Car engine repair VAZ-21051 «Zhiguli»

Description of the engine design
Longitudinal and cross section of the engine 2105 Engine Mount 1 - support casing; 2 – a support of a forward suspension bracket of the engine; 3 – a flange of the block of...

Removal and installation of the engine
1. Place the vehicle on a lift or over a pit, chock the front wheels and hang the rear axle on one or both sides. 2. Remove the hood, disconnect the wires from the battery and...

Engine disassembly
Dismantling the front of the engine 1 - top protective cover; 2 - tension roller; 3 - tension spring; 4 - camshaft drive belt; 5 – a cover of a drive of a camshaft; 6 - roller...

Engine Assembly
Labels on the main bearing caps and conditional number of the cylinder block Supports are counted from the front of the engine. Cylinder Head Bolt Tightening Order Installing the...

Bench tests of the engine
The overhauled engine is bench tested (running-in) without load for the following cycle: 820–900 min –1 2 minutes 1000 min –1 3 min 1500 min –1 4 min 2000 min –1 5 minutes During...

Checking the engine on a car
Install the engine on the car, carefully check the installation. Let the engine run for a while, then check: is there any leakage of coolant and fuel in the pipe connections,...

Cylinder block — design description
The main dimensions of the cylinder block The cylinder block is cast from special low-alloy ductile iron. cylinders are bored directly in the block and do not have insert sleeves....

General cleaning and inspection of the cylinder block
Wash the cylinder block thoroughly and inspect the oil passages. Blow and dry the cylinder block with compressed air, especially the oil passages. Inspect the cylinder block. If...

Checking the tightness of the cylinder block
If there is a suspicion that coolant has entered the crankcase, then check the tightness of the cylinder block on a special stand. To do this, after plugging the holes in the...

Cylinders — description and verification
Measuring cylinders with a bore gauge 1 - caliper; 2 - setting the inside gauge to zero according to caliber 67.8125.9501 Cylinder measurement scheme A and B are the directions of...

The plane of the connector with the cylinder head
There may be deformations on the plane of the cylinder block connector with the head. Therefore, check the plane of the connector using a ruler and a set of probes. The ruler is...

Pistons and connecting rods — design description
The main dimensions of the piston, connecting rod, piston pin and piston rings Piston The piston is made of aluminum alloy and coated with a layer of tin for improved run-in. The...

Pressing out the piston pin
It is necessary to remove the finger on the press using mandrel A.60308 and a support with a cylindrical recess into which the piston fits. Before pressing out the pin, remove the...

Cleaning pistons and connecting rods
Remove carbon deposits from the piston crown and piston ring grooves, and remove any deposits from the piston and connecting rod oil passages. Check carefully for damage on the...

Piston to cylinder selection
Estimated clearance between piston and cylinder (for new parts) is 0.05–0.07 mm. It is determined by measuring the cylinders and pistons and is ensured by installing pistons of...

Checking clearance between piston and pin
Piston pin installation The piston pin should be installed with a simple push of the thumb. Checking the fit of the piston pin The pin is pressed into the upper head of the...

Checking clearances between piston grooves and rings
Checking clearance between piston rings and grooves 1 – piston ring; 2 - piston; 3 - a set of probes Height gap check Check the height gap between the grooves and the rings as...

Checking clearance between bushings and crankshaft
Measuring with a scale the width of a calibrated wire after flattening 1 - calibrated wire; 2 - insert; 3 - connecting rod bearing cover; 4 - scale for calibrated wire The gap...

Piston mass control
Scheme of removing metal from the piston to adjust its mass The arrows indicate the places where the metal can be removed. In terms of mass, the pistons of one engine should not...

Assembling the connecting rod and piston group
Installing the piston pin on tool 02.7853.9500 to press it into the piston and connecting rod head 1 - fixture roller; 2 - piston pin; 3 - guide; 4 - stop screw Pressing the...

Checking the pressing of the piston pin
Piston-pin-connecting rod assembly assembled on tool A.95615 for pin extrusion test 1 - indicator pin in contact with the end of the rod; 2 - the head of the rod in contact with...

Parallelism of the axes of the lower head of the connecting rod and the piston pin
Checking the parallelism of the axes of the piston pin and the lower head of the connecting rod 1 - assembled set of connecting rod-pin-piston; 2 - retractable knives; 3 -...

Crankshaft and flywheel — design description
The main dimensions of the connecting rod and main journals of the crankshaft and their fillets Crankshaft The crankshaft is five-bearing, cast iron. The surfaces of the shaft...

Cleaning the channels of the crankshaft lubrication system
To clean, remove the channel plugs. Then drive the sockets of the plugs with a countersink A.94016/10, put on the spindle A.94016, thoroughly rinse the channels with gasoline and...

Main and connecting rod journals
Permissible runout of the main surfaces of the crankshaft Diameters of connecting rod journals, mm Rated reduced 0,25 0,50 0,75 1,0 47,814 47,564 47,314 47,064 46,814 47,834...

