Install the cylinder head on the fixture (device 67.7823-9567 for valve decompression and dehydration).
Lubricate the valve stems with engine oil, install and press in the oil-deflecting caps until the mandrel stops against the bearing surface of the cylinder head (mandrel 67.7853-9732 for pressing in the oil-deflecting cap, engine oil according to Appendix A of the current "Consumption standards for the main and auxiliary materials for maintenance and repair of LADA vehicles").
Install the spring support washers into the cylinder head.
Install the valve springs and spring retainers.
Compress the springs of one row of valves and install crackers (tweezers).
Repeat the operations for the second row of valves.
Lubricate the outer surfaces of the tappets with engine oil and install the tappets into the cylinder head according to the marking (engine oil according to Appendix A of the current "Consumption standards for main and auxiliary materials for maintenance and repair of LADA vehicles").
Screw new exhaust manifold mounting studs into the cylinder head with the short part into the head body (stud driver).
Remove the cylinder head from the fixture.
Press two cylinder head centering bushings into the cylinder block. The protrusion of the bushing above the mating plane of the cylinder block is 6...8 mm (hammer, SHG 250 type shtangenglubinometer).
Apply two dots of sealant to the cylinder block surface on the timing drive side, as shown in Figure 50 (sealant TV 1217 L, consumption rate - 1 g).
Figure 50 - Applying sealant to the cylinder block surface: 1 - places of sealant application
Figure 51 - Applying sealant to the cylinder head gasket: 1 - places of sealant application
Install a new cylinder head gasket on the cylinder block and apply two dots of sealant to the gasket on the timing drive side, as shown in Figure 51 (silicone sealant TV 1217 L, consumption rate - 1 g).
Screw the crankshaft pulley mounting bolt into the crankshaft and set the pistons to mid-stroke (replaceable head 19, ratchet).
Install the cylinder head, cylinder head mounting bolt washers, and new mounting bolts onto the cylinder block. Tighten and secure the cylinder head bolts.
Tighten the cylinder head mounting bolts in the order shown in Figure 52 in the following sequence: (replaceable head 11, ratchet, extension, torque wrench, angle measuring head):
- tighten the bolts to a tightening torque of 35.0...44.0 N·m (3.5...4.4 kgf·m);
- tighten the bolts to an angle of 60°...65°.
- unscrew all bolts;
- tighten the bolts to a tightening torque of 35.0...44.0 N·m (3.5...4.4 kgf·m);
- tighten the bolts to an angle of 75°...80°.
Figure 52 - Cylinder head bolt tightening sequence
Install new sealing rings on the oil pump.
Install the oil pump with rings assembly onto the engine and secure with three bolts. Tightening torque of oil pump mounting bolts - 21...29 Nm (2.1...2.9 kgf·m) (replacement head 10, ratchet, extension, torque wrench).
Install the water pump with a new gasket onto the engine and tighten the four mounting bolts. Tightening torque of water pump mounting bolts - 21...29 Nm (2.1...2.9 kgf·m) (replacement head 10, ratchet, extension, torque wrench).
Install the drive pulley onto the water pump, tighten the three water pump pulley mounting bolts, holding the pulley with a screwdriver. Tightening torque of water pump pulley mounting bolts - 7.0...7.5 Nm (0.70...0.75 kgf·m) (flat screwdriver, replaceable head 10, ratchet, torque wrench).
Lubricate the working edge of the rear crankshaft oil seal with engine oil and install the oil seal on the crankshaft flange (engine oil according to Appendix A of the current "Consumption standards for main and auxiliary materials for maintenance and repair of LADA vehicles").
Install guide bushing 1, Fig. 53, of the rear oil seal installation tool on the crankshaft, aligning the hole in the bushing with pin 2 (device 77 11 381 919).
Secure the bushing to the crankshaft using two flywheel mounting bolts 3 (replaceable head TORX E20, ratchet).
Install cover 1, Figure 54, fixtures, washer 2 and nut 3 on the guide bushing.
Apply a soap solution to the seal seating surface and press the seal into the cylinder block, rotating the nut until cover 1 touches the cylinder block (replacement head 17, ratchet).
