Removal
1. Remove the cylinder head (see "Cylinder head of the 1.6i engine - removal and installation").
2. Remove the oil intake (see "Oil intake - removal and installation").
3. Turning the crankshaft clockwise, set the piston of the first cylinder to the lower position.
4. Using a 14 mm socket wrench, unscrew the two nuts securing the connecting rod cover of the first cylinder and remove the connecting rod cover.
5. Resting the hammer handle against the piston, push it upward and remove the piston from the cylinder.
6. Remove the insert from the connecting rod and its cover.
Warning! When disassembling the connecting rod, do not press out the bolts from it.
7. Clamp the piston by the connecting rod in a vice.
8. Slightly moving the ring lock apart, remove the upper compression ring.
9. Remove the lower compression ring in the same way.
10. Remove the oil scraper ring...
... and its expander.
Installation
1. Thoroughly clean the piston from carbon deposits and deposits. We inspect the piston and connecting rod. Cracks on them are unacceptable.
2. We select new rings in accordance with the piston diameter - nominal or repair size. There are no markings on the nominal size rings; repair rings are increased in diameter by 0.4 or 0.8 mm and are marked "40" and "80" respectively.
3. Before installing new rings, use a set of feeler gauges to measure the gap between the piston ring and the wall of the groove into which the ring will be installed.
If the gap exceeds the maximum allowable (see table 16.3), the piston needs to be replaced.
We install the oil scraper ring and the upper compression ring with the inscriptions "TOR", "VAZ" or other facing upwards.
We orient the lower compression ring so that the groove is directed downwards or the inscription "TOP" is directed upwards.
1. We put the rings on the piston as follows: by moving the ring lock apart (no more than is required to put the ring on the piston), we first place the lock on the piston, and then the back part of the ring.
We install new rings on the piston, starting with the oil scraper ring expander. After installing the oil scraper ring, the expander lock should be rotated 180° relative to the ring lock.
After installing the rings on the piston, we turn their locks so that the lock of the upper compression ring is located at an angle of 45° to the axis of the piston pin, the lock of the lower compression ring is turned by 180°, and the lock of the oil scraper ring is turned by 90° relative to the lock of the upper compression ring.
2. Lubricate the piston, rings and inner surface of the cylinder with clean motor oil.
3. Place the mandrel on the piston and use it to compress the rings, periodically tapping the mandrel lightly with the hammer handle to ensure the rings are self-installing.
4. Wipe dry the bearing beds in the connecting rod and cover and install the bearings in the lower head of the connecting rod.
5. Lubricate the inner surfaces of the liners and the connecting rod journal of the crankshaft with clean engine oil. By turning the crankshaft, we move the journal to its lowest position.
6. Install the piston on the block and orient it so that the arrow on the bottom of the piston is directed towards the crankshaft pulley (see below).
7. Pressing the mandrel against the block and tapping the bottom of the piston with the hammer handle, we press it into the cylinder, while simultaneously monitoring the movement of the connecting rod toward the crankshaft journal.
8. Install the cover assembly with the liner on the connecting rod and tighten its nuts to a torque of 43.32-53.51 Nm (4.42-5.46 kgf·m).
Warning! Connecting rod caps are not interchangeable. The connecting rod and its cover indicate the number of the cylinder into which the connecting rod should be installed. On the assembled connecting rod, the numbers should be located on one side.
We replace the rings of the other three pistons in the same way.
After installing all the pistons, we assemble the engine in the reverse order of disassembly.