Main bearing shells
Determination of the gap on the scale 1 - scale; 2 - calibrated wire Do not perform any adjustment operations on the inserts. In case of scuffing, risks or deviations of the...

Flywheel — checking condition
Flywheel 1 - mounting surface to the crankshaft flange; 2 – a surface of fastening of coupling; 3 – a basic surface of a conducted disk of coupling The surfaces of the flywheel...

Checking the axial clearance of the crankshaft
The axial movement of the crankshaft is limited by two thrust half rings mounted on both sides of the rear main bearing. A steel-aluminum half ring is installed on the front side...

Cylinder head and valve train
Main dimensions of valves and guide bushings Cylinder head - common to four cylinders, cast aluminum alloy. The main dimensions of the valve cylinder head and guide bushings are...

Removing the cylinder head on a car
The cylinder head is removed from the engine on the car if the engine itself does not need to be removed to fix the problem, or if it is only necessary to remove carbon deposits...

Installing the cylinder head
1. Install the gasket, cylinder head on the cylinder block and tighten in sequence (see fig. Cylinder Head Bolt Tightening Order ) in two steps, the cylinder head bolts: first,...

Dismantling and assembly of a head of cylinders
Valve train parts 1 - valve; 2 - retaining ring; 3 - guide sleeve; 4 - oil deflector cap; 5 - support washer of the outer spring; 6 - support washer of the internal spring; 7 -...

Cleaning the cylinder head
1. Install the head on the stand A.60353. 2. Remove carbon deposits from the combustion chambers and from the surface of the exhaust channels with a metal brush driven by an...

Checking and grinding valve seats
Intake valve seat profile I - new seat; II - seat after repair Exhaust valve seat profile I - new seat; II - seat after repair The shape of the chamfers of the valve seats is...

Valves — wear check
1. Remove carbon deposits from valves. Check if the rod is deformed and if there are cracks on the plate; replace valve if damaged. 2. Check whether the working bevel is too worn...

Valve guide bushings
Pressing out guide bushings 1 - mandrel А.60153/Я Check the clearance between the valve guides and the valve stem by measuring the diameter of the valve stem and the bore of the...

Oil deflector caps for guide bushings
At oil seals, delamination of rubber from fittings, cracks and excessive wear of the working edge are not allowed. When repairing the engine, it is recommended to always replace...

Valve levers — check
Check the condition of the working surfaces of the lever in contact with the valve stem, with the camshaft cam and with the spherical end of the adjusting bolt. If nicks or marks...

Valve springs — check
Basic data for checking the outer valve spring Basic data for checking the internal valve spring Lever Spring Test Diagram A - the size in the free state; B - dimension under load...

Cylinder head gasket — check
The gasket surfaces must not be damaged. They should be smooth, without dents, cracks, swelling and kinks. Detachment of the lining material from the reinforcement is not allowed....

Checking the tightness of the cylinder head
Checking the tightness of the cylinder head using tool A.60334 1, 2, 4 - plugs; 3 - fixture plate; 5 - flange with water supply fitting Hydraulic pressure test of the cylinder...

Camshaft and its drive
The main dimensions of the camshaft and bores in the camshaft bearing housing Camshaft - cast iron, cast, rotates on five bearings in a cast aluminum bearing housing mounted on...

Adjusting the gap between the levers and camshaft cams
Checking the gap between the levers and camshaft cams with a feeler gauge A.95111 1 - adjusting bolt; 2 - adjusting bolt locknut Adjust the gaps on a cold engine, after adjusting...

Camshaft drive belt tension adjustment
1. Remove the top protective cover 8 (see fig. Camshaft Drive Diagram ). 2. Loosen the bolts 6 fastening the bracket 11 of the tension roller and turn the crankshaft with a key...

Replacing the camshaft drive belt
1. Remove fan drive belt 2 and top protective cover 8 (see fig. Camshaft Drive Diagram ). 2. Turn the crankshaft and align the mark "WITH" on pulley 1 of the crankshaft with a...

Checking the technical condition of the belt
1. The surface of the toothed part must be with a clear tooth profile, without wear, wrinkles, cracks, undercuts and delamination of the fabric from the rubber. 2. On the end...

Checking the belt tensioner
Basic data for checking the tension spring The working surface of the tension roller must be smooth, without nicks and burrs. The ball bearing of the tension roller should rotate...

Checking the camshaft
On the bearing journals of the camshaft, scuffing, nicks, scratches, aluminum enveloping from bearing housings are not allowed. On the working surfaces of the cams, wear of more...

Checking the camshaft bearing housing
Wash and clean the camshaft bearing housing and oil passages. Check the diameter of the holes in the supports. If the clearance between the camshaft journals and bearings exceeds...

Assembly of the camshaft bearing housing
Installing the camshaft oil seal holder A - the lower plane of the holder; B - the lower plane of the camshaft bearing housing 1. Attach the camshaft bearing housing to the...

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