Assembling the H4M engine

We install the cylinder block on the stand for dismantling and assembling the units.

We install on the crankshaft 1 (Figure 1) the pin 4 and the centring disc of the crankshaft position sensor.

We screw in and tighten the three bolts 3 fastening the position disc.

Tightening torque of the disc fastening bolts: 20–24 N·m (2.0–2.4 kgf·m).

We remove the centring pin from the crankshaft.

We select the crankshaft main bearing shells according to the classification of the crankshaft main journals and the cylinder block supports, in accordance with Table 1.

The colour in the table indicates the shell marking applied to its end face.

The marking colour corresponds to a specific shell class that must be installed depending on the class of the main journal diameter and the class of the bore diameter in the supports.

In the upper part of the table, the classes of bore diameters in the cylinder block supports are indicated; on the left, the classes of main journal diameters of the crankshaft.

Abbreviations used in Table 1:

• UPR — shell installed in the cylinder block support;
• LWR — shell installed in the main bearing cap.

We install the grooved shells in the cylinder block supports.

We align the new grooved bearing shells on the cylinder block, matching the shell groove with the support groove.

We install the bearing shell flush with the support, as shown in Figure 3, and press on it from the reverse side so as to install the shell flush with the support.

We adjust the position of the shells so that they are centred on the cylinder block supports.

We install the shells without grooves in the cylinder block caps.

We install the shells flush with the surface of the main bearing cap, as shown in Figure 4, and shift it to the opposite side until aligned with the cap.

In the same way we install the remaining shells.

We adjust the position of the shells so that they are centred on the cylinder block caps.

We install the crankshaft thrust half-rings in the seats of the third cylinder block support, matching the half-ring tabs with the grooves 1 (Figure 5) of the support.

The grooves 2 of the half-rings must be on the crankshaft side.

We lubricate with engine oil the surfaces of the main bearing shells and the crankshaft thrust half-rings that are in contact with the crankshaft.

We install the crankshaft in the cylinder block.

We install on the cylinder block the main bearing caps complete with shells in accordance with their numbering.

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

The arrows on the caps must point towards the timing drive.

The numbering and arrows are located on the surfaces of the cap bosses, as shown in Figure 6.

We install and screw in the new main bearing cap fastening bolts.

We tighten the main bearing cap fastening bolts in two passes (TORX E14 socket, handle, extension, torque wrench, angle gauge):

• tighten the bolts to a torque of 30–35 N·m (3.0–3.5 kgf·m);
• turn the bolts a further 60°–65°.

After this we check the rotation of the crankshaft. The shaft must rotate freely by hand and without jamming.

In case of tight rotation or jamming, it is necessary to remove the crankshaft and repeat the operation of selecting the bearing shell set.

We check the crankshaft axial clearance.

Install a stand with a dial indicator on the cylinder block, as shown in the figure.

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

Moving the crankshaft with screwdrivers, measure the shaft axial clearance.

The crankshaft axial clearance must be within 0.1–0.3 mm.

If the axial clearance is more than 0.3 mm, adjust the clearance by replacing the thrust half-rings (ШМ-ПВ-8 stand, ИЧ-10 indicator, flat screwdriver — 2 pcs., micrometer type МК 25-1).

We check the height clearances between the piston grooves and the rings, and the clearances in the ring end gaps.

The clearance between the ring 1 (Figure 8) and the wall of the piston groove 2 must be 0.06–0.15 mm for the upper compression ring, 0.03–0.07 mm for the second, 0.045–0.125 mm for the oil scraper ring.

Measure the clearance at three points located at 120° to each other.

The end gap of the upper compression ring must be 0.2–0.3 mm, for the second — 0.35–0.50 mm, for the oil scraper ring — 0.20–0.45 mm.

Piston rings with an end gap exceeding the maximum value must be replaced; if the gap is less than the minimum value, it is permissible to file the joint surfaces of the ring (feeler gauge set, needle file).

Assembling the connecting rod and piston group

We install the connecting rod caps on the connecting rods and screw them in without tightening the fastening bolts.

We place the connecting rods in an electric furnace heated to 240 °C.

The upper connecting rod ends must face the inside of the furnace.

The heating time of the connecting rods in the furnace is at least 15 minutes.

