General information and safety precautions for removing the power unit If it was decided to remove the engine, then certain preparatory measures must be taken. It is extremely important to determine the place where the work will be carried out. Undoubtedly, the best place is the workshop....
Removing old sealant Pic. 2.51. Removing old sealant After removing the mounting bolts and nuts, use a suitable tool to remove the sealant (pic. 2.51). Attention! Be careful not to damage the surface of the part. Remove sealant as...
Specification of the types of nuts and bolts used The types of bolts used are given in Table 2.15, the specification of dimensions and tightening torques of the bolts used - in Table 2.16. The types of nuts used are shown in table 2.17. Table 2.15. Types of bolts used...
Maintenance of the mechanical part of the engine Data for servicing the mechanical part of the engine are given in table 2.18. Table 2.18. Data for the maintenance of the mechanical part of the engine
Removing the oil filter Unscrew the oil filler cap. Remove the PCV valve. Remove spark plugs. Pic. 2.53. Removing the oil filter: 1 - special tool Remove the oil filter using the special tool 09228-06501 (pic. 2.53). Unscrew the nut and...
Removing the crankshaft pulley Remove the camshaft position sensor. Set the number one piston to TDC on the compression stroke. Pic. 2.55. Combination of markings with marks on the camshaft bearing caps: 1 - marks on the covers; 2 - marking «0» To...
Removing the coolant pump Pic. 2.57. Nuts of fastening of a tensioner of a chain of a drive of the mechanism of gas distribution Remove the timing chain tensioner by unscrewing the two nuts shown by the arrows in Figure 2.57. Pic. 2.58. Nuts and...
Removing the oil pan Remove the crankshaft position sensor. Loosen the oil pan drain plug. Pic. 2.59. Removing the oil pan To remove the oil pan, unscrew the twelve bolts and two nuts. Insert the blade of the special tool 09032-00100...
Disassembly of the working components of the timing mechanism drive Pic. 2.60. Bolts and nuts for fastening the timing chain cover Remove the fourteen bolts and two nuts securing the timing chain cover (pic. 2.60). Using a screwdriver, separate the cover from the head and cylinder...
Removing the oil pump drive chain Pic. 2.62. correct (combined by labels) crankshaft position: 1 - hole on the pump housing Turn the crankshaft 90°counterclockwise and align the oil pump shaft mark with the hole on the pump housing, as shown in Figure...
Removing the oil pump Pic. 2.64. Oil pump mounting bolts After unscrewing the three mounting bolts, remove the oil pump (pic. 2.64).
Removing caps and camshaft bearing Pic. 2.65. How to remove the intake and exhaust camshaft covers Remove covers of a camshaft of final and inlet valves in the order shown in drawing 2.65. Remove the camshaft bearing. Remove the VVT-i valve.
Checking the radial play of the balance shafts Pic. 2.68. The sequence of unscrewing the bolts of the cover of the balancing mechanism In several passes, sequentially, unscrew the eight mounting bolts and remove the cover of the balancing mechanism (pic. 2.68). Pic....
Replacement of a back epiploon of a cranked shaft Pic. 2.72. Oil seal removal Cut off the edge of the seal with a knife. Using a screwdriver wrapped in cloth, remove the oil seal (2.72). Note. Using sandpaper, remove the remaining oil seal from the lip of the rear oil...
Checking the operation of the timing chain tensioner Pic. 2.75. Scheme for checking the operation of the timing chain tensioner Make sure the plunger moves freely when the ratchet is raised. Release the ratchet and make sure the plunger is locked (pic. 2.75).
Camshaft Runout Check Pic. 2.76. Checking the runout of the camshaft on the stand using the indicator Install the camshaft on two prisms. Install the sensitive head of the indicator on the neck. Turn the camshaft manually to one side and...
Camshaft lobe height check Pic. 2.77. Measuring the height of the camshaft cam with a micrometer Measure the camshaft lobe height (pic. 2.77). The standard height of the cam contour is 46.495–46.595 mm. The minimum height of the cam contour is...
