General information This book covers 1.4L petrol engines (H4J), 1.6 l (K4M) and 2.0 l (M4R). Valve clearance adjustment is automatic using hydraulic tappets and does not require manual adjustment. The water pump is driven by a V-belt or...
Engine identification data M4R engine identification data located on the cylinder block (A) and on the timing cover (IN). Identification data for K-series engines located on the cylinder block (1). The quality class is indicated on the bolt at...
Bolt tightening methods As a rule, when repairing cars, two methods of controlled tightening are used: this is tightening with the required torque and tightening at a given angle (also called torque and angle tightening). Torque tightening The...
Safety precautions when performing internal combustion engine repairs To ensure a quality repair: use recommended professional repair materials and original spare parts; observe tightening torques; follow the instructions for parts requiring mandatory replacement after removal,...
Aggregate replacement (new engine) Parts to be removed from a used engine and installed on a new engine (provided they are correct): all hoses of the engine cooling system; oil pressure sensor; knock sensor; intake manifold; an exhaust manifold;...
Cylinder Leak Check Note. Checking cylinders for leaks can be done as an alternative to measuring compression. Using this method, you can measure the total amount of leakage from the engine cylinders and determine its location. A similar...
Compression test Remove the engine top cover, coils and spark plugs (see corresponding operation). Connect a compression gauge to cylinder #1. Run the following commands using the scan tool: RZ003: «ADAPTATIFS MOTEUR»; VP036:...
Auxiliary equipment drive belt (K4M engine) Attention. Do not turn the engine crankshaft in the opposite direction of rotation. Attention. Be sure to replace the accessory drive belt. Removing Place the car on a lift. Disconnect the battery. Remove the engine top...
Auxiliary equipment drive belt (M4R engine) Removing Place the car on a lift. Remove: right front wheel; right front fender (see corresponding operation); protective screen. Turn the accessory drive belt tensioner clockwise with a 14mm wrench. Lock the tension...
Lower jet thrust (M4R engine) Removing Install the car lift. Remove: engine crankcase mounting bolts; protective screen. Remove: fastening bots (1) anti-skid rods; anti-skid traction (2); bolt (3) fixing the lower jet thrust on the subframe; lower...
Right pendulum suspension (M4R engine) Removing Remove: engine crankcase mounting bolts; engine undertray protection; lower jet thrust. Disconnect the fuel feed line from the engine swing arm mount. Disconnect the fuel supply line (1) from the fuel rail....
Left pendulum suspension (M4R engine) Removing Place the car on a lift. Remove: left front wheel; left front fender liner; battery; battery shelf; air filter housing; engine undertray protection; lower jet thrust. Establish a support for removal and...
Lower jet thrust (K4M engine) Removing Place the car on a lift. Remove the engine crankcase mounting bolts and the protective screen. Remove: bolt (1) fastening the lower jet thrust to the front suspension subframe, lower tie rod bracket bolt to...
Right pendulum suspension (K4M engine) Removing Place the car on a lift. Remove: top cover of the engine; engine crankcase mounting bolts; engine undertray protection; lower jet thrust. Install fixture (replaces tool Mot. 1367), consisting of devices for...
Left pendulum suspension (K4M engine) Removing Place the car on a lift. Remove: top cover of the engine; battery; battery shelf; air filter housing; lower jet thrust. Install the battery harness groove (1). Move aside the battery harness groove. Disconnect...
Wiring harnesses K4M engine The R37 connector of the circuit between the engine harness and the injection harness is shown in the figure. Switch off the ignition. Disconnect the battery. Disconnect the R37 connector of the circuit...
Wiring and connectors K4M engine Disconnect connectors: block of wires from the air temperature sensor (12); wiring harnesses for ignition coils (13); knock sensor (14); oil pressure sensor (15); air conditioning compressor (16);...
Timing belt (K4M engine) Tightening torques when removing and installing the timing belt Attention. Together with the belt, be sure to replace the tension and bypass rollers. Note. The method for removing and installing the timing belt for...
Timing chain (H4J engine) Remove the engine complete with gearbox. Install the engine on a stand for assembly and disassembly. Drain the engine oil. Loosen the bolts (1) water pump pulley by blocking the water pump pulley with a screwdriver....
Timing chain (M4R engine) Tightening torques when removing and installing the timing chain Removing Remove the engine complete with gearbox. Install the engine on a stand for assembly and disassembly. Drain the engine oil. Remove the accessory...