Figure 53 - Installing the guide sleeve of the crankshaft rear oil seal installation tool: 1 - guide sleeve: 2 - crankshaft pin; 3 - flywheel mounting bolt
Figure 54 - Cover of the device for installing the rear crankshaft oil seal: 2 - washer: 3 - nut
Remove the seal installation tool from the crankshaft.
Install the coolant outlet pipe with a new gasket onto the engine and secure with seven bolts. Tightening torque of the branch pipe mounting bolts: 21...29 Nm (2.1...2.9 kgf·m) (replaceable head 10, ratchet, torque wrench).
Screw the coolant temperature sensor outlet into the pipe. Tightening torque of the coolant temperature sensor - 25...35 N·m (2.5...3.5 kgf·m) (ring spanner 19, replaceable insert 19, torque wrench).
Install the flywheel onto the crankshaft and tighten the new flywheel mounting bolts (replaceable head TORX E20, ratchet).
Figure 55 - Flywheel mounting bolt tightening sequence
Install the flywheel lock on the engine and tighten the flywheel mounting bolts in the sequence shown in Figure 55. Tightening torque of the bolts is 103...112 N·m (10.3...11.2 kgf·m) (flywheel lock 67.7820-9708 or 00 00 143 100, replaceable head TORX E20, torque wrench).
Remove the flywheel retainer.
Screw the new phase regulator oil filter with washer into the cylinder head. Filter tightening torque - 36.0...43.0 Nm (3.6...4.3 kgf·m) (replaceable head 8 for internal hexagon, ratchet and extension, torque wrench).
Lubricate the sealing ring of the electromagnetic valve of the phase regulator with engine oil, install the valve in the cylinder head and secure it with a bolt. Tightening torque of the valve mounting bolt - 8.0...12.0 N·m (0.8...1.2 kgf·m) (engine oil according to Appendix A of the current "Consumption standards for main and auxiliary materials for maintenance and repair of LADA vehicles", replaceable head 8, ratchet and extension, torque wrench).
Install the thermostat valve into the cylinder block, with the mark on the valve facing outward and located at the top along the vertical axis.
Install the thermostat cover and secure it with two bolts. Tightening torque of thermostat cover mounting bolts: 16...17 Nm (1.6...1.7 kgf·m) (replaceable head 12, ratchet and extension, torque wrench).
Install the oil level indicator tube retaining clip.
Lubricate the sealing ring of the oil level indicator tube and install the tube into the cylinder block (engine oil according to Appendix A of the current "Consumption standards for main and auxiliary materials for maintenance and repair of LADA vehicles").
Fix the tube to the thermostat cover.
Install the oil level indicator.
Lubricate the oil filter sealing ring, tighten the oil filter until the sealing ring touches the cylinder block and tighten the filter by hand by % of a turn (motor oil according to Appendix A of the current "Consumption standards for main and auxiliary materials for maintenance and repair of LADA vehicles").
Apply sealant to the threaded part of the oil pressure sensor and screw the sensor into the cylinder block. Sensor tightening torque: 12...17 Nm (1.2...1.7 kgf·m) (sealant TV 1211, ring spanner 22, replaceable insert 22, torque wrench).
Install the knock sensor on the cylinder block and secure it with a bolt. In this case, the sensor connector should be directed towards the flywheel. Tightening torque of the sensor mounting bolt - 20...25 Nm (2.0...2.5 kgf·m) (replacement head 10, ratchet, extension, torque wrench).
Lubricate the crankshaft position sensor sealing ring with engine oil, install the sensor on the engine and secure with a bolt. Tightening torque of the crankshaft position sensor mounting bolt - 6.0...8.0 N·m (0.6...0.8 kgf·m) (engine oil according to Appendix A of the current "Consumption standards for main and auxiliary materials for maintenance and repair of LADA vehicles", replaceable head 12, ratchet, extension, torque wrench).
Install the key and timing sprocket on the crankshaft (hammer).
Install the oil pump sprocket onto the oil pump shaft, screw in and tighten the sprocket mounting nut. Tightening torque of the oil pump sprocket mounting nut - 21...29 N·m (2.1...2.9 kgf·m) (ring spanner 10, replaceable head TORX E8, ratchet, replaceable insert 10, torque wrench).
Install a new oil pump drive chain onto the timing belt and oil pump drive sprockets.
