We install the cylinder block on a stand for disassembly and assembly of aggregates

We install the centering disk of the crankshaft setting position on the crankshaft 1, Figure 1, pin 4

 Сборка двигателя H4M

We tighten and tighten the three bolts 3 fixing the drive of the master. The tightening torque of the disc mounting bolts is 20-24 Nm (2.0-2.4 kg cm)

Remove the centering pin from the crankshaft

 Сборка двигателя H4M

We select the inserts of the crankshaft main bearings according to the classification of the crankshaft main necks and supports in the cylinder block in accordance with Table 1

The color in the table means the marking of the liner applied to its end.

The marking color corresponds to a certain class of liner, which must be installed depending on the diameter class of the root necks and the diameter class of the holes in the supports.

In the upper part of the table, the diameter classes of the holes in the cylinder block supports are indicated, in the left part - the diameter classes of the crankshaft main necks.

Abbreviations given in table 1:

UPR - insert installed in the cylinder block support;

LWR is a liner installed in the cover of the main bearing.

We install inserts with grooves in the cylinder block supports. Align the new bearing liners with grooves on the cylinder block by aligning the groove of the liner with the groove of the support

 Сборка двигателя H4M

We install the bearing inserts flush with the support, as shown in Figure 2, and press on it from the reverse side in order to install the liner flush with the support

Adjust the position of the inserts so that they are located in the center of the cylinder block supports

We install inserts without grooves in the cylinder block covers

 Сборка двигателя H4M

We install the inserts flush with the surface of the cover of the main bearing, as shown in Figure 3, and shift it to the opposite side until it aligns with the cover

We install the other inserts in the same way

Adjust the position of the inserts so that they are located in the center of the cylinder block covers

We install the thrust half-rings of the crankshaft in the sockets of the third support of the cylinder block, combining the antennae of the half-rings with the grooves 1, Figure 4, of the support. In this case, the grooves of the 2 half-rings should be located on the side of the crankshaft

 Установка упорных полуколец двигателя H4M

Lubricate with engine oil the surfaces of the liners of the main bearings and thrust half-rings of the crankshaft in contact with the crankshaft

We install the crankshaft in the cylinder block

We install the caps of the main bearings assembled with inserts on the cylinder block in accordance with their numbering

 маркировка крышек коренных подшипников H4M

The numbering of the covers starts from the timing drive side.

The arrows on the covers should be directed towards the timing drive

The numbering and arrows are located on the surfaces of the cap bosses, as shown in Figure 5

We install and tighten the new bolts for fixing the caps of the main bearings

Tighten the bolts securing the caps of the main bearings in two steps (replaceable TORX E14 head, collar, extension cord, torque wrench, rotation angle measuring head):

- tighten the bolts with a tightening torque of 30...35 NM (3.0...3.5 kgf.m);

- screw the bolts to an angle of 60°...65 °.

After that, we check the rotation of the crankshaft. The shaft must rotate freely and without jamming due to the force of the hand.

In case of tight rotation or jamming, it is necessary to remove the crankshaft and repeat the operation to select a set of inserts.

Check the axial clearance of the crankshaft

Install a rack with an indicator on the cylinder block, as shown in the figure.

 Проверка осевого зазора коленчатого вала

Place the indicator measuring rod on the crankshaft flange and set the indicator scale to zero.

Moving the crankshaft with screwdrivers, measure the axial clearance of the shaft. The axial clearance of the crankshaft should be within 0.1...0.3 mm. With an axial clearance of more than 0.3 mm, adjust the gap by replacing the thrust half-rings (tripod SHM-PV-8, indicator ICH-10, flat screwdriver - 2 pcs., micrometer type MK 25-1).

We check the height gaps between the piston grooves and the rings and the gaps in the ring locks.

 Проверка зазоров поршневых колец

The gap between the ring 1, figure, and the wall of the piston groove 2 for the upper compression ring should be 0.06...0.15 mm, for the second - 0.03 ... 0.07 mm, for the oil ring - 0.045... 0.125 mm. The gap should be measured at three points at an angle of 120 ° to each other.