K4M engine cylinder head gasket Place the car on a two post lift. Disconnect the battery. Remove the battery. Remove the engine top covers. Remove the engine undertray. Remove the accessory drive belt. Remove the timing belt. Remove the front bumper....
Cleaning the cylinder head of the K4M engine Clean mating surfaces with DECAPJOINT (or similar) for removing gasket residue from mating surfaces of the oil pan and cylinder block. After applying the composition to the surface to be cleaned, wait about ten minutes,...
Checking the mating surface of the cylinder head of the K4M engine Use a feeler gauge to check the flatness of the cylinder head mating surface. The maximum allowable flatness: no more than 0.05 mm. Attention. Grinding of the cylinder head is not permitted. Valve spring plunger...
Removing the valve springs of the K4M engine To properly compress the valve springs, the tool plunger must be centered (Mot. 1502) along the valve stem. The valve spring plate must fit into the bore of the pressure sleeve of the tool (Mot. 1502). Remove: crackers;...
Checking the height and tightness of the cylinder head of the K4M engine Checking the height of the cylinder head Measure the height of the cylinder head. The height of the cylinder head is 137 mm. Check of tightness of a head of the block of cylinders Check the cylinder head for cracks...
Checking the axial movement of the camshafts of the K4M engine Install the camshafts, making sure they are in the correct position, and the cylinder head cover. Tighten in the order shown in the figure to the required torque: cylinder head bolts 13 -20-22-23 (8 Nm), cylinder head...
Checking the valves of the K4M engine The diameter D of the valve stem is measured at distance X1. Inlet valves X1: = 75.14±0.35 mm, D = 5, 470 - 5.485 mm. Exhaust valves X1: = 77.5±0.35 mm, D = 5, 456 - 5.471 mm. Valve Test Diagram Valve head diameter D:...
Checking the gap between the rods and the valve guides of the K4M engine There are two ways to check the clearance between the valve stem and the valve guide. First way. Raise the valve head by 25 mm, then measure the movement of the valve in the direction of the arrows at an angle of 90°to...
Checking the valve springs of the K4M engine Check the deflection of the spring from the vertical, which should not exceed 1.2 mm. Check spring calibration. Spring length under load: under a load of 18 - 20 N, the length of the spring is 34.50 mm; under a load of...
Assembling the MCC of the K4M engine Insert the valve into the cylinder head. Put on the tip of the tool (Mot. 1511) on the valve stem (the inner diameter of the tip must be equal to the diameter of the rod). Keep the valve pressed against the seat. Spring...
Cylinder block and crankshaft of the K4M engine Install the flywheel retainer (Mot. 582-01 or Mot. 1677). Remove the cover and clutch disc. Remove flywheel. Remove the engine oil pan. Remove the timing belt tensioner pulley. Remove the water pump. Remove the engine...
Removing the piston pins of the K4M engine Remove the piston rings with piston ring pliers. Install the piston assembly with the connecting rod on the tool prism (Mot. 574-22). Align the piston pin with its exit hole in the prism (1). Using a press, press out...
Checking the gaps in the lock of the piston rings of the K4M engine Install the piston ring in the cylinder. Move the piston ring to the middle of the cylinder with the piston. Measure the ring gap in the lock with a set of feeler gauges. Checking clearances in the piston ring lock: 1 -...
Installing the shells of the main bearings of the K4M engine Installing the main bearing shells in the bed of the cylinder block Install the fixture on the block (Mot. 1493-01). Press the special tool until the insert contacts the tool plate. Installing shells in main bearing...
Checking the axial movement of the crankshaft of the K4M engine Install the crankshaft. Check the presence of thrust half rings on the 3rd support (the grooves of the half rings must face the cheeks of the crankshaft). Note. The mating surfaces of the cylinder block and main bearing...
Installing the connecting rod bearing shells of the K4M engine The engine is equipped with liners without a mustache. Inserts are installed with a tool (Mot. 1492). Select the liner holder according to the engine model (engine model is indicated on the bracket). Install the insert...
Assembly of connecting rods with pistons of the K4M engine The piston pins are installed with an interference fit in the upper heads of the connecting rods and rotate freely in the piston bosses. use kit (Mot. 574-22) and fixture (Mot. 574-24). Visually check: condition of...
Preparing the piston pins of the K4M engine Check that the piston pins rotate freely in the bosses of the corresponding new pistons. Use centering mandrel C 13 and mounting mandrel A13 from the kit (Mot. 574-22) for piston pins without collar. Use centering...