Gap in the camshaft (outside diameter) Pic. 2.78. Measuring the diameter of the camshaft journal with a micrometer Measure the outer diameter of the camshaft journal (pic. 2.78). Camshaft bracket standard inner diameter: No. 1 - 35.971–35.985 mm; No. 2,3,4,5...
Installing the WT sprocket (intake camshaft) Pic. 2.79. Installing the intake camshaft sprocket: 1 - locking pin; 2 - notch Hold the sprocket in such a position that the groove in it is slightly to the left of the camshaft locating pin (shaft side). Install the...
Dismantling of a head of the block of cylinders Remove the oil pressure sensor. Remove the coolant temperature sensor. Remove the camshaft position sensor by removing the mounting bolt. Remove pushers. Pic. 2.80. Removing crackers, spring plates, springs and valves...
Checking the cylinder head Pic. 2.82. Scheme for checking the warping of the surfaces of the cylinder head Using a ruler and feeler gauge, check for warping of the cylinder head surfaces mating with the cylinder block surface and with the...
Checking valve seats Apply a thin layer of white to the bevel of the valve. Lightly press the valve face against the seat, but do not rotate the valve. Then remove the valve and inspect the valve seat and bevel. If the paint remains around...
Checking the end play of the camshaft Pic. 2.85. Checking the end play of the camshaft Install the camshafts. Measure the end play with an indicator by moving the camshaft back and forth (pic. 2.85). Rated backlash: inlet - 0.040–0.095 mm; release -...
Checking the radial play in the camshaft bearings Clean the working surfaces of the bearing caps and camshaft journals. Install the front bearing shell. Lay the camshaft in the bed of the cylinder head. Place a piece of plastic gauge on each camshaft journal. Install...
Checking the valve spring Pic. 2.87. Measuring valve spring length Use a caliper to measure the free length of the spring (pic. 2.87). Valve spring length: 45.70 mm. Pic. 2.88. Measuring valve spring misalignment clearance Using a metal square...
Valve length check Check overall valve length. Nominal length: intake valve - 101.71 mm; exhaust valve - 101.15 mm. Limit length: intake valve - 101.21 mm; exhaust valve - 100.70 mm. If the overall length is less than the minimum, replace...
Checking the thickness of the valve disc Check the thickness of the valve head with a vernier caliper. Standard intake valve thickness: 1.05–1.45 mm. Minimum tolerance: 0.5 mm. Standard thickness of exhaust valves: 1.20-1.60 mm. Minimum tolerance: 0.5 mm. If...
Valve Stem Diameter Measurement Pic. 2.89. Valve Stem Diameter Measurement Measure the diameter of the valve stem with a micrometer (pic. 2.89). Valve stem diameter: intake valve - 5.470–5.485 mm; exhaust valve - 5.465–5.480 mm.
Checking the internal diameters of the valve guides Check the inside diameters of the valve guides. Using an inside gauge, measure the inside diameters of the valve guides at three levels. The inner diameter of the sleeve is 5.510–5.530 mm. Calculate by subtracting the...
Checking tappets and tappet bores in the cylinder head housing Pic. 2.90. Checking the tappet diameter with a micrometer Measure the diameter of the plunger with a micrometer (pic. 2.90). The pusher diameter is 30.966–30.976 mm. Calculate by subtracting the tappet diameter from the...
Cylinder head assembly Pic. 2.92. Valve stem seals for intake and exhaust valves and their installation: 1 - special tool Using the special tool 09201-41020, install new valve stem seals. Inlet valve stem seals painted black and exhaust valve...
Dismantling of the block of cylinders Pic. 2.95. Measuring the end play of the crank head of the connecting rod Check the axial clearance of the connecting rod bearing. Using a dial indicator, measure the axial play of the crank head of the connecting rod...
Checking the radial play of the connecting rod bearing Remove the connecting rod cap and check the radial clearance of the connecting rod bearing. Pic. 2.96. Connecting rod cap bolts Check alignment of marks on connecting rod and connecting rod cap to ensure correct...