The gap in the lock of the upper compression ring should be 0.2 ... 0.3 mm, for the second – 0.35 ... 0.50 mm, for the oil ring - 0.20 ... 0.45 mm.

Piston rings with a gap in the lock exceeding the maximum value should be replaced, if the gap is less than the minimum value, it is allowed to saw the butt surfaces of the ring (a set of probes, a file).

Assembly of the connecting rod-piston group

We install the connecting rod covers on the connecting rods and tighten them without tightening the fastening bolts

We mark the connecting rods in an electric furnace heated to 240o. The upper connecting rod heads should be directed inside the furnace. The heating time of connecting rods in the furnace is at least 15 minutes

 Установка поршневого пальца на приспособление

We install the device 1, the drawing, the piston pin 2 and the guide 3 on the roller

We remove the heated connecting rod from the electric furnace, quickly fasten it to the lower head in the vise so that the installation mark 1, figure, is located on the side of the piston pin installation

 Расположение установочной метки на шатуне

We put the piston on the connecting rod head so that the installation mark (the point on the bottom of the piston) is located on the side of the piston pin installation.

We combine the hole for the piston pin with the hole of the upper connecting rod head and insert the device assembly with the piston pin into the hole until the mandrel shoulder pads stop in the piston boss.

In this case, the piston should be pressed against the upper head of the connecting rod against the direction of pressing the finger.

Repeat this operation for the remaining pistons.

Next, unscrew the mounting bolts and remove the connecting rod covers

 Сборка двигателя H4M

After that, you need to pick up the connecting rod inserts according to the classification of the crankshaft connecting rod necks and holes in the lower connecting rod heads in accordance with Table 2

The color in the table means the marking of the liner applied to its end.

The marking color corresponds to a certain class of liner, which must be installed depending on the diameter class of the connecting rod necks and the diameter class of the holes in the lower connecting rod heads.

The upper part of the table shows the diameter classes of the holes in the lower connecting rod heads, in the left part - the diameter classes of the crankshaft crank necks.

Abbreviations given in the table:

UPR - insert installed in the connecting rod;

LWR - insert, installed in the connecting rod cover.

We install piston rings on the pistons

We install the lower compression ring with a scraper down

 Ориентация замков поршневых колец

The orientation of the piston ring locks is shown in the figure

We install it in a connecting rod with a hole flush with the plane of the connector, as shown in the figure

We shift the insert from the opposite side until it aligns with the plane of the connector

 Установка вкладышей в шатуны

Adjust the position of the insert so that the hole in the insert completely coincides with the hole in the connecting rod and the distance from the side surfaces of the connecting rod to the insert on each side is the same

Repeat this operation to install the inserts for the remaining connecting rods

We install an insert without a hole in the connecting rod cover flush with the connector plane, as shown in the figure. We shift the insert from the opposite side until it aligns with the plane of the connector

Adjust the position of the liner so that the distance from the side surfaces of the lid to the liner on each side is the same

Repeat the operations for installing the inserts for the remaining covers

Lubricate engine oil cylinders, liners, piston skirts, connecting rod crankshaft necks

 Установка поршней в блок цилиндров

We install the device 2 on the piston 1, figure 2, so that the piston skirt protrudes from the device by about 1 cm

We compress the piston rings and install the piston assembly with the connecting rod into the cylinder, in accordance with the marking. The mark on the bottom of the piston should be facing towards the timing drive.

Repeat the operations for the other three pistons.

We install the connecting rod covers in accordance with the marking. The markings on the cover and on the connecting rod must correspond to the cylinder number.

We install and tighten the new bolts for fixing the connecting rod covers.

