2.2.6. Engine repair (Z10XE, Z10XEP, without the conditioner)

Remove a transmission from the engine.

Remove directing tube щупа an oil meter.

Turn out a bolt.

Dismantle heated up a lambda sensor of regulation of structure of a fuel mix.

Disconnect the socket of a plait of wires.

Release a plait of wires.

Carefully turn out a lambda sensor by means of the KM-6129 adaptation.

Dismantle a guard of a final collector.

Turn off 2 bolts of fastening.

Dismantle a final collector.

Turn off 7 nuts of fastening.

Take out consolidation.

Lift the engine.

Establish on the engine on the KM-412-18 adaptation.

Tighten 4 bolts of fastening.

Fix the engine on the KM-412 2 adaptation.

Tighten 8 carving connections.

Establish the KM-2358 adaptation.

Merge engine oil.

Substitute the reception pallet.

Turn out a carving stopper of a drain opening.

Uncover cases of the oil filter.

Take out the loose leaf of the oil filter.

Dismantle coupling.

Remove a flywheel.

Establish the KM-652 adaptation.

Turn off 6 bolts of fastening.

Dismantle the KM-652 adaptation.

Remove the holder of the engine on the right 1.

Turn off 3 bolts of fastening.

Wrap a carving stopper of a masloslivny opening.

Replace a sealing ring.

Tighten a bolt the moment of 10 N · m.

Remove the reception pallet for oil.

Remove a poliklinovy belt.

NOTE Mark the rotation direction.

Pull the tension device of a poliklinovy belt in the arrow direction.

Insert the KM-955-2 adaptation.

Remove from a pulley poliklinovy ременя a cranked shaft.

Remove a pulley poliklinovy ременя the pump of cooling liquid.

Turn off 3 bolts of fastening.

Dismantle a pulley poliklinovy ременя a cranked shaft.

Turn off 6 bolts of fastening.

Hold a bolt of a nave of a cranked shaft.

Remove the tension device of a poliklinovy belt.

Turn off 2 bolts of fastening.

Dismantle plaits of wires of the engine.

Turn off a plait of wires of the generator.

Turn off 2 nuts.

Отболт ите plait of wires of a starter.

Turn off 2 nuts 1.

Remove cable collars.

Dismantle the generator.

Turn off 2 carving connections.

Dismantle a starter.

Turn off 2 bolts of fastening (shooters).

Dismantle a plait of wires of a control system of the engine.

On the Z 10 XEP engine: dismantle a casing of a pipe of the fuel distributor.

Turn off 2 bolts of fastening.

Disconnect 12 sockets of a plait of wires of a control system of the engine.

The relay of pressure of oil 6, the sensor of temperature of cooling liquid 8, the sensor of a camshaft 9, the module of a butterfly valve 2, the controler of engine management 12, the valve of system of a retsirkulyatsiya of OG 4, the module of ignition 3, the sensor of a detonation 10, the sensor of a cranked shaft 11, fuel nozzles 1.

Turn off a wire of weight of the controler of engine management 13.

Release the channel for a plait of wires 7.

Release a plait of wires – 4 holders 14.

Disconnect 3 hoses from the pump of cooling liquid.

Hose of cooling liquid disconnect from a flange of cooling liquid of a retsirkulyatsiya of exhaust gases.

Release a collar.

Dismantle the pump of cooling liquid 1.

NOTE At removal pay attention to directing plugs.

Substitute the reception pallet.

Turn off 9 bolts of fastening.

NOTE Consider different length of bolts of fastening (an arrow – short bolts).

Dismantle the ignition module.

Uncover the ignition module, having shifted it to the right.

Turn off 2 bolts of fastening.

Take out a cover by means of the KM-6009 1 adaptation.

Uncover heads of the block of cylinders.

Remove a hose of ventilation of a case of the engine.

Release a collar.

Turn off 17 bolts of fastening.

Release a bolt of a nave of a cranked shaft 1.

NOTE For this work participation of two people is required.

