Assembling the VAZ-2112 engine - continued

In the previous article we examined how to sub-assemble the main engine components.

In this article we continue assembling the VAZ-2112 engine components: we will install the oil pick-up, the oil sump, the crankshaft pulley and the water pump, and also consider running-in the engine after assembly.

Installing the oil pick-up

1. We lubricate the oil pick-up sealing ring with engine oil.

It is recommended to replace the oil pick-up sealing ring.

2. We install the oil pick-up in place and tighten the bolt securing the oil pick-up to the oil pump to a torque of 7.0–8.0 N·m (0.7–0.8 kgf·m).

3. We tighten the two bolts securing the oil pick-up to the second main bearing cap to a torque of 8–10 N·m (0.8–1.0 kgf·m).

Installing the oil sump

1. We cut off the protruding ends of the seal retainer gaskets.

2. We lubricate the cylinder block surface with consistent grease.

3. We install the oil sump gasket.

4. We install the sump. If the sump is slightly deformed, it is better to coat the sump gasket with sealant.

5. We tighten the oil sump securing bolts to a torque of 5–8 N·m (0.5–0.8 kgf·m).

Installing the crankshaft pulley

1. We fit the key into the crankshaft groove.

2. We install the crankshaft toothed pulley.

3. We fit the toothed belt onto the crankshaft pulley.

4. We fit the washer onto the belt drive pulley.

5. We fit the alternator drive pulley and start the bolt with the washer.

6. We tighten the pulley securing bolt, holding the flywheel on the other side, to a torque of 97.9–108.8 N·m (9.90–11.10 kgf·m).

Installing the water pump

1. We fit the sealing gasket to the water pump and lubricate the gasket with consistent grease.

2. Install the water pump in the cylinder block so that the factory marking on the pump faces the mating face of the cylinder block, since the securing bolts are arranged asymmetrically.
3. We tighten the coolant pump securing bolts to a torque of 7.64–8.01 N·m (0.78–0.82 kgf·m).

After that we install the cylinder head as described in the article «Removing and installing the cylinder head».

We install the timing belt, install the fuel rail with injectors, and install the resonator and intake pipe.

Running-in the engine after assembly

The repaired engine is subjected to bench tests (running-in) without load according to the following cycle:

• 750–800 min⁻¹ — 2 min;
• 1000 min⁻¹ — 3 min;
• 1500 min⁻¹ — 4 min;
• 2000 min⁻¹ — 5 min.

After installing the engine on the bench and starting it, check:

• whether there are leaks of coolant or fuel between the mating parts and at the pipe connections;
• the oil pressure and whether there is any oil seepage through the gaskets.

If abnormal knocking or faults are detected, stop the engine, rectify them, and then continue the tests.

If oil seeps through the gasket between the sump and the cylinder block, retighten the securing bolts to the recommended torque. If the oil leak does not stop, check the gasket and replace it if necessary.

If oil seeps through the gasket between the cover and the cylinder head, check the gasket and the rubber bushes on the cylinder head cover securing studs. If necessary, replace the gasket and bushes, following the recommendations set out in the article «Engine assembly».

After repairing the engine, a certain period of running-in of the working surfaces of the new parts is required. This applies in particular to engines on which the pistons, connecting rod and main bearing shells have been replaced, the crankshaft journals reground, and the cylinders honed.

Therefore, during the running-in of the repaired engine, do not subject it to maximum loads. The engine running-in must continue in the vehicle while observing the driving speeds recommended for the vehicle's running-in period.