We install on the fixture shaft 1 (Figure 9) the piston pin 2 and the guide 3.

We take the heated connecting rod out of the electric furnace and quickly clamp it by the lower end in a vice so that the installation mark 1 (Figure 10) is on the piston pin installation side.

We fit the piston onto the connecting rod end so that the installation mark (dot on the piston crown) is on the piston pin installation side.

We match the piston pin bore with the bore of the upper connecting rod end and insert into the bore the fixture complete with the piston pin until the mandrel shoulders stop against the piston boss.

The piston must be pressed by its boss against the upper connecting rod end in the direction opposite to the pin press-fitting direction.

We repeat this operation for the remaining pistons.

Then we unscrew the fastening bolts and remove the connecting rod caps.

After this, the connecting rod bearing shells must be selected according to the classification of the crankshaft connecting rod journals and the bores in the lower connecting rod ends, in accordance with Table 2.

The colour in the table indicates the shell marking applied to its end face.

The marking colour corresponds to a specific shell class that must be installed depending on the class of the connecting rod journal diameter and the class of the bore diameter in the lower connecting rod ends.

In the upper part of the table, the classes of bore diameters in the lower connecting rod ends are indicated; on the left, the classes of connecting rod journal diameters of the crankshaft.

Abbreviations used in the table:

• UPR — shell installed in the connecting rod;
• LWR — shell installed in the connecting rod cap.

We install the piston rings on the pistons

We install the lower compression ring with the scraper downwards.

The orientation of the piston ring end gaps is shown in Figure 12.

We install in the connecting rod with a bore flush with the parting plane, as shown in the figure.

We shift the shell from the opposite side until aligned with the parting plane.

We adjust the position of the shell so that the bore in the shell fully coincides with the bore in the connecting rod and the distance from the side surfaces of the connecting rod to the shell is the same on each side.

We repeat this shell installation operation for the remaining connecting rods.

We install in the connecting rod cap the shell without a bore flush with the parting plane, as shown in the figure.

We shift the shell from the opposite side until aligned with the parting plane.

We adjust the position of the shell so that the distance from the side surfaces of the cap to the shell is the same on each side.

We repeat the shell installation operations for the remaining caps.

We lubricate with engine oil the cylinders, shells, piston skirts, connecting rod journals of the crankshaft.

We install on the piston 1 (Figure 14) the fixture 2 so that the piston skirt protrudes from the fixture by about 1 cm.

We compress the piston rings and install the piston complete with connecting rod in the cylinder in accordance with the marking.

The mark on the piston crown must face the timing drive side.

We repeat the operations for the remaining three pistons.

We install the connecting rod caps in accordance with the marking.

The marking on the cap and on the connecting rod must correspond to the cylinder number.

We install and screw in the new connecting rod cap fastening bolts.

Carry out the tightening of the connecting rod cap fastening bolts in two passes (11 socket, handle, extension, torque wrench, angle gauge):

• tighten the bolts to a torque of 19–20 N·m (1.9–2.0 kgf·m);
• turn the bolts a further 60°–65°.

Install in the cylinder block a new cylinder block stiffener sealing ring and two centring pins.

Protrusion of the pins from the cylinder block: 9–11 mm.

Apply a bead of sealant 4–5 mm in diameter (Figure 15) to the parting plane of the cylinder block stiffener with the cylinder block at a distance of 6.5 mm from the inner edge of the stiffener (silicone sealant ТВ 1217 L, consumption rate — 14 g).

Caution! Open holding time of the sealant — no more than 5 minutes.

Install the cylinder block stiffener on the cylinder block and fasten it with ten bolts in the sequence shown in Figure 16.

Tightening torque of the bolts: 21.0–29.0 N·m (2.1–2.9 kgf·m).

Remove residues of the protruding sealant.

Apply a bead of sealant 4–5 mm in diameter (Figure 17) to the parting plane of the oil sump cover with the cylinder block stiffener at a distance of 6.5 mm from the inner edge of the stiffener (silicone sealant ТВ1217 L, consumption rate — 8 g).

Caution! Open holding time of the sealant — no more than 5 minutes.

After this we install the assembled cylinder head, as specified in the article “Dismantling and repair of the engine cylinder head”.

Install the oil pump with rings complete on the engine and fasten it with three bolts.