Replacement of liners of radical bearings Pic. 2.99. Marking of the size group of the main bearing shells When replacing standard size liners, use liners of the same size group as indicated on the bearing cap. There are size groups of liners, indicated «1»,...
Removing the piston and connecting rod assembly Pic. 2.100. Removing carbon deposits from the top of the cylinder Before removing the piston and connecting rod assembly, remove carbon deposits from the top of the cylinder with a reamer, as shown in Figure 2.100. Pic....
Checking clearance between piston and cylinder Pic. 2.109. Measuring the skirt diameter With a micrometer, measure the diameter of the piston skirt at the distance indicated in Figure 2.109 from the surface of the piston bottom from the end of the skirt (below the...
Checking the gap between the compression ring and the groove Pic. 2.110. Measuring the gap between the compression ring and the groove Check up a backlash between a compression ring and a flute, having measured its flat probe, as is shown in drawing 2.110. Standard Clearance:...
Checking the clearance in the piston pin lock Pic. 2.111. Pushing the piston ring: 1 - piston ring In order to check the clearance in the piston ring lock, install the ring in the block cylinder. The piston push a ring from a surface of the block of cylinders, as...
Checking the inner diameter of the pin hole in the piston Pic. 2.113. Measuring the inside diameter of the pin hole in the piston Using a dial gauge, measure the inside diameter of the finger hole in the piston (pic. 2.113). The inner diameter of the sleeve is 22.001–22.010 mm.
Checking the piston pin diameter Pic. 2.114. Piston pin measurement Using a micrometer, measure the diameter of the piston pin (pic. 2.114). The standard diameter is 21.997–22.009 mm. The limiting diameter is 21.990 mm.
Checking the fit of the piston pin Pic. 2.115. Measuring the inner diameter of the bushing of the upper head of the connecting rod Using a dial gauge, measure the inside diameter of the connecting rod bushing (pic. 2.115). The standard diameter is...
Connecting rod check Pic. 2.116. Checking bending and twisting of the connecting rod Using a special tool and a flat feeler gauge, check the bending of the connecting rod. In the same way, check the twisting of the connecting rod (pic....
Checking the crankshaft Pic. 2.117. Checking the runout of the crankshaft To check the runout of the crankshaft, lay the crankshaft on the prisms. Using a dial indicator, check the runout of the crankshaft on the central main journal (pic....
Checking the connecting rod and main journals Pic. 2.118. Measurement of connecting rod and main journals With a micrometer, measure the diameter of each connecting rod and main journal in two mutually perpendicular planes, as shown in Figure 2.118. The diameter of...
Checking the connecting rod bolts Pic. 2.119. Measurement of the diameter of the neck of the connecting rod bolt Using a vernier caliper, measure the diameter of the connecting rod bolt neck (pic. 2.119). The standard diameter is 7.5–7.6 mm. The minimum...
Checking and replacing the main bearing shells Pic. 2.120. Measurement of clearances in plain bearings: 1 - plastic gauge Clean each main journal and bearings. Check the surface of each main journal and bearings for pitting and scratches. If the neck or insert is...
Assembling the connecting rod and piston group Pic. 2.124. Installing a new retaining ring Using a screwdriver, install a new retaining ring on one side into the piston cylinder bore (pic. 2.124). Gradually heat the piston to a temperature of 80–90°C. Apply some...
Installation of piston rings Pic. 2.126. The correct position of the compression ring marks before installation Install the expander and two oil ring scrapers. Use a piston ring expander to install two compression rings. Ring labels should be...
Cylinder block assembly Pic. 2.128. Installing the main bearing shells To install the main bearing shells, align the tabs on the upper bearing shells with the grooves (grooves) bed block and insert liners (pic. 2.128). Note. Top halves of...