Tighten the bolts for fixing the caps of the main bearings in two steps (replaceable head 11, collar, extension cord, torque wrench, rotation angle measuring head):

- tighten the bolts with a tightening torque of 19...20 NM (1.9...2.0 kgf.m);

- screw the bolts to an angle of 60°...65 °.

Install a new cylinder block booster O-ring and two centering pins in the cylinder block. The protrusion of the pins from the cylinder block is 9...11 mm

Нанесение герметика на плоскость усилителя блока

Apply a roller of sealant with a diameter of 4...5 mm, Figure 6, on the plane of the cylinder block amplifier connector with the cylinder block at a distance of 6.5 mm from the inner edge of the amplifier (silicone sealant TV 1217 L, flow rate - 14 g).

Attention! The time of open exposure of the sealant is not more than 5 minutes.

Install the cylinder block booster on the cylinder block and fasten with ten bolts in the order shown in Figure 7

 Порядок затяжки болтов усилителя блока

Bolt tightening torque – 21.0...29.0 NM (2.1...2.9 kgf.m)

Remove the remnants of the protruding sealant

Apply a roller of sealant with a diameter of 4...5 mm, Figure 8, on the plane of the connector of the oil sump cover with the cylinder block amplifier at a distance of 6.5 mm from the inner edge of the amplifier (silicone sealant TV 1217 L, consumption rate - 8 g).

 Схема нанесения герметика на поддонПорядок затяжки болтов поддона

Attention! The time of open exposure of the sealant is not more than 5 minutes.

After that, we install the assembled cylinder head, as indicated in the article "Disassembly and repair of the cylinder head of the H4M engine"

Install an oil pump with rings assembled on the engine and fix it with three bolts. The tightening torque of the oil pump mounting bolts is 21...29 NM (2.1...2.9 kgf.m)

Install a water pump with a new gasket on the engine and wrap and tighten the four mounting bolts.

The tightening torque of the water pump mounting bolts is 21...29 NM (2.1...2.9 kgf.m) (replaceable head 10, collar, extension cord, torque wrench).

Install the drive pulley on the water pump, wrap and tighten the three bolts securing the water pump pulley, holding the pulley with a screwdriver. The tightening torque of the water pump pulley mounting bolts is 7.0...7.5 NM (0.70...0.75 kgf.m) (flat screwdriver, replaceable head 10, collar, torque wrench).

Lubricate the working edge of the rear crankshaft oil seal with engine oil and install the oil seal on the crankshaft flange

 установка направляющей втулкиЗапрессовка заднего сальника коленвала

Install the guide sleeve 9, Figure, accessories for installing the rear oil seal on the crankshaft by aligning the hole in the sleeve with the pin 2 (device 77 11 381 919).

Fix the bushing on the crankshaft using two bolts 3 fixing the flywheel (replaceable TORX E20 head, collar)

Install the cover 1, Figure 10, fixtures, washer 2 and nut 3 on the guide sleeve.

Apply a soap solution to the seat surface of the oil seal and press the oil seal into the cylinder block by rotating the nut until the cover 1 comes into contact with the cylinder block (replaceable head 17, collar).

Remove the oil seal fitting from the crankshaft.

Install a coolant outlet pipe with a new gasket on the engine and secure it with seven bolts. The tightening torque of the pipe mounting bolts is 21...29 NM (2.1...2.9 kgf.m)

Wrap the exhaust coolant temperature sensor in the nozzle. The tightening torque of the coolant temperature sensor is 25...35 NM (2.5...3.5 kgf.m)

 Порядок затяжки болтов маховика

Install the flywheel on the crankshaft and wrap the new flywheel mounting bolts (replaceable TORX E20 head, collar).

Install the flywheel lock on the engine and tighten the flywheel mounting bolts in the sequence shown in the figure. Bolt tightening torque - 103...112 NM (10.3...11.2 kgf.m)

Remove the flywheel lock.

