Checking, draining and filling oil Note. When checking, draining and refilling oil, use an 8 mm square wrench for the drain plug. Oil consumption measurement procedure Note. The operation is performed on a hot engine after turning on the electric fan of...
Removal and installation of the oil filter (F4R engine) Attention! During operation, do not allow engine oil to get on the drive belts. Removing Place the car on a two post lift. Remove the engine undertray. Pic. 2.3. Bolts of fastening of a strut of the compressor of the...
Removal and installation of the oil filter (engines K4J, K4M) Removing Place the car on a two post lift. Remove the engine undertray. Pic. 2.5. Installing the special tool on the oil filter Install special tool (Mot. 1329) to the oil filter (pic. 2.5). Installation Lubricate the...
Oil pressure measurement To measure oil pressure, special tools and tools are required. Attention! Oil pressure is checked with a hot engine (at a temperature of about 80°C). Examination Disconnect the battery. Remove the oil pressure sensor....
Air filter replacement (K4J engine) Filter element replacement Pic. 2.7. Silencer bolt: 1 - bolt Remove the intake silencer mounting bolt (pic. 2.7). Remove the intake silencer. Pic. 2.8. Removing the vacuum hose and air filter cover bolts: 1 - vacuum...
Air filter replacement (F4R engine) Filter element replacement Pic. 2.9. Removing the air filter housing cover: 1 - bolts Remove the air filter housing cover bolts (pic. 2.9). Pic. 2.10. Removing the casing and filter element: 1 - casing Remove the cover...
Removing and installing the air filter housing (K4J engine) Removing Remove the engine top covers. Disconnect the wires from the battery terminals, starting with the negative terminal. Pic. 2.11. Removing the gasket and plastic rivets: 1 - gasket; 2 - rivets Remove gasket and...
Removing and installing the air filter housing (K4M engine) Removing Remove the engine top covers. Disconnect the wires from the battery terminals, starting with the negative terminal. Remove the battery. Disconnect the injection computer connectors. Pic. 2.19. Disconnecting the...
Draining the fuel tank Attention! When performing this operation, the following requirements must be strictly observed: - do not smoke in the working area and do not bring hot objects to the working area; - take measures to prevent splashing...
Removal and installation of a bulk mouth Removing Drain the fuel from the tank. Place the car on a two post lift. Disconnect the wires from the battery terminals, starting with the negative terminal. Remove the right rear wheel. Remove the right rear fender....
Removing and installing the multifunctional bracket (F4R) Removing Place the car on a two post lift. Drain the refrigerant from the refrigeration circuit. Disconnect the battery. Disconnect the wiring harness from the A/C compressor. Disconnect the wiring harness from the...
Removal and installation of a belt of a drive of auxiliary units (F4R) 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 two post lift. Disconnect the battery. Remove the...
Removing and installing timing belt (K4J) Attention! Together with the belt, be sure to replace the tension and bypass rollers. Note. The procedure for removing and installing the timing belt for engines with or without a camshaft dephaser is the same. Removing...
Removing and installing timing belt (F4R) Attention! Together with the belt, be sure to replace the tension and bypass rollers. Note. The procedure for removing and installing the timing belt for engines with or without a camshaft dephaser is the same. Removing...
Removal and installation of the power unit (K4M) Removing Place the car on a two post lift. Attention! When carrying out this operation, it is necessary to secure the vehicle on a lift using a safety harness to prevent the vehicle from becoming unbalanced. Remove the...
Removal and installation of the power unit (F4R) Note. To remove the air supply pipe from the air-to-air cooler (F4R engine) disconnect the hose using the tool (Sag. 1363). Do not use brake cleaners or other cleaning agents. Wipe the air-to-air cooler seat and hose...
Removing the cylinder head gasket (K4J, K4M) Removing 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...
Removing valve springs To properly compress the valve springs, the tool plunger must be centered (Mot. 1502) along the valve stem. Pic. 2.110. Valve spring plunger alignment: 1 - boring; 2 - plunger; 3 - pressure sleeve; 4 - valve stem The...
Checking the height of the cylinder head Pic. 2.111. Cylinder Head Height Measurement Measure the height of the cylinder head (pic. 2.111). The height of the cylinder head is 137 mm.
Check of tightness of a head of the block of cylinders Pic. 2.112. Check the cylinder head for cracks using a special tool (pic. 2.112). Pic. 2.113. Jaw height Measure the height of the cams (pic. 2.113). Jaw height: intake: 40.661±0.03 mm; exhaust: 40.038±0.03 mm.
Checking the axial movement of the camshafts Install the camshafts, making sure they are in the correct position, and the cylinder head cover. Pic. 2.116. The order of tightening the bolts of the cover and cylinder head Tighten in the order shown in figure 2.116...
Checking valves The diameter D of the valve stem is measured at distance X1. intake valves: Х1=75.14±0.35 mm, D=5.470–5.485 mm. Exhaust valves: Х1=77.5±0.35 mm, D=5.456–5.471 mm. Valve head diameter D: intake valves - 32.7±0.12 mm;...
Checking clearance between valve stems and valve guides There are two ways to check the clearance between the valve stem and the valve guide. First way Pic. 2.120. Checking clearance between valve stems and valve guides (first way) Raise the valve head by 25 mm, then measure...