Tightening torque of the oil pump fastening bolts: 21–29 N·m (2.1–2.9 kgf·m).

Install the water pump with a new gasket on the engine and screw in and tighten the four fastening bolts.

Tightening torque of the water pump fastening bolts: 21–29 N·m (2.1–2.9 kgf·m) (10 socket, handle, extension, torque wrench).

Install the drive pulley on the water pump, screw in and tighten the three water pump pulley fastening bolts, holding the pulley with a screwdriver.

Tightening torque of the water pump pulley fastening bolts: 7.0–7.5 N·m (0.70–0.75 kgf·m) (flat screwdriver, 10 socket, handle, torque wrench).

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

Install the guide sleeve 1 (Figure 19) of the rear oil seal installation fixture on the crankshaft, matching the bore in the sleeve with the pin 2 (fixture 7711381919).

Fasten the sleeve on the crankshaft using two flywheel fastening bolts 3 (TORX E20 socket, handle).

Install on the guide sleeve the cover 1 (Figure 20) of the fixture, the washer 2 and the nut 3.

Apply soapy water to the seating surface of the oil seal and press the oil seal into the cylinder block, turning the nut until the cover 1 touches the cylinder block (17 socket, handle).

Remove the oil seal installation fixture from the crankshaft.

Install the coolant outlet stub pipe with a new gasket on the engine and fasten it with seven bolts.

Tightening torque of the stub pipe fastening bolts: 21–29 N·m (2.1–2.9 kgf·m).

Screw the coolant temperature sensor into the outlet stub pipe.

Tightening torque of the coolant temperature sensor: 25–35 N·m (2.5–3.5 kgf·m).

Install the flywheel on the crankshaft and screw in the new flywheel fastening bolts (TORX E20 socket, handle).

Install the flywheel locking tool on the engine and tighten the flywheel fastening bolts in the sequence shown in Figure 21.

Tightening torque of the bolts: 103–112 N·m (10.3–11.2 kgf·m).

Remove the flywheel locking tool.

Screw a new phase regulator oil filter with washer into the cylinder head.

Tightening torque of the filter: 36.0–43.0 N·m (3.6–4.3 kgf·m) (8 socket for internal hexagon, handle and extension, torque wrench).

Lubricate the sealing ring of the phase regulator solenoid valve with engine oil, install the valve in the cylinder head and fasten it with a bolt.

Tightening torque of the valve fastening bolt: 8.0–12.0 N·m (0.8–1.2 kgf·m).

Install the thermostat valve in the cylinder block; the mark on the valve must face outwards and be located at the top on the vertical axis.

Install the thermostat cover and fasten it with two bolts. Tightening torque of the thermostat cover fastening bolts: 16–17 N·m (1.6–1.7 kgf·m).

Install the clip fastening the oil level dipstick tube.

Lubricate the sealing ring of the oil level dipstick tube and install the tube in the cylinder block.

Fix the tube on the thermostat cover.

Install the oil level dipstick.

Lubricate the oil filter sealing ring, screw the oil filter in until the sealing ring touches the cylinder block and turn the filter by hand a further ¾ of a turn.

Apply sealant to the threaded part of the oil pressure sensor and screw the sensor into the cylinder block.

Tightening torque of the sensor: 12–17 N·m (1.2–1.7 kgf·m).

Install the knock sensor on the cylinder block and fasten it with a bolt.

The sensor connector must face the flywheel side.

Tightening torque of the sensor fastening bolt: 20–25 N·m (2.0–2.5 kgf·m) (10 socket, handle, extension, torque wrench).

Lubricate the sealing ring of the crankshaft position sensor with engine oil, install the sensor on the engine and fasten it with a bolt.

Tightening torque of the crankshaft position sensor fastening bolt: 6.0–8.0 N·m (0.6–0.8 kgf·m).

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

Install the oil pump sprocket on the oil pump shaft, screw in and tighten the sprocket fastening nut.

Tightening torque of the oil pump sprocket fastening nut: 21–29 N·m (2.1–2.9 kgf·m) (ring spanner 10, TORX Е8 socket, handle, 10 insert, torque wrench).

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

Install a new oil pump drive chain tensioner 1 (Figure 22) on the guide pin and hook the tensioner spring tab 2 into the bore on the cylinder block.