Wrap a new phase regulator oil filter with a washer in the cylinder head. The tightening torque of the filter is 36.0...43.0 NM (3.6...4.3 kgf.m) (replaceable 8 head for an internal hexagon, a collar and an extension cord, a 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 fasten with a bolt. The tightening torque of the valve mounting bolt is 8.0...12.0 NM (0.8...1.2 kgf.m)

Install the thermostat valve in the cylinder block, while the label on the valve should be facing outward and located at the top along the vertical axis.

Install the thermostat cover and secure it with two bolts. The tightening torque of the thermostat cover mounting bolts is 16...17 NM (1.6...1.7 kgf.m)

Install the oil level indicator tube mounting clip.

Lubricate the O-ring of the oil level indicator tube and install the tube in the cylinder block

Fix the tube on the thermostat cover.

Install the oil level indicator.

Lubricate the oil filter O-ring, wrap the oil filter until the cylinder block O-ring touches and turn the filter by hand force by ¾ turns

Apply sealant to the threaded part of the oil pressure sensor, wrap the sensor in the cylinder block. The tightening torque of the sensor is 12...17 NM (1.2...1.7 kgf.m)

Install the detonation sensor on the cylinder block and fasten it with a bolt. In this case, the sensor connector should be directed towards the flywheel. The tightening torque of the sensor mounting bolt is 20...25 NM (2.0...2.5 kgf.m) (10 replaceable head, collar, extension cord, torque wrench).

Lubricate the O-ring of the crankshaft position sensor with engine oil, install the sensor on the engine and fasten it with a bolt. The tightening torque of the crankshaft position sensor mounting bolt is 6.0...8.0 NM (0.6...0.8 kgf.m)

Install a key and a timing sprocket (hammer) on the crankshaft.

Install the oil pump sprocket on the oil pump shaft, wrap and tighten the sprocket mounting nut.

The tightening torque of the oil pump sprocket mounting nut is 21...29 NM (2.1...2.9 kg.m) (ring wrench 10, replaceable TORX E8 head, collar, replaceable insert 10, torque wrench).

Install a new oil pump drive chain on the timing and oil pump sprockets.

Install a new tensioner 1, Figure 14, of the oil pump drive chain on the guide pin and insert the tendril of the tensioner spring 2 into the hole on the cylinder block.

Lubricate the support surfaces of the camshafts and install the camshafts in the cylinder head. Install the camshaft with oil channels on the flange from the inlet side

Lubricate the camshaft necks, install the camshaft covers and the bolts securing the intake covers

 Порядок затяжки болтов крышек распредвала

Wrap and tighten the cap mounting bolts in the sequence shown in Figure 11.

Tightening the bolts of fastening the covers of the bearings of the camshafts should be performed in two steps:

- tighten the bolts with a tightening torque of 5.0 Nm;

- tighten the bolts with a tightening torque of 9.0...11.0 NM.

Turn the camshafts so that the mounting pins are in the upper position (wrench 22).

Turn the crankshaft key to the upper position.

 Проверка положения звеньев цепи

Install a new timing chain on the phase regulator so that the label 2, Figure 12, of the phase regulator is located in the middle of the orange link 1 of the chain.

Install a phase regulator with a chain on the intake camshaft and fasten it with a bolt. Do not tighten the bolt completely (wrench 22, replaceable head 13, collar and extension cord).

Attention! When installing the phase regulator, it is necessary to align the mounting hole on the hub of the phase regulator located between the two oil channels with the mounting pin on the camshaft.

Attention! After installing the phase regulator from the spare parts, remove the transport pin from it.

Install the chain on the camshaft sprocket so that the label 2, figure, of the sprocket is located in the middle of the orange link 1 of the chain.

Install the sprocket on the exhaust camshaft, aligning the mounting hole with the pin, and secure with a bolt. Do not tighten the bolt completely

Install the timing chain on the crankshaft sprocket so that the mark 2, Figure 12, is located in the middle of the yellow link 2 of the chain.

Install a flywheel lock on the engine and lock the flywheel.