Install a new tensioner 1, Fig. 14, of the oil pump drive chain onto the guide pin and insert the spring antenna 2 of the tensioner into the hole in the cylinder block.
Lubricate the bearing surfaces of the camshafts and install the camshafts into the cylinder head. The camshaft with oil channels on the flange should be installed on the intake side (engine oil according to Appendix A of the current "Consumption standards for main and auxiliary materials for maintenance and repair of LADA vehicles").
Lubricate the camshaft journals, install the camshaft covers and the intake cover mounting bolts (motor oil according to Appendix A of the current "Consumption standards for primary and auxiliary materials for maintenance and repair of LADA vehicles").
Tighten and tighten the cover mounting bolts in the sequence shown in Figure 56. Tighten the camshaft bearing cover mounting bolts in two steps:
- tighten the bolts to a torque of 5.0 Nm;
- tighten the bolts to a tightening torque of 9.0...11.0 N·m.
Figure 56 - Tightening order of camshaft bearing cap bolts
Turn the camshafts so that the dowel pins are in the upper position (spanner 22).
Turn the crankshaft key to the upper position.
Install the new timing chain onto the phase regulator so that mark 2, Figure 12, of the phase regulator is located in the middle of the orange link 1 of the chain.
Install the phase regulator with the chain on the intake camshaft and secure with a bolt. Do not tighten the bolt completely (22 mm spanner, 13 mm replaceable head, ratchet and extension).
Attention! When installing the phase regulator, be sure to align the mounting hole on the phase regulator hub, located between the two oil channels, with the mounting pin on the camshaft.
Attention! After installing the phase regulator from spare parts, remove the transport pin from it.
Install the chain on the camshaft sprocket so that mark 2, Figure 12, of the sprocket is located in the middle of the orange link 1 of the chain.
Install the sprocket onto the exhaust camshaft, aligning the mounting hole with the pin, and secure with the bolt. Do not tighten the bolt completely (22 mm spanner, 13 mm replaceable head, ratchet and extension).
Install the timing chain on the crankshaft sprocket so that mark 2, Figure 12, is located in the middle of yellow link 2 of the chain.
Install the flywheel lock on the engine and lock the flywheel.
Install a new chain guide on the engine and secure it with two bolts. Tightening torque of damper mounting bolts - 21...29 Nm (2.1...2.9 kgf·m) (replaceable head 10, ratchet, torque wrench).
Install a new chain tensioner shoe onto the guide pin in the cylinder block.
Install a new chain tensioner on the engine and secure with two bolts. The tightening torque of the chain tensioner mounting bolts is 8.0...12.0 N·m (0.8...1.2 kgf·m). Remove the transport pin from the tensioner housing (replaceable head 8, ratchet, torque wrench, pliers).
Tighten the phase regulator and camshaft sprocket mounting bolts. Tightening torque of mounting bolts - 74...83 Nm (7.4...8.3 kgf·m) (replaceable head 13, ratchet and extension, torque wrench).
Remove the flywheel lock from the engine.
Screw the auxiliary drive pulley mounting bolt into the crankshaft, turn the crankshaft one revolution clockwise and check that the marks on the chain match the marks on the sprockets and on the phase regulator. If the marks do not match, repeat the chain installation operations (replaceable head 19, ratchet).
Check the clearances in the valve drive mechanism by turning the crankshaft so that the camshaft cam being checked is directed upwards, as shown in Figure 57. The permissible clearance should be: for intake valves - 0.26-0.34 mm, for exhaust valves - 0.29-0.37 mm. If the clearance deviates from the specified value, remove the camshafts and replace the corresponding tappets. Depending on the thickness, tappets are supplied in several classes of spare parts. The classification of pushers is given in Table 9. The pusher class is indicated on the inner surface of the pusher, Figure 58.
After replacing the tappets, install the camshafts and timing drive mechanism according to the above procedure.