Lubricate the supporting surfaces of the camshafts and install the camshafts in the cylinder head.

The camshaft with oil channels on the flange must be installed on the inlet side.

Lubricate the camshaft journals, install the camshaft caps and the inlet cap fastening bolts.

Screw in and tighten the cap fastening bolts in the sequence shown in Figure 22.

Carry out the tightening of the camshaft bearing cap fastening bolts in two passes:

• tighten the bolts to a torque of 5.0 N·m;
• tighten the bolts to a torque of 9.0–11.0 N·m.

Turn the camshafts so that the installation pins are in the upper position (ring spanner 22).

Turn the crankshaft by the key to the upper position.

Install the new timing drive chain on the phase regulator so that the mark 2 (Figure 23) of the phase regulator is in the middle of the orange link 1 of the chain.

Install the phase regulator with the chain on the inlet camshaft and fasten it with a bolt.

Do not finally tighten the bolt (ring spanner 22, 13 socket, handle and extension).

Caution! When installing the phase regulator, it is essential to match the installation bore on the phase regulator hub, located between two oil channels, with the installation pin on the camshaft.

Caution! After installing the phase regulator supplied as a spare part, remove the transport pin from it.

Install the chain on the camshaft sprocket so that the mark 2 (Figure 23) of the sprocket is in the middle of the orange link 1 of the chain.

Install the sprocket on the exhaust camshaft, matching the installation bore with the pin, and fasten it with a bolt. Do not finally tighten the bolt.

Install the timing drive chain on the crankshaft sprocket so that the mark 2 (Figure 23) is in the middle of the yellow link 2 of the chain.

Install the flywheel locking tool on the engine and lock the flywheel.

Install a new chain damper on the engine and fasten it with two bolts. Tightening torque of the damper fastening bolts: 21–29 N·m (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. Tightening torque of the chain tensioner fastening bolts: 8.0–12.0 N·m (0.8–1.2 kgf·m).

Remove the transport pin from the tensioner body (8 socket, handle, torque wrench, pliers).

Tighten the phase regulator and camshaft sprocket fastening bolts.

Tightening torque of the fastening bolts: 74–83 N·m (7.4–8.3 kgf·m).

Remove the flywheel locking tool from the engine.

Screw the auxiliary drive pulley fastening bolt into the crankshaft, turn the crankshaft one revolution clockwise and check that the marks on the chain coincide with the marks on the sprockets and on the phase regulator.

If the marks do not coincide, repeat the chain installation operations (19 socket, handle).

Check the clearances in the valve train by turning the crankshaft so that the cam being checked is pointing upwards, as shown in Figure 24.

The permissible clearance must be: for inlet 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 their thickness, tappets are supplied as spare parts in several classes.

Table — Classification of tappets

The classification of tappets is given in the table.

The tappet class is indicated on the inner surface of the tappet (Figure 25).

After replacing the tappets, install the camshafts and the timing drive mechanism according to the procedure given above.

Apply two strips of sealant along the parting line of the cylinder block with the cylinder head and two strips of sealant along the parting line of the cylinder block with the cylinder block stiffener on the timing drive side.

Install the centring pins of the timing drive cover on the engine. Protrusion of the pins above the mating surface: 10±0.5 mm.

Apply sealant to the surface of the timing drive cover that mates with the cylinder block, as shown in Figure 26, in a bead 3.5 mm in diameter (sealant ТВ 1217L, consumption rate — 14 g).

Install the cover and fasten it with bolts in the following order (8, 10, 13 sockets, handle, torque wrenches):

• preliminarily tighten bolts 3, 2, 8 and 7 (Figure 27). Tightening torque of the bolts: 8.0 N·m (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 N·m (2.1–2.9 kgf·m);
  • bolts 11, 12, 13, 14 and 15: 47–63 N·m (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).

Apply soapy water to the seating surface of the oil seal, install the mandrel 1 (Figure 28) with the oil seal on the crankshaft, screw in the auxiliary drive pulley fastening bolt 2 until the mandrel touches the timing drive cover (19 socket, handle).

Unscrew the bolt and remove the mandrel.

Press two cylinder head cover centring pins into the cylinder head.