Establish and hold KM-956-1/KM-956-2 adaptations.

Hold KM-956-1/KM-956-2.

Adjust camshafts.

Cranked shaft by means of the KM-956-1/KM-956-2 adaptation evenly turn in the direction of rotation of the engine until the KM-953 1 adaptation against the stop will not come into a camshaft groove.

Remove a nave of a cranked shaft.

NOTE Observe the assembly provision of a nave.

Turn out a bolt.

Take out a nave by means of KM-956-1/KM-956-2 adaptations.

Remove the oil pallet.

The engine turn on 180 °.

Turn off 14 bolts of fastening.

Remove consolidation of the oil pallet.

Remove the GRM case.

The engine turn on 90 °.

Turn out 15 bolts of fastening (shooters).

Consider length of bolts of fastening.

Do not damage the sensor of a camshaft 1.

To Poddnta also take a sealing ring of the GRM case.

NOTE Do not damage a sealing surface.

Dismantle a chain drive.

Release bolts of driving gears of a camshaft.

Camshafts hold for a shestigrannik.

Stop the tension device of a chain 1.

Insert the KM-955-1 adaptation.

Dismantle the level of an uspokoitel 3 directing a level 5, a sled for a tension 7 and driving gear wheels of camshafts.

Take out a driving chain of a cam-shaft 4 with a driving wheel 6. Take GRM case consolidation.

Dismantle a head of the block of cylinders.

The engine turn on 90 °.

Dismantle the KM-953 adaptation.

Turn off 10 bolts of fastening.

NOTE Release hairpins of a head of cylinders in that order: – release hairpins of a head of cylinders (90 °); – release hairpins of a head of cylinders (180 °); – take out hairpins of a head of cylinders.

Head of the block of cylinders enclose in wooden blocks.

Take out consolidation of a head of the block of cylinders.

Dismantle the case of the oil filter.

Turn off 3 bolts of fastening.

Dismantle the detonation sensor.

Turn out a bolt.

Remove a maslootrazhatel.

Turn the engine on 180 °.

Turn off 6 bolts of fastening.

Dismantle the sensor of provision of a cranked shaft.

Turn out a bolt.

Dismantle the block of cylinders.

Establish the KM-2358 adaptation.

The engine suspend on the crane.

Remove the KM-412-18 adaptation.

Establish the block of cylinders.

Establish on the engine the KM-412-18 adaptation. Tighten 4 bolts of fastening.

Dismantle the KM-2358 adaptation.

6 directing sleeves by means of the KM-427 adaptation press in the block of cylinders.

Dismantle soaking-up oil pipeline 1.

Turn off 4 bolts of fastening.

Remove a sealing ring 2.

Clean sealing surfaces of the block of cylinders and a head of cylinders, a cover of a head of cylinders, the case of the oil filter, a support of a cranked shaft, the GRM case, the oil pallet, the pump of cooling liquid and a final collector.

Examine knots of the power unit.

NOTE If it is necessary check and process a head of cylinders, remove from a head of cylinders everything established outside of a detail: the block of cylinders, a head of cylinders, a cover of a head of cylinders, the case of the oil filter, a support of a cranked shaft, a chain drive, the GRM case, the oil pallet, the pump of cooling liquid, a final collector.

By means of a lekalny ruler and kaliberny щупа check flatness of a head of the block of cylinders.

Stop a cranked shaft.

Remove a carving stopper 1.

Insert on its place the KM-952 2 adaptation.

Cranked shaft evenly turn until the adaptation will not be grasped.

Establish a maslootrazhatel.

Tighten 6 bolts of fastening the moment of 8 N · m.

Establish the case of the oil filter.

Turn the engine on 180 °.

Replace consolidation.

Tighten 3 bolts of fastening the moment of an inhaling of 20 N · m.

Replace the loose leaf of the oil filter.

Establish a cover of the case of the oil filter.

Replace a sealing ring.

Tighten bolts of fastening of a cover the moment of 10 N · m.

Adjust camshafts.

Insert the KM-953 adaptation.