Install a new chain calmer on the engine and fasten it with two bolts. The tightening torque of the mounting bolts of the pacifier is 21...29 NM (2.1...2.9 kgf.m)

Install a new chain tensioner shoe on the guide pin in the cylinder block.

Install a new chain tensioner on the engine and fasten it with two bolts. The tightening torque of the chain tensioner mounting bolts is 8.0...12.0 NM (0.8...1.2 kgf.m).

Remove the transport pin from the tensioner housing (replaceable head 8, collar, torque wrench, pliers).

Tighten the mounting bolts of the phase regulator and the camshaft sprockets. The tightening torque of the fastening bolts is 74...83 NM (7.4...8.3 kgf.m)

Remove the flywheel lock from the engine.

Wrap the bolt of the auxiliary drive pulley attachment into the crankshaft, turn the crankshaft one turn clockwise and check the coincidence of the marks on the chain with the marks on the sprockets and on the phase regulator.

If the labels do not match, repeat the chain installation operations (replaceable head 19, collar).

 Проверка зазоров клапановМаркировка толкателя клапана

Check the gaps in the valve actuator mechanism by turning the crankshaft so that the cam of the camshaft being checked is pointing upwards, as shown in the figure.

The permissible clearance should be: for intake valves – 0.26 ...0.34 mm, for exhaust valves - 0.29 ...0.37 mm.

If the gap deviates from the specified value, remove the camshafts and replace the corresponding pushrods. Depending on the thickness, the pushers are supplied in spare parts of several classes.

Table - Classification of pushers

№ пп.

Иден-ный

номер

Толщина,

мм

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

The classification of pushers is given in the table.

The pusher class is indicated on the inner surface of the pusher, figure.

After replacing the pushrods, install the camshafts and the timing mechanism, according to the above procedure.

Apply two strips of sealant along the line of the cylinder block connector with the cylinder head and two strips of sealant along the line of the cylinder block connector with the cylinder block amplifier from the timing drive side

Install the centering pins of the timing cover on the engine. The protrusion of the pins above the stopping surface is 10 ± 0.5 mm

 схема нанесения герметика на крышку ГРМпорядок затяжки крышки ГРМ

Apply the sealant to the surface of the timing cover mated to the cylinder block, as shown in the figure, with a roller with a diameter of 3.5 mm (sealant TV 1217L, flow rate - 14 g).

Install the cover and fasten with bolts in the following order (replaceable heads 8, 10, 13, collars, torque wrenches):

- pre-tighten bolts 3, 2, 8 and 7, Figure 14. The tightening torque of the bolts is 8.0 NM (0.8 kgf.m);

- finally tighten the 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 N.m (2.1...2.9 kgf.m);

- bolts 11, 12, 13, 14 and 15 - 47...63 NM (4.7...6.3 kgf.m).

Install a new front crankshaft oil seal on the mandrel (mandrel 77 11 381 918 for installing the front crankshaft oil seal).

 Установка переднего сальника коленчатого вала

Apply a soap solution to the seat surface of the oil seal, install the mandrel 1, figure, with the oil seal on the crankshaft, wrap the bolt 2 fastening the pulley of the drive of auxiliary units until the mandrel comes into contact with the timing cover (replaceable head 19, collar).

Unscrew the bolt and remove the mandrel.

Press two centering pins of the cylinder head cover into the cylinder head. The protrusion of the pins above the sealing surface of the cylinder head is 7+1 mm

Install a new gasket on the cylinder head cover.

Apply two strips of sealant 20 mm long at the junction of the cylinder head with the timing cover in the upper part (sealant TV 1217L, flow rate - 3 g).

