H4M Engine Disassembly Description

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We install the engine on a stand for disassembly and assembly of units

Unscrew the oil drain plug and drain the oil from the crankcase

Fig. 1. Removing the water pump pulley: 1 - the water pump pulley bolts

Loosen the water pump pulley bolts by blocking the water pump pulley with a screwdriver

(If you hold the drive belt, you can not block the pulley)

Unscrew the bolts with a 10 head and remove the pulley

Disconnect the heating hoses from the throttle with pliers

Disconnect the throttle pipe heating hoses from the coolant outlet pipe and remove the hoses from the engine

Remove the crankcase ventilation tube

Remove the intake module assembly with the throttle pipe and gaskets

Using an 8 socket, remove the wiring harness bracket

With the help of heads for 8 and 10, we remove the protective screen of the fuel rail

Disconnect the pads from the ignition coils

Disconnect the injector wire blocks from the fuel injectors and remove the harness from the engine

With a head of 8, unscrew the bolts securing the ignition coils and remove the coils

Using a 14-inch spark plug wrench, unscrew the spark plugs

With a 10 head, unscrew the mounting bolt and remove the phase sensor

With a head of 8, unscrew the fastening bolt and remove the solenoid valve of the phase regulator

Using a clamshell grip, remove the oil level indicator tube

With a head of 8, unscrew the bolts and remove the cylinder head cover

Set the TDC of the compression stroke in the first cylinder, for this:

Turn the crankshaft clockwise until mark 1 (Figure 2) of the crankshaft pulley and mark 2 on the timing cover are aligned

fig. 2. TDC setting: 1 - mark on the crankshaft pulley, 2 - mark on the timing cover

In this case, the marks of the camshaft phase regulator 1 and the intake camshaft sprocket 2 should be located as shown in the figure

fig. 3. Checking the marks in the timing drive mechanism: 1 - camshaft dephaser marks, 2 - camshaft sprocket marks

If this is not the case, turn the crankshaft one more turn until the marks on the crankshaft pulley and on the timing cover are aligned

fig. 4. Installing the flywheel retainer: 1 - flywheel retainer

Installing the flywheel retainer 67.7820-9708 or 0000143100

With a 19 head, unscrew the mounting bolt and remove the crankshaft pulley

fig. 5. Removing the front crankshaft oil seal: 1 - thrust plate, 2 - flat screwdriver

Using a slotted screwdriver and a flat wood or plywood thrust plate, remove the crankshaft front oil seal as shown

fig. 6. Removing the crankshaft rear oil seal

Use the TORX E20 head to unscrew the mounting bolts and remove the flywheel and flywheel retainer

Using a screwdriver, remove the crankshaft rear oil seal

Using heads 8, 10, 13, unscrew the bolts securing the timing cover

fig. 7. Removing the timing cover
fig. 8. Removing the timing cover: 1 - tool 67.7812-9712 for removing the crankcase or 7711381716

Carefully remove the timing cover as shown in the pictures

fig. 9. Checking the position of the chain links: 1 - chain links, 2 - marks on the crankshaft sprocket, on the camshaft sprocket and on the phase regulator

Checking the position of links 1 (figure), the timing chain relative to marks 2 on the crankshaft sprocket, camshaft sprocket and phase regulator

The difference in the position of the chain links relative to all three marks must be the same

fig. 10. Removing the hydraulic timing chain tensioner: 1 - tensioner shoe, 2 - retainer (steel rod), 3 - hydraulic tensioner

We sink the plunger of the chain tensioner into the tensioner body by pressing the shoe 1

We fix the plunger by installing a piece of steel wire 2 with a diameter of 2.5 mm into the hole in the tensioner body

With a head of 8, unscrew the mounting bolts and remove the tensioner, preventing the plunger from unlocking

Remove the timing chain tensioner shoe

With a head of 10, unscrew the mounting bolts and remove the timing chain damper

Remove the timing chain from the engine

fig. 11. Removing the oil pump drive chain tensioner: 1 - oil pump drive chain tensioner, 2 - tensioner spring, 3 - oil pump drive chain

