Specifications and overhaul dimensions of engines Cylinder head Maximum non-flatness of the bottom surface: – 4-cylinder petrol engines: • parallel to the axis 0.15 mm • perpendicular to the axis 0.05 mm – other...
General techniques for disassembling the cylinder head This part of the chapter includes general techniques for disassembling the cylinder head and other engine components. The information concerns the sequence of...
Recommendations for removing the engine On all models, the power unit, consisting of the engine and gearbox, is removed upwards from the engine compartment. If you decide to remove the engine for repair, then...
Removal and installation of 4-cylinder petrol engines Removing Attachment points of pipelines to the pump of the self-leveling rear suspension system Removing the auxiliary drive belt tensioner On models without a shock...
Removal and installation of 6-cylinder petrol engines Removing 1. Remove the gearbox. 2. Remove the lower engine mudguard. 3. Drain the engine oil from the engine. 4. Drain the coolant from the cooling system. 5. Remove the...
Removal and installation of diesel engines Removing 1. Remove the gearbox. 2. Remove the lower engine mudguard. 3. Drain the engine oil from the engine. 4. Drain the coolant from the cooling system. 5. Remove the...
Engine disassembly sequence Removing the oil filter cover Removing the breather cover Installing the engine on a special stand greatly facilitates the assembly and disassembly processes. Before...
Dismantling of a head of the block of cylinders Compressing the valve spring with a special tool Removing crackers from the end of the valve Removing the upper spring plate Removing the valve spring Removing the oil...
Cleaning and inspection of the cylinder head Checking the flatness of the cylinder head Measurement of swirl chamber protrusion from the cylinder head Carefully inspect the cylinder head for cracks or other damage....
Valves — checking and lapping Valve Stem Diameter Measurement Lapping of valves 1. Check each valve seat for localized corrosion, burns, cracks, and general wear. Check the valve stem for wear and...
Cylinder head assembly Installing the valve in the cylinder head Installing the lower spring seat 1. Lubricate the valve stems with clean engine oil and insert them into place. Install the...
Removing the crankshaft Arrangement of bolts of fastening of a back cover of a cranked shaft on the 4-cylinder petrol engine Location of the identification mark on the main bearing cap Removing...
Engine block Cylinder block of 4-cylinder petrol engine 1 – block of cylinders; 2 – a back cover of a cranked shaft; 3 – a forward cover of a cranked shaft; 4 – an arm of a support...
Pistons and connecting rods — removal and installation Removing piston rings Removing the piston pin circlip Piston pin removal Oil hole in connecting rod head On 4-cylinder gasoline engines and 6-cylinder SOHC engines, the...
Crankshaft — check Checking the crankshaft end play using a dial gauge Checking the end play of the crankshaft using a feeler blade Measuring the crankshaft journal with a micrometer...
Inspection of main and connecting rod bearings Typical bearing defects Even though the main and connecting rod bearings should be replaced when the engine is overhauled, they must be carefully inspected as they can...
Engine assembly sequence during overhaul Installing the oil filter housing When installing the oil filter housing, a new gasket must be used. Water pump installation When installing the water pump, a new O-ring...
Installation of piston rings Piston ring gap measurement Installation on the piston of the oil scraper ring expander The location of the piston rings on the piston 1 - top sealing ring; 2 – an...
Choice of crankshaft bearings Four-cylinder petrol engines To determine the required thickness of new main bearings, it is necessary to measure the internal diameter of the main bearing, the diameter...
Checking the operating clearance of the main bearings Installing the main bearing shells When installing the main bearing shells in the cap, align the protrusion on the bushing with the groove in the cap. Plastigage rod for...
Installing the crankshaft Tightening the main bearing cap bolt to the required torque Tightening the main bearing cap bolt by turning it to a certain angle Applying a thin layer of sealant to the...
Installing pistons with connecting rods Four-cylinder petrol engines To determine the required thickness of new connecting rod bearings, it is necessary to measure the inner diameter of the connecting rod...
Starting the engine after a major overhaul With the engine installed in the vehicle's engine compartment, check the engine oil and coolant levels. Check that all previously removed wires and hoses are installed...