Removing and installing a gasoline engine The engine is removed along with the gearbox and then separated from the gearbox. This job requires lifting equipment, but can be lifted by two strong people. The following description is general, as it is impossible to...
Gasoline engine disassembly Before describing engine disassembly, it is worth mentioning the most important data on the engines of the models described. Both engines are 1.6 l (carburetor and injection), as well as the 2.0 L engine, are single-row...
Engine assembly Like disassembly, engine assembly is described in various subsections. The assembly order is the reverse of the disassembly order. The following general instructions must be observed during assembly: Before assembly,...
Removing the cylinder head The cylinder head can be removed without removing the engine, and this is the job shown below. Engines 4A-F/FE Unscrew the water pump pulley nuts, loosen the V-belt adjusting bolt and remove the V-belt (Pic. 5). Unscrew...
Disassembling the cylinder head Disassembling the cylinder head is done the same way on both engines. Clamp the cylinder head in a vice using a bar attached to one of the exhaust manifold studs. To remove and install the valves, a special tool...
Cylinder head inspection Determine wear of all cylinder head parts. Clean the cylinder head surfaces thoroughly (remove the remaining old sealant with a scraper without damaging the cylinder head material). Control should be carried out in...
Cylinder head assembly Clean all cylinder head parts and place them on a workbench in the order of assembly. If the valves have been ground in, they must be installed on their seats, since the wear pattern of the valves varies. On a 1.6 liter...
Installing the cylinder head Engine 4A-F/FE Place a new cylinder head gasket on the cylinder block. Both centering pins should go through the gasket. Place the cylinder head on the cylinder block. Apply engine oil to the threads and the underside...
Checking and adjusting valve clearances On these engines, valve clearances are checked and adjusted when the engine is cold. Remove the cylinder head cover. The adjustment is the same on both engines. Check valve clearances as follows: Rotate the crankshaft...
Checking compression in cylinders If you suspect a loss of compression in a cylinder, you should purchase a compression tester and check the compression in individual cylinders. This identifies pistons, valves or piston rings that are not holding...
Pistons and connecting rods — removal and disassembly The pistons and connecting rods are removed from the inside of the cylinder with the hammer handle upwards, after removing the connecting rod bearing caps and bearing shells. When carrying out this work, the...
Cylinder measurement A dial indicator is required to measure cylinders (Pic. 89), which can be used to measure in the middle and at the bottom of the cylinder. If there is no dial indicator, these works cannot be carried out. Pic. 89....
Checking pistons and connecting rods Check all details. If there are scratches or wear, replace the parts. Measure the piston ring clearances in the piston grooves in height, inserting the piston rings one by one, as shown in Figure 91. First clean the...
Assembling pistons and connecting rods When assembling pistons and connecting rods, observe the following instructions: Arrow on the piston crown (applied, or on a new connecting rod with the inscription "VORN") should be towards the front of the engine....
Installing pistons and pins Lubricate the cylinder bore. Sort all connecting rods by cylinder numbers. Label "VORN" on the connecting rod and on the bottom of the piston should be directed towards the engine pulleys. Pic. 96. On the 1.6 liter...
Cylinder block When completely disassembling the cylinder block, clean and remove all foreign objects from the cavities and lubrication channels. Cleaning liquids should also be completely removed. If possible, blow out the block with...
Crankshaft and flywheel — parts inspection Check the crankshaft for damage and measure the main and connecting rod bearing journals. Measurements to determine taper and ovality should be carried out in the directions indicated in Figure 100. To install a...
Checking the crankshaft end play Install the dial indicator on the stand in front of the cylinder block so that the dipstick rests against the outer journal of the crankshaft, as shown in Figure 104. Push the crankshaft to the side with a screwdriver,...
Installing the crankshaft using Figure 24: Wipe the bearing beds and insert the bearing shells with their protrusions into the slots of the bearings. Lubricate the liners well, but make sure that the oil does not come out. Place the thrust...
Oil seals — removal, installation Whenever the oil pump crankshaft or oil seal flange is removed, the seals must be replaced. The front flange is also the housing of the oil pump. Both oil seals can be replaced without removing the engine when oil leaks...
Flywheel — removal, inspection and installation To remove the flywheel, it must be properly locked (insert a screwdriver into the teeth). You can also drill holes in the metal plate, secure it with the clutch mounting bolts and remove the bolts. When tightening the...
Timing drive and camshaft — 4A-F/FE engine Pic. 109. Parts of the gas distribution mechanism drive of the 4A-F/FE engine. 1. Timing belt upper protective cover; 2 Middle toothed belt protective cover; 3. Bolt. 120 Nm; 4. Crankshaft pulley; 5 Lower toothed belt...
Timing drive and camshaft — 3S-FE engine Pic. 110. Parts of the gas distribution mechanism of the 2.0 l engine 1. Cover bolt; 2. Toothed belt upper protective cover; 3. Bolt, 55 Nm; 4. Camshaft gear; 5. Tension roller; 6. Release spring; 7. Oil pump drive...
Removing and installing the exhaust manifold The intake and exhaust manifolds on all engines are mounted separately. Removal and installation are similar on all models. Before removing any part of the device, it is important to remember the location of the...
Removing and installing the muffler Compression and installation is not difficult. The following points should be especially taken into account: Be sure to replace the gasket between the exhaust manifold and the exhaust pipe of the muffler. Tighten the...
Precautions when installing a catalyst If large quantities of unburned fuel are allowed to enter the catalyst, it may overheat and create a fire hazard. For this reason, the following should be considered: Refuel only with unleaded gasoline. Avoid prolonged...
Size and adjustment tables — engine — mechanics Cylinder head Permissible deformation of the cylinder head surface - 0.05 mm Permissible deformation of surfaces to collectors: engines 4A-F/FE intake side - 0.05 mm, exhaust manifold side - 0.10 mm 3S-FE engines all -...
Table of tightening torques for threaded connections — petrol engines Engine 3S-FE Engine 4A-F/FE 65 60 Cylinder head bolts 19 11-13 Camshaft bearing cover 15 — 20 15 — 20 Spark plug 13 Exhaust gas return valve to manifold 60 Exhaust gas return line on cylinder head 13 4 — 8 Cylinder head...