Camshafts turn for a shestigrannik.

Take out the KM-953 adaptation.

Establish a head of the block of cylinders.

Replace consolidation.

NOTE Marking of "OPEN/TOP" should indicate up. Replace bolts of fastening of a head of the block of cylinders.

By means of a lekalny ruler level a head of cylinders in relation to the block of cylinders.

Tighten 10 bolts of fastening the moment of 25 N · m + 60 ° + 60 ° + 60 °.

NOTE Observe sequence of an inhaling of bolts.

Establish a driving chain of a cam-shaft.

Establish the KM-953 adaptation.

Replace GRM case consolidation.

NOTE Watch correctness of landing (arrow).

Replace bolts.

Driving wheel 5 shift.

Get a gear wheel of a final camshaft. Screw a bolt.

Establish a driving chain of a cam-shaft 3.

Insert into a driving chain of a cam-shaft a gear wheel of an inlet camshaft with a disk of the phase sensor, screw a bolt.

NOTE The disk of the phase sensor should turn manually.

Establish a sled for a tension of a driving chain of a cam-shaft 6.

Tighten a bolt the moment of an inhaling of 20 N · m.

NOTE Watch correctness of landing of a driving chain of a cam-shaft.

Establish directing fillet of a driving chain of a cam-shaft 4.

Tighten 2 bolts of fastening with the moment of 8 N · m.

NOTE Watch correctness of landing of a driving chain of a cam-shaft.

Establish a level of an uspokoitel of a driving chain of a cam-shaft 2.

Tighten 2 bolts of fastening with the moment of 8 N · m.

Weaken a tension of the tension device of a chain.

Take out the KM-9551 adaptation.

At replacement of details consider various options of a design. Watch correctness of numbers of details.

Establish the pump of cooling liquid.

NOTE Watch correctness of landing of directing plugs (arrow).

Consolidation 1 replace.

Fix the pump by means of short bolts of fastening 2.

Tighten 3 bolts of fastening of 8 N · m.

Dismantle a branch pipe of cooling liquid, открутитв 3 bolts of fastening.

Establish the GRM case.

Screw bolts.

NOTE Observe sequence of an inhaling

Tighten 5 bolts of fastening (М6) the moment of 18 N · m.

Tighten 14 bolts of fastening (М6) the moment of 28 N · m.

Tighten 2 bolts крепленияов (M10) 3 the moment of 35 N · m.

Establish a branch pipe of cooling liquid.

Check, clear sealing surfaces.

Replace a sealing ring.

Tighten 3 bolts of fastening the moment of 8 N · m.

Replace a sealing ring of a cranked shaft in front 1.

Sealing edges grease with silicone greasing (white).

Establish the KM-960 2 adaptation and press a sealing ring of a cranked shaft.

Take out adaptations KM-952, KM-953.

NOTE Fixing tools cannot be used for keeping.

Establish a nave of a cranked shaft.

Observe the assembly provision of a nave of a cranked shaft 2, the mark should indicate up.

Bolt of a nave replace.

Hold a nave by means of KM-956-1/KM-956-2 adaptations.

Tighten a bolt the moment of 150 N · m +45 °.

Remove KM-956-1/KM-956-2 adaptations.

Establish a pulley poliklinovy ременя a cranked shaft 1.

Tighten 6 bolts of fastening the moment of 8 N · m.

Hold a bolt of a nave of a cranked shaft.

Insert the KM-952 adaptation.

The KM-953 adaptation insert into a flute of camshafts.

Establish the KM-954 1 adaptation.

Turn a disk of the phase sensor 2, there will be no yet a possibility to establish the KM-954 adaptation on the GRM case.

Fix driving gear wheels of camshafts.

NOTE Driving gear wheels of camshafts and disk of the phase sensor tighten with the moment of 10 N · m.

Tighten 2 bolts of fastening the moment of 210 N · m.

NOTE In the beginning tighten a bolt of a driving gear wheel of an inlet camshaft.

Camshafts support for a shestigrannik 1.