Figure 57 - Checking valve clearances
(Original posted on the website: «ladaman.ru»)
Figure 58 - Pusher marking: 1 - marking location
Table 9 - Classification of pushers
item No. | Identification number | Thickness, mm |
1 | 300 | 3,00 |
2 | 302 | 3,02 |
3 | 304 | 3,04 |
4 | 306 | 3,06 |
5 | 308 | 3,08 |
6 | 310 | 3,10 |
7 | 312 | 3,12 |
8 | 314 | 3,14 |
9 | 316 | 3,16 |
10 | 318 | 3,18 |
11 | 320 | 3,20 |
12 | 322 | 3,22 |
13 | 324 | 3,24 |
14 | 326 | 3,26 |
15 | 328 | 3,28 |
16 | 330 | 3,30 |
17 | 332 | 3,32 |
18 | 334 | 3,34 |
19 | 336 | 3,36 |
20 | 338 | 3,38 |
21 | 340 | 3,40 |
22 | 342 | 3,42 |
23 | 344 | 3,44 |
24 | 346 | 3,46 |
25 | 348 | 3,48 |
26 | 350 | 3,50 |
Apply two strips of sealant along the parting line of the cylinder block to the cylinder head and two strips of sealant along the parting line of the cylinder block to the cylinder block reinforcement on the timing drive side (sealant TV 1217L, consumption rate 4 g).
Install the timing belt cover centering pins on the engine. The pin protrusion above the mating surface is 10±0.5 mm (hammer, SHG 250 type shtangenglubinometer).
Apply sealant to the surface of the timing cover mating with the cylinder block, as shown in Figure 59, using a 3.5 mm diameter roller (sealant TV 1217L, consumption rate - 14 g).
Install the cover and secure with bolts in the following order (replaceable heads 8, 10, 13, ratchet, torque wrenches):
- pre-tighten bolts 3, 2, 8 and 7, Figure 60. Bolt tightening torque: 8.0 Nm (0.8 kgf·m);
- finally tighten bolts 1, 2, 3, 4, 5, 6, 7, 8, 11, 12, 13, 14, 15, 9 and 10. Tightening torques:
- bolt 1 - 5...8 N·m (0.5...0.8 kgf·m);
- bolts 2, 3, 4, 5, 6, 7, 8, 9 and 10 - 21...29 Nm (2.1...2.9 kgf·m);
- bolts 11, 12, 13, 14 and 15 - 47...63 Nm (4.7...6.3 kgf·m).
Install the new front crankshaft oil seal onto the drift (mandrel 77 11 381 918 for installing the front crankshaft oil seal).
Apply a soap solution to the seal seating surface, install mandrel 1, Figure 61, with the seal on the crankshaft, tighten bolt 2 for fastening the auxiliary drive pulley until the mandrel touches the timing belt drive cover (replaceable head 19, ratchet).
Figure 59 - Scheme of applying sealant to the surface of the timing belt cover
Figure 60 - Timing Belt Cover Bolt Tightening Sequence
Figure 61 - Installing the front crankshaft oil seal: 1 - mandrel 77 11 381 918; 2 - bolt for fastening the auxiliary drive pulley
Loosen the bolt and remove the mandrel.
Press two cylinder head cover centering pins into the cylinder head. The protrusion of the pins above the mating surface of the cylinder head is 7+1 mm (hammer, SHG 250 type shtangenglubinometer).
Install a new gasket on the cylinder head cover.
Apply two 20mm long strips of sealant to the junction of the cylinder head and timing cover at the top (sealant TV 1217L, consumption rate - 3 g).
Install the cylinder head cover with the gasket on the cylinder head, cover mounting bolts and tighten the bolts in the order shown in Figure 62. Tightening torque of the cylinder head cover mounting bolts is 8.0...12.0 N·m (0.8...1.2 kgf·m) (replaceable head 8, ratchet and extension, torque wrench).
Figure 62 - Cylinder head cover bolt tightening sequence
Install the phase sensor into the cylinder head cover and secure it with a bolt. Tightening torque of the phase sensor mounting bolt - 9.0...12.0 N·m (0.9...1.2 kgf·m) (replacement head 10, ratchet, extension, torque wrench).
Tighten the spark plugs. Spark plug tightening torque: 21.0...27.0 Nm (2.1...2.7 kgf·m) (14 key for spark plugs, torque wrench).
Install the ignition coils and secure them with bolts to the cylinder head cover. Tightening torque of ignition coil mounting bolts: 9.0...12.0 Nm (0.9...1.2 kgf·m) (replacement head 10, ratchet, extension, torque wrench).