Installation of balance shafts Pic. 2.132. The correct position of the driven gear Turn driven gear #1 of balance shaft #1 in the direction of rotation until it stops, making sure that the marks on gears #1 and #2 are aligned (pic. 2.132). Pic....
Engine crankcase installation Pic. 2.135. Sealing locations Remove old sealant. Be careful not to damage the contact surfaces. Using a blade and scraper, remove old sealant from the contact surfaces and sealant recesses. Thoroughly clean all...
Installation of bolts of fastening of a head of the block of cylinders Wrap bolts of fastening of a head of the block of cylinders. Pic. 2.143. The order of tightening the cylinder head bolts The block head bolts are tightened in two steps. If one of the bolts is damaged, replace it....
Installing the VVT-i sprocket Install the VVT-i sprocket. Pic. 2.145. Correct position of the VVT-i sprocket: 1 - groove; 2 - pin Hold the sprocket in such a position that the groove in it is slightly to the left of the camshaft locating pin (viewed...
Installation of camshafts Install the lower and upper shells of the front camshaft bearing. Pic. 2.147. The order of tightening the bolts for fastening the bearing caps of the intake and exhaust valves Establish camshafts of inlet and final...
Oil pump installation Pic. 2.148. Oil pump mounting bolts Install the oil pump with a new gasket and tighten the bolts to 19 Nm (pic. 2.148).
Installing the sprocket and oil pump drive chain Pic. 2.149. Installing the oil pump drive shaft To install the oil pump drive chain and sprocket, install the crankshaft with the key to the left, and the oil pump shaft with the notch up, as shown in the figure (pic....
Installing the timing chain drive Pic. 2.156. Alignment of crankshaft sprocket marks Slide the chain onto the crankshaft sprocket, aligning the link with the color markings (blue or orange) marked with an asterisk (pic. 2.156). Pic. 2.157. Fixing the...
Installing the crankshaft position sensor rotor Pic. 2.159. Marking «F» crankshaft position sensor rotor sprocket alignment Install the crankshaft position sensor rotor as shown in Figure 2.159.
Installing the Timing Chain Cover When removing old sealant, take care not to damage the contact surfaces of the timing chain cover, coolant pump, cylinder head and cylinder block. Using a blade and scraper, remove old sealant from the contact surfaces...
Oil pan installation Pic. 2.163. Places for applying sealant to the surface of the pallet: 1 - sealant Remove the old sealant from the surfaces of the sump and crankcase, being careful not to damage the contact surfaces. Clean the contact...
Installing the coolant pump Pic. 2.165. Places for applying sealant to the surface of the coolant pump Before installation, clean the contact surfaces of the coolant pump from the old sealant. Apply new sealant to pump lip (layer thickness 2–2.5...
Installing the crankshaft position sensor Pic. 2.168. Installing the crankshaft position sensor: 1 - cable; 2 - clamp; 3 - bolt Install the crankshaft position sensor by tightening the clamp mounting bolts to 9 Nm. After installation, make sure that the sensor...
Installing the crankshaft pulley Pic. 2.169. Installing the crankshaft pulley Clean the crankshaft pulley. Align the key with the keyway of the crankshaft pulley and install the pulley. With special tool 09213-54015 (91651-60855), 09330-00021 tighten...
Installing the Timing Chain Tensioner Mechanism Pic. 2.170. Scheme of preparing the timing chain tensioner mechanism for installation: 1 - pin; 2 - hook Press the ratchet, push the plunger of the chain tensioner fully in and hook the hook onto the pin (pic. 2.170)....
Translating the timing chain tensioner into working condition Pic. 2.172. Putting the timing chain tensioner into working condition: 1 - hook; 2 - pin; 3 - plunger Rotate the crankshaft counterclockwise and release the plunger pin from the hook. Then turn the crankshaft clockwise...
Final assembly of the unit Install the camshaft position sensor, tightening it to 9 Nm. Pic. 2.176. Sealing locations Apply new sealant to the places shown in Figure 2.176. Pic. 2.177. Bolts of fastening of a cover of a head of the block of...