Take out fixing tools KM-952, KM-953, KM-954.

Tighten driving gear wheels of camshafts.

Tighten 2 bolts of fastening the moment of 50 N · m + 60 °.

NOTE In the beginning tighten a bolt of a driving gear wheel of an inlet camshaft. Camshafts hold for a shestigrannik.

Check installation of phases of a gazoraspredeleniye.

Establish the oil pallet.

Tighten 14 bolts of fastening the moment of 10 N · m.

Establish a carving stopper of a support of a cranked shaft.

Replace a sealing ring.

Tighten a bolt of fastening the moment of 50 N · m.

Establish the detonation sensor.

Tighten a bolt of fastening the moment of an inhaling of 20 N · m.

Establish the sensor of provision of a cranked shaft.

Replace a sealing ring.

Tighten a bolt of fastening the moment of 8 N · m.

Establish a cover of a head of the block of cylinders 1.

Turn the engine on 180 °.

Replace consolidation 2, a sealing ring.

Put hermetic (distance of 1-2 mm).

NOTE Installation works finish within 10 minutes.

Tighten 17 bolts of fastening the moment of 8 N · m.

Establish a hose of ventilation of a case of the engine.

Fix a collar.

Establish the ignition module.

Tighten 2 bolts of fastening with the moment of 8 N · m.

Establish hoses of cooling liquid.

On the pump of cooling liquid and on the valve of a retsirkulyatsiya of OG fix collars.

Establish a plait of wires of a control system of the engine.

Lay a plait of wires.

Connect 13 sockets of a plait of wires.

Attach a wire of weight of the controler of management of the engine.

Tighten a fastening nut.

Fix the channel for a plait of wires.

Fix a plait of wires.

On the Z 10 XEP engine: establish a casing of a pipe of the fuel distributor.

Tighten 2 bolts of fastening.

Establish a starter.

Turn the engine on 90 °.

Tighten 2 bolts of fastening the moment of 25 N · m.

Establish the generator.

Tighten 2 carving connections by the moment of 35 N · m.

Establish a plait of wires of the engine.

Turn the engine on 90 °.

Fix plaits of wires of the generator and a starter and tighten 4 nuts of fastening.

Establish the tension device of a poliklinovy belt.

Turn the engine on 180 °.

Bolt (М8) tighten the moment of an inhaling of 20 N · m.

Bolt (М10) tighten the moment of an inhaling of 55 N · m.

Establish a pulley poliklinovy ременя the pump of cooling liquid.

Tighten 6 bolts of fastening the moment of an inhaling of 20 N · m.

Establish a poliklinovy belt.

NOTE Observe the direction of rotation and assembly situation.

Weaken a tension of the tension device of a poliklinovy belt.

Take out the KM-955-2 adaptation.

Establish the holder of the engine on the right.

Tighten 2 bolts of fastening the moment of 60 N · m.

Establish a flywheel.

Clear 6 carving connections in cranked to a shaft.

Replace fastening bolts.

Tighten 6 bolts of fastening the moment of 35 N · m +60 °.

Block a flywheel by means of the KM-652 adaptation.

Establish coupling.

Fill in engine oil.

Check and, if necessary, modify level of engine oil.

Disconnect the engine from the KM-412 adaptation.

Turn off 8 carving connections.

Dismantle the KM-412-18 adaptation.

Turn off 4 bolts of fastening.

Establish a final collector.

Replace consolidation.

Replace nuts.

Tighten 7 nuts of fastening the moment of an inhaling of 20 N · m.

Establish a guard of a final collector.

Tighten 2 bolts of fastening the moment of 8 N · m.

Establish heated up a lambda sensor of regulation of structure of a fuel mix.

Put on a carving assembly paste (white).

Tighten a lambda sensor the moment of 40 N · m.

Connect the socket of a plait of wires.

Fix a plait of wires.

Establish directing tube щупа an oil meter.

Replace 2 sealing rings.

Tighten a bolt the moment of 8 N · m.

Establish a transmission on the engine.