 Порядок затяжки болтов крышки ГБЦ

Install the cylinder head cover with a gasket on the cylinder head, the cover mounting bolts and tighten the bolts in the order shown in Figure 15. The tightening torque of the cylinder head cover mounting bolts is 8.0...12.0 NM (0.8...1.2 kgf.m)

Install the phase sensor in the cylinder head cover and fasten it with a bolt. The tightening torque of the phase sensor mounting bolt is 9.0...12.0 NM (0.9...1.2 kgf.m)

Wrap the spark plugs. The tightening torque of the spark plugs is 21.0...27.0 NM (2.1...2.7 kgf.m)

Install the ignition coils and fasten them with bolts on the cylinder head cover. The tightening torque of the bolts securing the ignition coils is 9.0...12.0 NM (0.9...1.2 kgf.m)

Install a fuel ramp with nozzles assembled on the engine and fasten it with two bolts. The tightening torque of the fuel ramp mounting bolts is 21.0...29.0 NM (2.1...2.9 kgf.m)

Attach the plug pads of the nozzle wiring harness to the nozzles.

Install the protective screen of the fuel ramp and secure it with two bolts to the cylinder head cover and two bolts to the fuel ramp. The tightening torque of the mounting bolts of the ec-rana to the cylinder head cover is 21.0...29.0 NM (2.1...2.9 kgf.m), the tightening torque of the screen mounting bolts to the fuel ramp is 10.0...13.0 NM (1.0...1.3 kgf.m)

Install the wiring harness mounting bracket on the engine and bolt it to the cylinder head cover. The tightening torque of the bracket mounting bolt is 8.0...12.0 NM (0.8...1.2 kgf.m) (replaceable head 8, collar, torque wrench).

Attach the plug pads of the wiring harness to the ignition coils and fix the harness on the cylinder head cover and on the bracket.

Install the intake module with new gaskets on the engine and secure it with bolts on the cylinder head and on the cylinder head cover. The tightening torque of the bolts securing the intake module is 7...15 NM (0.7...1.5 kgf.m)

Install the crankcase gas ventilation tube and secure with clamps

Install the hoses for heating the throttle branch pipe and fix it with clamps

Install a flywheel lock on the engine and lock the flywheel

Lubricate with engine oil the landing surface of the auxiliary drive pulley under the oil seal, install the pulley on the crankshaft and secure with a new bolt. The tightening torque of the pulley mounting bolt is 30.0...40.0 NM (3.0...4.0) kgf.m. After tightening, screw the bolt to an angle of 60 ° ...66 °

Remove the flywheel lock.

Install the auxiliary units bracket on the engine and fasten it with four bolts. The tightening torque of the bracket mounting bolts is 21.0...29.0 NM (2.1...2.9 kgf.m)

Install a thermoprotective lower screen on the exhaust manifold and fasten it with bolts. The tightening torque of the screen mounting bolts is 10.0...13.0 NM (1.0...1.3 kgf.m) (10 replaceable head, collar and extension cord, torque wrench).

Install a new exhaust manifold gasket on the engine, the manifold and fix it with nuts. The tightening torque of the nuts of the exhaust manifold mounting is 30.0...40.0 NM (3.0...4.0 kgf.m)

Wrap the oxygen sensor in the exhaust manifold. The tightening torque of the oxygen sensor is 38...50 Nm (3.8...5.0 kgf.m)

Install a heat-protective upper screen on the exhaust manifold and fasten it with bolts.

The tightening torque of the screen mounting bolts is 10.0...13.0 NM (1.0...1.3 kgf.m) (10 replaceable head, collar and extension cord, torque wrench).

Install the generator on the bracket of the auxiliary units and fix it with two bolts. The tightening torque of the generator mounting bolts is 21.0...29.0 NM (2.1...2.9 kgf.m)

Install the air conditioner compressor on the bracket of auxiliary units and fix it with three bolts. The tightening torque of the compressor mounting bolts is 21.0...29.0 NM (2.1...2.9 kgf.m) (10 replaceable head, collar and extension cord, torque wrench).

Install the auxiliary units drive belt on the engine (device 67.7834-9703 for installing an elastic belt).

Install the funnel on the oil filler neck.

Pour 4.7 liters of oil into the engine

Install the oil filler cap.