Assembling the piston and connecting rod of the K4M engine Install ring B10 on the prism (1) and a piston supported by a ring (oriented in the correct position) and fasten all parts with a clamp (2). Make sure the piston pin bore is aligned with the B10 ring bore. Lubricate the...
Installation of piston rings of the K4M engine The piston rings are matched to the piston and must move freely in the piston grooves. Observe the installation direction of the rings (TOP label is directed upwards). Observe the position of the lock of each ring.
Assembly of the lower part of the K4M engine Lubricate the upper parts of the cylinders and the connecting rod journals of the crankshaft with engine oil. Reinstall the pistons and connecting rods with the tool. Install the crankshaft connecting rods. Install the...
Installing the crankshaft oil seals of the K4M engine Press in the crankshaft rear oil seal with a mandrel (Mot. 1129-01). Press in the front crankshaft oil seal with a mandrel (Mot. 1385). Install the flywheel with new mounting bolts. Install the flywheel retainer (Mot....
Installing the cylinder head gasket for the K4M engine Install a new cylinder head gasket. Install the cylinder head. Tighten the cylinder head bolts. Refill hydraulic tappets as working fluid from the pushers may leak if they are not operated for a long time. To make sure...
K4M Engine Tightening Procedure Tighten in order to the correct torque: bolts of fastening 22, 23, 20, 13 of a cover of a head of the block of cylinders (80 Nm); bolts 1-12, 14-19, 21-24 of fastening of a cover of a head of cylinders (120 Nm). Loosen...
Replacing the camshaft seals of the K4M engine Elastic camshaft seals are used in two versions, the seal in the first version has a spring (1) and V-shaped working edge (2). In the second variant, the stuffing box has a flat working edge (1) and safety sleeve (2),...
Main head cover for H4J, M4R engines Remove: intake air duct; ignition coils; spark plug. Remove: fastening bolt (1) holder for connectors of the wiring harness of ignition and injection systems; holder (2) wiring harness connectors for ignition and...
Timing pulleys for H4J and M4R engines Remove the exhaust camshaft gear (3) with a flat wrench and a ratchet. Remove the intake camshaft dephaser (4) with a flat wrench and a ratchet. Replace: bolt of fastening of a gear pulley of a camshaft of final valves;...
Camshafts for H4J and M4R engines Turn away bolts of fastening of a case of camshafts. Detach the camshaft housing using a crankcase separator with silicone seals (Mot. 1716) (3). Remove the crankcase distribution rooms (4). Remove camshafts (5) and...
Checking the camshafts of the H4J and M4R engines Clean the camshafts with a cleaner and dry them with a compressed air blow gun. Check that the surfaces of the camshafts are free of scratches, impact marks and excessive wear (replace the camshaft if necessary). The...
Camshaft color coding for H4J and M4R engines H4J engine: bearing journal No. 1: 27.04 - 27.06 mm, bearing neck No. 2, 3, 4 and 5: 24.95 -24.97 mm. Place the camshaft on two lightly oiled v-blocks. Using a micrometer, measure the height of the cams (H). M4R engine:...
Valvetrain for H4J and M4R engines Mark the positions of the valve lifters in relation to the cylinder block using an indelible pencil. Remove the valve lifters, keeping their original installation position. Compress the valve springs with a valve lifter...
Valve spring designation for H4J and M4R engines Exhaust and exhaust valve springs are color coded. M4R engine: green label - intake valve springs; purple label - exhaust valve springs. H4J engine: yellow mark - intake valve spring; white or green label - exhaust...
Checking valve spring wear on H4J and M4R engines The length of the springs in the free state. M4R engine: intake valves: 45.59 - 45.96 mm; exhaust valves: 45.13 - 45.40 mm. H4J engine: intake valves: 46.73 mm; exhaust valves: 54.3 mm. Use a dynamometer to check the...
Checking clearances in the valve drive mechanism of engines H4J and M4R Rotate the camshaft so that the cam to be checked is pointing up. Using a feeler gauge, measure the clearance in the valve drive mechanism, which should be (on a cold engine): intake valves: 0.26 - 0.34 mm; exhaust...
Pusher class of H4J and M4R engines Note. As a repair kit, one-piece pushers are supplied in 26 grades, 3.00 mm - 3.50 mm thick in 0.02 mm increments. The class of the pusher is indicated on its inner side.
