2.2.5. Removal and installation of the GRM case (Z10XE, Z10XEP)

NOTE Since a year of release 04 instead of KM-6169-1 adaptation it is necessary to use KM-6394.

Open a cowl.

Disconnect plugs of the rechargeable battery.

NOTE On cars since a year of release 04 with ESP – after each detachment of the accumulator the sensor of an angle of rotation of a steering wheel loses the main installation. It needs to be calibrated anew.

Disconnect a weight wire.

Merge cooling liquid.

NOTE On option of the ECO model uncover motor office below.

Substitute the reception pallet.

Open a carving stopper of a drain opening (shooter).

Remove the case of the air filter 1.

Disconnect 2 sockets of a plait of wires, a termoanemometrichesky film mass flowmeter of air 3 and the valve of ventilation of a tank 2.

Release the valve of ventilation of a tank.

Dismantle the soaking-up branch pipe 4.

Turn off 2 nuts.

Dismantle a hose of ventilation of a case of the engine 5.

On Z10XEP engines: remove the soaking-up air hose.

Release a collar.

Unscrew a bolt (shooter).

Remove a hose of heating of a branch pipe of a butterfly valve 1.

Release a collar.

Remove the giving hose of heated water 6 from the pump of cooling liquid.

Release a collar.

Dismantle a plait of wires of a control system of the engine.

Disconnect 3 sockets of a plait of wires, the oil 3 pressure relay, the sensor of temperature of cooling liquid 4, the sensor of the camshaft 5.

Free the canal for a plait of wires 2.

Put a plait of wires aside.

Remove a radiator hose above 1.

Release 2 collars.

Below 2 disconnect a radiator hose from the pump of cooling liquid.

Release a collar.

Dismantle the ignition module.

Uncover the ignition module.

Shift it to the right.

Disconnect the socket of a plait of wires.

Turn off 2 bolts of fastening.

Take out by means of KM-6009 adaptation.

NOTE Do not warp the provision of a cover.

Uncover a head of cylinders.

Remove a hose of ventilation of a case of the engine.

Release a collar.

Turn off 13 bolts of fastening.

Release a forward wheel on the right.

Turn off 4 bolts of fastening.

Lift the car.

Remove a forward wheel on the right.

Turn off 4 bolts of fastening.

Lift the car.

Remove a casing of a poliklinovy belt.

NOTE On option of the ECO model uncover motor office below 1.

Unscrew 3 bolts of fastening 1.

Remove a clip (shooter).

Close a carving stopper of a drain opening of cooling liquid.

Merge engine oil.

Substitute other reception pallet.

Turn off a carving stopper of a drain opening.

NOTE Bends of a flexible tube even angular degrees in relation to the provided assembly position can cause on 5-10 damage of a flexible hose with the subsequent exit it out of operation.

Release an exhaust system.

NOTE At removal of the average muffler, catalyst, a final collector or final collector with the catalyst it is necessary to secure the part of system of release of OG remaining in the car against uncontrollable sagging. For this purpose a part of system of release of OG with the flexible tube which is in it it is possible to fix by suitable means, for example, by means of a wire on a running gear.

Remove the socket of a plait of wires a lambda sensor of control of the catalyst 1.

Release 2 damping partitions (arrows).

Turn off an exhaust pipe in front 2.

Turn off 3 nuts.

In front attach an exhaust pipe to the case of the forward bridge at the left.

Bolts a krepleniyay stopper for discharge of oil of the engine tighten the moment 10 N · m.

Replace a sealing ring.

Remove a plait of wires of the generator 1.

Turn off 2 nuts.

Remove cable collars.

Take off a poliklinovy belt.

Pull the tension device of a poliklinovy belt by means of KM-6131 adaptation in the direction of an arrow.

Insert the KM-6130 device.

Dismantle the tension device of a poliklinovy belt.

NOTE It is necessary to track an appropriate support of the tension device of a poliklinovy belt (the arrow shows up). If it cannot be provided, it is necessary to let out the air from the tension device of a poliklinovy belt. For this purpose it is necessary to execute not less than 5 courses (to extend-press), and the speed of loading has to remain a constant, and loading to be carried out evenly. Do not allow damages of a tension element.

Pull the tension device of a poliinovy belt by means of KM-6131 adaptation.

Take out KM-6130 adaptation.

