Installing pistons with connecting rods

Lubricate the top of the cylinders and the crankshaft connecting rod journals with engine oil.

Reinstall the pistons and connecting rods using a ring to install the piston with piston rings in the cylinder liner, observing the correspondence of the pistons and cylinders

The marks on the pistons should point towards the flywheel.

Install the connecting rods to the crankshaft connecting rod journals.

Сборка блока цилиндров К4М

Install the connecting rod caps (see Fig. 13).

Tighten the connecting rod cap stud nuts to 20 Nm + (45˚ ± 5˚).

Сборка блока цилиндров К4М

Install the oil pump drive sprocket, oil pump timing chain, and oil pump (see Fig. 14).

Torque tighten the oil pump mounting bolts.

The front cover of the engine block can be sealed either by installing a gasket or by installing the cover over Loctite 518.

The seating surfaces of the cylinder block and the front cover of the engine block must be clean, dry and free of traces of oil, do not touch them with your hands.

Сборка блока цилиндров К4М

Loctite 518 is applied in a 1 mm wide strip, the location of the compound is shown in fig. 15.

Install the engine block front cover.

Сборка блока цилиндров К4М

Tighten the bolts of the front cover of the cylinder block in the order shown in Fig. sixteen.

The seating surfaces of the cylinder block and the water pump must be clean, dry and free from oil, do not touch them with your hands.

Сборка блока цилиндров К4М

Install the water pump.

Instead of the gasket, use Loctite 518 (1 mm wide strip), see fig. 17.

Сборка блока цилиндров К4М

Note. Apply one to two drops of Loctite Frenetanch to the bolts (1) and (4) of the water pump (see Fig. 18).

Tighten the M6 bolts and M8 bolt in the order shown in fig. eighteen.

Сборка блока цилиндров К4М

Apply four strips of Rhodorseal 5661, approximately 5 mm wide, to the joint of the front and rear covers and to the seating surfaces of the cylinder block.

For the location of the application sites, see 1, Fig. 19. for the back cover, the composition is applied in the same way.

Apply two drops of Rhodorseal5661, approximately 7 mm in diameter, to the seating surface of the front cover and cylinder block (2).

Сборка блока цилиндров К4М

When installing the oil pan, make sure that the tabs (1) of the oil damper are installed in the grooves (2) (see Fig. 20).

The cylinder block and sump must be aligned on the flywheel side to avoid damaging the clutch housing when connecting the engine to the gearbox.

Install the oil damper.

Install the oil pan with a new gasket.

Сборка блока цилиндров К4М

Tighten the oil pan mounting bolts in the order shown in fig. 21:

- First pass, Nm 8;

- second pass, Nm 14.

Install the oil level sensor and tighten to the specified torque.

The tightening torques are indicated at the beginning of the article Assembling the cylinder block of the K4M engine

Install the knock sensor and tighten to the specified torque.

Install the oil pressure switch and tighten to the specified torque.

Сборка блока цилиндров К4МСборка блока цилиндров К4М

Press in the crankshaft rear oil seal with a tool Mot. 1129-01 (see Fig. 22).

Press in the front crankshaft oil seal with a tool Mot. 1385 (see Fig. 23).

Replace the flywheel mounting bolts. Do not reuse old bolts.

Clean the crankshaft seat flange and threaded bolt holes.

Check the technical condition of the flywheel.

Degrease the flywheel bearing surface and the counter surface on the crankshaft flange.

Сборка блока цилиндров К4М

Install the spacer sleeve (A, Fig. 24), installation position with the bevel towards the flywheel.

Coat the screw threads with Loctite Frenetanch.

Сборка блока цилиндров К4М

Tighten the mounting bolts by hand until they come into contact with the flywheel, then block the flywheel with locking tool Mot. 582-01 or Mot. 1677 (see fig. 25).

Tighten the flywheel mounting bolts to 55 Nm.

Install the clutch plate and clutch cover / pressure plate assembly.

Сборка блока цилиндров К4М

Center the driven disc using the Emb. 1518 (see Fig. 26), the mandrel is suitable for centering the disks of a VAZ car.

Tighten the clutch cover mounting bolts.

Remove the flywheel retainer.