Turn tensioner 1 (figure), oil pump drive chain counterclockwise

Remove the oil pump drive chain tensioner from the shaft and tensioner spring 2 from the cylinder block

fig. 12. Removing the oil pump drive chain: 1 - oil pump drive sprocket nut, 2 - oil pump drive sprocket, 3 - oil pump drive chain

Using a 10 wrench and a TORX E8 head, unscrew the nut 1 of the oil pump drive sprocket

Remove the sprocket 2 of the oil pump drive with the chain 3 of the pump assembly

Using a universal puller, remove the crankshaft sprocket

With a head of 10, unscrew the three mounting bolts and remove the oil pump from the cylinder block

We unscrew the four bolts securing the water pump, remove the water pump and gasket

With a 10 head, unscrew the two bolts securing the generator and remove the generator from the engine

We unscrew the three bolts securing the air conditioning compressor and remove the compressor from the engine

We unscrew the four bolts securing the bracket of auxiliary units and remove the bracket

fig. 13. Removing the thermostat: 1 - thermostat cover bolts, 2 - thermostat cover

With a 12 head, we unscrew the two bolts 1 (figure), fastening the thermostat cover, remove the clip for fastening the oil level indicator tube, the thermostat cover 2 and remove the thermostat valve from the cylinder block

fig. 14. Removing the knock and oil pressure sensors: 1 - knock sensor mounting bolt, 2 - knock sensor, 3 - oil pressure sensor

With a head of 10, unscrew the bolt 1 (figure), fastening the knock sensor and remove the sensor 2

Using a 22 key, we unscrew oil pressure sensor 3 from the cylinder block

fig. 15. Removing the oil filter: 1 - oil filter, 2 - cylinder block booster

Unscrew and remove the oil filter with a special key

Using a 19 spanner wrench, we unscrew the temperature sensor from the coolant outlet pipe

With a head of 10, unscrew the seven bolts securing the coolant outlet pipe, remove the pipe and gasket

Unscrew the crankshaft position sensor mounting bolt, and remove the sensor

We unscrew the bolts securing the thermal screen of the upper intake manifold and remove the screen

Using a 22 wrench, unscrew the oxygen sensor from the exhaust manifold

With a head of 10, unscrew the five nuts securing the exhaust manifold, remove the manifold and gasket

We unscrew the bolts securing the heat shield of the lower exhaust manifold and disconnect the screen from the manifold

fig. 16. Removing the phase regulator and camshaft sprocket: 1 - intake camshaft phase regulator, 2 - camshaft sprocket

Using a 22 wrench and a 13 head, unscrew the bolts securing the phase regulator and camshaft sprocket, holding the camshafts with a wrench

Remove phase regulator 1 (picture) and sprocket 2

With a head of 8, we unscrew the nineteen bolts securing the camshaft bearing caps, and remove the caps

Remove the camshafts

Using a 10 socket socket, unscrew the ten cylinder head bolts, remove the washers, cylinder head and gasket

fig. 17. Removing the oil sump cover: 1 - oil sump cover, 2 - cylinder block booster

With a head of 8, unscrew the eight bolts securing the oil sump cover and remove the cover

With a head of 10, unscrew ten bolts securing the cylinder block amplifier

fig. 18. Removing the cylinder block booster

Carefully separate the cylinder block booster with a screwdriver, as shown in the picture

Fig. 19. Removing the cylinder block booster: 1 - cylinder block booster, 2 - crankcase removal tool 67.7812-9712

Remove the O-ring from the cylinder block

With a head of 11, unscrew the bolts securing the connecting rod caps and remove the caps

Remove the pistons with connecting rods from the cylinder block from the side of the cylinder head

When removing the pistons, take care not to damage the grease nozzles

Using a TORX E14 head, unscrew the bolts of the crankshaft main bearing caps and remove the caps

Remove the crankshaft and thrust washers

After removing the half rings, you need to mark their position relative to the cylinder block

Using a Torx T40 head, unscrew the three bolts securing the crankshaft positioning disk and remove the disk

After removing all engine parts, we wash, defect and prepare for assembly