Checking valve springs Pic. 2.122. Checking valve springs Check the deviation of the spring from the vertical, which should not exceed 1.2 mm (pic. 2.122). Check spring calibration. Spring length under load: under a load of 18–20 N, the...
Cylinder head assembly Pic. 2.124. Installing the valve in the cylinder head Insert the valve into the cylinder head (pic. 2.124). Put on the tip of the tool (Mot. 1511) on the valve stem (the inner diameter of the tip must be equal to the...
Dismantling of the block of cylinders Install the flywheel retainer (Mot. 582-01 or Mot. 1677). Pic. 2.136. Removal of a casing and a conducted disk of coupling Remove cover and clutch disc (pic. 2.136). Remove flywheel. Pic. 2.137. Removing the engine tray...
Removing nozzles for cooling piston bottoms Pic. 2.143. Removing the piston head cooling nozzles: 1 - pistons Remove the piston head cooling nozzles (pic. 2.143). Do not remove the ball so that the chips do not fall into the oil channel. Drill out the nozzles for...
Checking the mating plane of the cylinder block Pic. 2.148. Checking the mating plane of the cylinder block Check with a straightedge and a set of feelers for the non-flatness of the mating plane of the cylinder block, which should not exceed 0.03 mm (pic. 2.148).
Checking the diameter of the main bearings of the crankshaft Install the crankshaft main bearing caps by installing cap 1 on the flywheel side. Pic. 2.149. The order of tightening the bolts of the crankshaft main bearing caps Tighten in the order shown in figure 2.149 with the...
Checking the diameter of the main journals Pic. 2.151. Checking the diameter of the main journals Check the diameter of the main journals (pic. 2.151). The diameter of the main journals should be between 47.990–48.010 mm.
Checking the diameter of the connecting rod journals Pic. 2.152. Checking the diameter of the connecting rod journals Check the diameter of the connecting rod journals (pic. 2.152). The diameter of the connecting rod journals must be between 43.960–43.980 mm.
Removing piston pins 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. Pic. 2.153. Pressing out the...
Checking the clearance between piston rings and piston grooves Pic. 2.154. Checking the clearance between piston grooves and piston rings: 1 - probes; A - incorrect position of the probe; B - the correct position of the probe Use a feeler gauge to check the clearances between the...
Checking clearances in the piston ring lock Install the piston ring in the cylinder. Move the piston ring to the middle of the cylinder with the piston. Pic. 2.155. Checking clearances in the piston ring lock: 1 – piston ring; 2 - piston; 3 - probe Measure the...
Installation of nozzles for cooling the piston crown Install the tool plate on the cylinder block (Mot. 1494), without tightening the two mounting bolts. Install the jig into the plate (the end of the conductor must enter the hole for the nozzle) to center the plate. Pic....
Installation of injectors for cylinders 2 and 4 Install the tool plate on the cylinder block (Mot. 1494), without tightening the two mounting bolts. Install the jig into the plate (the end of the conductor must enter the hole for the nozzle) to center the plate. Pic....
Installation direction of the crankshaft main bearing shells Establish liners with flutes in all beds of the block of cylinders. Pic. 2.161. Installation direction of the crankshaft main bearing shells Install grooved shells in main bearing caps 2 and 4 and non-grooved shells in...
Installing shells in main bearing caps Pic. 2.163. Installing the special tool on the main bearing cap Install the tool on the main bearing cap (Mot. 1493-01) (pic. 2.163). Press at points A and B shown in Figure 2.164 until the bushing is in contact with...
Checking the axial movement of the crankshaft 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 connecting rod bearing shells Pic. 2.168. Insert without mustache The engine is equipped with liners without a mustache (pic. 2.168). Inserts are installed with a tool (Mot. 1492). Select the liner holder according to the engine model (engine model...
Assembly of connecting rods with pistons 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...
Piston pin preparation Check that the piston pins rotate freely in the bosses of the corresponding new pistons. Use the centering mandrel C13 and the mounting mandrel A13 from the kit (Mot. 574-22) for piston pins without collar. Use...
Setting the position of the pistons in relation to the connecting rods Pistons are labeled «V» on the head, which should be located on the side of the flywheel. Position the piston head with the mark «V» up. Pic. 2.177. Installing the piston pin on the mounting mandrel: 1 - label; 2 -...
Piston and connecting rod assembly Pic. 2.178. Installing the piston on the ring: 1 - ring; 2 - clamp Install the ring B10 and the piston supported by the ring on the prism (oriented in the correct position) and fasten all parts with a clamp (pic....
Installation of piston rings The piston rings are matched to the piston and must move freely in the piston grooves. Pic. 2.179. Installation of piston rings Observe the installation direction of the rings (TOP label is directed upwards) (pic....
Assembly of the lower part of the 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...
Installation of crankshaft seals Pic. 2.183. Pressing in the crankshaft rear oil seal Press in the crankshaft rear oil seal with a mandrel (Mot. 1129-01) (pic. 2.183). Pic. 2.184. Pressing in the front crankshaft oil seal Press in the front crankshaft...
Installing the cylinder head gasket 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. Pic. 2.186....
Replacing camshaft seals Pic. 2.192. Elastomeric seal (first option): 1 - spring; 2 - V-shaped working edge Elastomeric camshaft seals are used in two versions, the elastomer seal in the first version has a spring and a V-shaped working edge...