, and the engine is back in service. However, they also have significant disadvantages - weight (it is three times heavier than aluminum), heat dissipation (more passages and channels are needed to effectively cool it), and corrosion (the walls can rust from prolonged inactivity).

Aluminum is lightweight, has the best heat dissipation, and is not subject to corrosion. A big plus is its weight; now many manufacturers are chasing to reduce the weight of their cars; the aluminum version gives them greater savings, and therefore lower fuel consumption of the car. BUT this metal is soft and short-lived compared to cast iron. For better wear resistance, the inner walls are coated with a special coating with a high silicon content. THEN and only then can the motors operate for a sufficiently long time.

How is cylinder head porting carried out?

Before porting the cylinder head, you need to check that you have several components:

1. Inlet/outlet type channels;
2. Guide bushings;
3. Valves;
4. Springs/plates for bushings;
5. Combustion chambers.

Next we follow the instructions:

1. Take the cylinder head and remove all the valves present on it.
2. Inspect the channels, remember the places where defects are present.
3. Remove the guides.
4. Use the helper pins to install the intake manifold.
5. Using bolts, screw the auxiliary studs into the separate channels intended for the cooling mixture. Small holes can be made in the studs to maintain normal heating.
6. We combine the manifold with the cylinder head.
7. File down the intake manifold.
8. When work on the collector comes to completion, you will have to combine the channels. Docking can be done using plasticine.
9. Use a chisel to remove any rough spots on the exhaust type valves.
10. Subject the remaining channels to a thorough polish to remove all surface defects.

The result of all the above-described manipulations will be that the cylinder head will have more advanced characteristics:

• The diameter of the intake channels is 32 millimeters;
• The diameter of the exhaust channels is 29 millimeters;
• The diameter of the valve stems is 8 millimeters;
• Camshafts cylinder head, sports - standard - 13.5 millimeters;
• The guide type bushings are longer than standard.

Thus, by modifying the cylinder head, it is possible to maximize the potential of a car engine.