Protrusion of the pins above the mating surface of the cylinder head: 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 drive cover in the upper part (sealant ТВ 1217L, consumption rate — 3 g).

Install the cylinder head cover with the gasket on the cylinder head, the cover fastening bolts, and tighten the bolts in the sequence shown in Figure 29.

Tightening torque of the cylinder head cover fastening bolts: 8.0–12.0 N·m (0.8–1.2 kgf·m).

Install the phase sensor in the cylinder head cover and fasten it with a bolt.

Tightening torque of the phase sensor fastening bolt: 9.0–12.0 N·m (0.9–1.2 kgf·m).

Screw in the spark plugs. Tightening torque of the spark plugs: 21.0–27.0 N·m (2.1–2.7 kgf·m).

Install the ignition coils and fasten them with bolts on the cylinder head cover.

Tightening torque of the ignition coil fastening bolts: 9.0–12.0 N·m (0.9–1.2 kgf·m).

Install the fuel rail with injectors complete on the engine and fasten it with two bolts.

Tightening torque of the fuel rail fastening bolts: 21.0–29.0 N·m (2.1–2.9 kgf·m).

Connect the injector wiring harness plug connectors to the injectors.

Install the fuel rail protective shield and fasten it with two bolts to the cylinder head cover and two bolts to the fuel rail.

Tightening torque of the shield fastening bolts to the cylinder head cover: 21.0–29.0 N·m (2.1–2.9 kgf·m); tightening torque of the shield fastening bolts to the fuel rail: 10.0–13.0 N·m (1.0–1.3 kgf·m).

Install the wiring harness fastening bracket on the engine and fasten it with a bolt to the cylinder head cover.

Tightening torque of the bracket fastening bolt: 8.0–12.0 N·m (0.8–1.2 kgf·m) (8 socket, handle, torque wrench).

Connect the wiring harness plug connectors to the ignition coils and fasten the harness on the cylinder head cover and on the bracket.

Install the intake module with new gaskets on the engine and fasten it with bolts to the cylinder head and to the cylinder head cover.

Tightening torque of the intake module fastening bolts: 7–15 N·m (0.7–1.5 kgf·m).

Install the crankcase ventilation tube and fasten it with clamps.

Install the throttle stub pipe heating hoses and fasten them with clamps.

Install the flywheel locking tool on the engine and lock the flywheel.

Lubricate the seating surface of the auxiliary drive pulley under the oil seal with engine oil, install the pulley on the crankshaft and fasten it with a new bolt.

Tightening torque of the pulley fastening bolt: 30.0–40.0 N·m (3.0–4.0 kgf·m). After tightening, turn the bolt a further 60°–66°.

Remove the flywheel locking tool.

Install the auxiliary unit bracket on the engine and fasten it with four bolts.

Tightening torque of the bracket fastening bolts: 21.0–29.0 N·m (2.1–2.9 kgf·m).

Install the lower heat shield on the exhaust manifold and fasten it with bolts.

Tightening torque of the shield fastening bolts: 10.0–13.0 N·m (1.0–1.3 kgf·m) (10 socket, handle and extension, torque wrench).

Install a new exhaust manifold gasket, the manifold, on the engine and fasten it with nuts.

Tightening torque of the exhaust manifold fastening nuts: 30.0–40.0 N·m (3.0–4.0 kgf·m).

Screw the oxygen sensor into the exhaust manifold. Tightening torque of the oxygen sensor: 38–50 N·m (3.8–5.0 kgf·m).

Install the upper heat shield on the exhaust manifold and fasten it with bolts.

Tightening torque of the shield fastening bolts: 10.0–13.0 N·m (1.0–1.3 kgf·m) (10 socket, handle and extension, torque wrench).

Install the alternator on the auxiliary unit bracket and fasten it with two bolts.

Tightening torque of the alternator fastening bolts: 21.0–29.0 N·m (2.1–2.9 kgf·m).

Install the air conditioning compressor on the auxiliary unit bracket and fasten it with three bolts.

Tightening torque of the compressor fastening bolts: 21.0–29.0 N·m (2.1–2.9 kgf·m) (10 socket, handle and extension, torque wrench).

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

Install the funnel on the oil filler neck.

Pour 4.7 l of oil into the engine.

Install the oil filler neck cap.