Engine oil sump for H4J and M4R engines Remove the engine undertray. Drain the engine oil. Turn away in the specified order bolts of fastening of the pallet crankcase of the engine. Detach the engine oil pan using a crankcase separator with silicone gaskets...
Crankshaft pulley for H4J and M4R engines Install the crankshaft pulley retainer (Mot. 1789) (1), to block it. Tighten the fastening bolt (2) retainer on the cylinder block. Loosen the bolt (3) crankshaft pulley and crankshaft pulley retainer bolt (Mot. 1789)...
Cylinder block marking for H4J and M4R engines Cylinder block marking: A - a new cylinder block; B - cylinder block for aggregate replacement; 1 -class according to the diameter of the cylinder No. 1; 2 -class according to the diameter of the cylinder No. 2; 3...
Checking the diameter of the crankshaft bearings Install the crankshaft main bearing caps by installing the #1 timing cover. Measure the diameter with a micrometer (X1) crankshaft bearings. The diameter value must be between 55.997-56.017 mm (for M4R engine) and...
Crankshaft for H4J and M4R engines Mark the crankshaft main bearing caps with an indelible pencil, if necessary (bearing No. 1 is located on the timing drive side). Remove: bolts of fastening of covers of main bearings of a cranked shaft; crankshaft...
Crankshaft marking for H4J and M4R engines Crankshaft marking: 1 - diameter class of the connecting rod journal No. 1; 2 - diameter class of the connecting rod journal No. 2; 3 - diameter class of the connecting rod journal No. 3; 4 - diameter class of the...
Checking the axial runout of the crankshaft of the H4J and M4R engines Install: liners of main bearings of a cranked shaft in the block of cylinders; bearing shells for crankshaft main bearing caps. Note. Lubricate the surfaces of the main bearing shells of the crankshaft in contact with...
Crankshaft seals for H4J and M4R engines Crankshaft oil seal on flywheel side Remove the crankshaft seal (1) , using a screwdriver and a piece of wood, being careful not to damage the crankshaft seating surface. Degrease and clean the mating surface of the...
Removing the block «piston-rod» H4J and M4R engines Attention. Do not use a punch or engraver to mark the cylinder affiliation on caps and connecting rods, as this may cause the connecting rod to begin to break. Use an indelible pencil. Mark the position of the...
Removing piston rings on H4J and M4R engines Note. This operation should only be performed when replacing or checking piston rings. Remove the piston rings with piston ring pliers. Note. Be careful not to damage the piston when removing the rings. Do not spread...
Block «piston-rod» H4J and M4R engines Disassembly Note. These steps need only be performed when replacing or inspecting a connecting rod or piston. Mark the position of the piston relative to the cylinder with an indelible pencil. Remove the retaining ring...
Piston ring installation for H4J and M4R engines Note. Observe the position of the piston rings when installing them (mark up). If there are no marks on the piston ring, it can be installed in any position. Install the piston rings with piston ring pliers. Separate...
Installing connecting rod bearing shells for H4J and M4R engines When replacing the crankshaft, connecting rods, connecting rod bearing shells, it is necessary to determine the thickness class of the bearing shells installed in the connecting rods. Degrease the mating surfaces with a...
Block installation «piston-rod» H4J and M4R engines Apply engine oil: into cylinders; piston skirts; on the connecting rod journals of the crankshaft. Make sure the piston rings are properly seated in the piston grooves. Install the piston in the installer (with...
Checking the piston pin length for H4J and M4R engines Before checking, make sure that the piston pin rotates freely in the piston. Using a micrometer, measure the outer diameter of the piston pin (D) which should be 19.989-19.995 mm.
Piston to piston pin clearance for H4J and M4R engines Using a micrometer, measure the inside diameter of the piston. Piston markings: 1 - piston identification code; 2 - direction of installation of the piston; 3 - piston pin diameter class; 4 - piston class by diameter....
Checking the piston skirt diameter of H4J and M4R engines Using a micrometer, measure the piston diameter (X1) to size (X2) = 39.9 mm. M4R engine H4J engine Checking the clearance between piston grooves and piston rings A: Wrong probe position. B: Correct probe position....
Connecting rod marking for H4J and M4R engines Connecting rods with a detachable shear lower head are used. Note. The bushings of the upper heads of the connecting rods are not replaced. Connecting rod marking: 1 - used only by the factory; 2 - cylinder number; 3...