Install the fuel rail with injectors assembly onto the engine and secure with two bolts. Tightening torque of fuel rail mounting bolts - 21.0...29.0 N·m (2.1...2.9 kgf·m) (replacement head 10, ratchet, extension, torque wrench).
Connect the injector wire harness connectors to the injectors.
Install the fuel rail protective screen and secure it with two bolts to the cylinder head cover and two bolts to the fuel rail. The tightening torque of the bolts securing the screen to the cylinder head cover is 21.0...29.0 N·m (2.1...2.9 kgf·m), the tightening torque of the bolts securing the screen to the fuel rail is 10.0...13.0 N·m (1.0...1.3 kgf·m) (replaceable heads 8, 10, extension, ratchet, torque wrench).
Install the wiring harness mounting bracket onto the engine and secure it with a bolt to the cylinder head cover. Tightening torque of the bracket mounting bolt - 8.0...12.0 N·m (0.8...1.2 kgf·m) (replaceable head 8, ratchet, torque wrench).
Connect the wiring harness connectors to the ignition coils and secure the harness to the cylinder head cover and bracket.
Install the intake module with new gaskets onto the engine and secure with bolts to the cylinder head and cylinder head cover. Tightening torque of intake module mounting bolts - 7...15 Nm (0.7...1.5 kgf·m) (replacement head 10, ratchet, extension, torque wrench).
Install the crankcase ventilation tube and secure with clamps (pliers).
Install the throttle body heating hoses and secure with clamps (pliers).
Install the flywheel lock on the engine and lock the flywheel (flywheel lock 67.7820-9708 or 00 00 143 100).
Lubricate the seating surface of the accessory drive pulley under the oil seal with engine oil, install the pulley on the crankshaft and secure with a new bolt. Tightening torque of the pulley mounting bolt is 30.0...40.0 N·m (3.0...4.0) kgf·m. After tightening, tighten the bolt by an angle of 60°...66° (engine oil according to Appendix A of the current "Consumption standards for main and auxiliary materials for maintenance and repair of LADA vehicles", replaceable head 19, extension, ratchet, torque wrench, angle measuring head).
Remove the flywheel retainer.
Install the accessory bracket onto the engine and secure with four bolts. Tightening torque of bracket mounting bolts - 21.0...29.0 N·m (2.1...2.9 kgf·m) (replacement head 10, ratchet, extension, torque wrench).
Install the lower heat shield on the exhaust manifold and secure with bolts.
Tightening torque of screen mounting bolts - 10.0...13.0 N·m (1.0...1.3 kgf·m) (replaceable head 10, ratchet and extension, torque wrench).
Install a new exhaust manifold gasket and manifold onto the engine and secure with nuts. Tightening torque of exhaust manifold mounting nuts - 30.0...40.0 N·m (3.0...4.0 kgf·m) (replacement head 10, ratchet, extension, torque wrench).
Screw the oxygen sensor into the exhaust manifold. Tightening torque of the oxygen sensor - 38...50 N·m (3.8...5.0 kgf·m) (ring spanner 22, replaceable insert 22, torque wrench).
Install the upper heat shield on the exhaust manifold and secure with bolts.
Tightening torque of screen mounting bolts - 10.0...13.0 N·m (1.0...1.3 kgf·m) (replaceable head 10, ratchet and extension, torque wrench).
Install the generator on the auxiliary unit bracket and secure it with two bolts. Tightening torque of generator mounting bolts - 21.0...29.0 N·m (2.1...2.9 kgf·m) (replaceable head 10, ratchet and extension, torque wrench).
Install the air conditioning compressor onto the accessory bracket and secure with three bolts. Tightening torque of compressor mounting bolts - 21.0...29.0 N·m (2.1...2.9 kgf·m) (replaceable head 10, ratchet and extension, torque wrench).
Install the accessory drive belt onto the engine (67.7834-9703 elastic belt installation tool).
Place a funnel on the oil filler neck.
Fill the engine with oil in the amount of 4.7 liters (motor oil according to Appendix A of the current "Consumption standards for main and auxiliary materials for maintenance and repair of LADA vehicles").
Install the oil filler cap.
Present the OTK engine. OTC check the quality of the engine assembly in the scope of work performed.
It is permissible to control the quality of assembly, including control of tightening torques of threaded connections and application of sealant to the planes of engine connectors, on a step-by-step basis during the execution of work.