Weaken a tension of the tension device of a poliklinovy belt.

Turn off 2 bolts of fastening 1.

Dismantle the generator.

Turn off 2 threaded connections 1.

Dismantle the oil pallet.

On the transmission unscrew 3 bolts of fastening 1.

On a support of a bent shaft turn off 14 bolts of fastening.

Install KM-6169-2 adaptation on the transmission.

Tighten 2 bolts of fastening the moment of 95 N · m.

Install KM-61691 adaptation.

Spread KM-6169 at the left on the case of the forward bridge (an arrow, fig. I).

NOTE The directing finger has to settle down in an opening in the case of the forward bridge.

Both holders install on the case of the forward bridge on the right (shooters, fig. II).

NOTE The directing finger has to settle down in an opening in the case of the forward bridge (the shooter, fig. III).

Tighten 8 bolts of fastening.

Install a support on KM-6169 adaptation.

Establish fastening 2 for a support.

Put the clamp 1.

Adjust support.

From the transmission wrap spindles so that fastenings 3 on the directing pins adjoined without gap.

From management of the engine insert a pin of a support into an opening of the block of cylinders without gap (shooter).

Tighten a nut 1.

Turn off the holder of the engine on the right.

Release a bolt 1 below.

Lower the car.

Dismantle the compressor.

NOTE The air conditioning system remains closed.

Disconnect the socket of a plait of wires (shooter).

Unscrew 3 bolts of fastening 1.

Put the compressor aside.

Lower the car.

Remove the holder of the engine on the right.

Release the depreciation block of the engine.

Turn off 2 bolts of fastening 1.

Turn off 2 bolts of fastening (arrow).

Dismantle a pulley poliklinovy ременя the pump of cooling liquid.

Turn off 3 bolts of fastening.

Remove the tension device of a poliklinovy belt.

Turn out a bolt.

Dismantle a branch pipe of cooling liquid.

Turn off 3 bolts of fastening.

Establish the provision of VMT of ignition of the cylinder 1.

Remove a carving stopper of a support of a bent shaft.

Insert the KM-952 device.

NOTE The mark in a belt pulley of a bent shaft 4 has to be on one line with a lug 3 on the GRM case.

Evenly turn a bent shaft until KM-952 adaptation is captured.

Insert the KM-953 device.

NOTE KM-953 has to enter a groove of camshafts.

Take out KM-953 adaptation.

Lift the car.

Dismantle a pulley poliklinovy ременя a bent shaft 1.

Turn off 6 bolts of fastening.

Hold a bolt of a nave of a bent shaft.

Release a bolt of a nave of a bent shaft.

Take out KM-952 adaptation.

Install KM-956-1/KM-956-2 3 adaptation.

Hold KM-956-1/KM-956-2 devices.

Remove a nave of a bent shaft 2.

NOTE Observe assembly situation.

Insert the KM-952 device.

Turn out a bolt.

Take out it by means of KM-956-1/KM-956-2 devices.

Release the GRM case from below.

NOTE Consider the different length of bolts of fastening.

Turn off 2 bolts of fastening 3 (M10).

Turn off 14 bolts of fastening (M6) (arrow).

Lower the car.

Dismantle the pump of cooling liquid.

NOTE At removal pay attention to the directing plugs.

Substitute other reception pallet.

Turn off 4 bolts of fastening 2.

NOTE Consider the different length of bolts of fastening.

Dismantle the GRM case.

Turn off 4 bolts of fastening 1.

Dismantle the chain drive.

Release 2 bolts of fastening of a gear wheel of the camshaft.

Hold camshafts for a hexagon.

To stop the tension device of a chain 1.

Insert the KM-955-1 device.

Dismantle the level of an uspokoitel 3 directing a level 5, a sled for a tension 7, driving gear wheels of camshafts.

Take out a driving chain of a cam-shaft 4 with a driving wheel 6.

Take out consolidation of the GRM case.

Remove a sealing ring of a bent shaft in front.

Hook and take out a sealing ring.

NOTE Do not damage a sealing surface.

Clean the sealing surfaces of the GRM case, block of cylinders, heads of cylinders, support of a bent shaft, the oil pallet, a cover of a head of cylinders, the pump of cooling liquid, the thermostat case.

If is available, remove sealant in the field of consolidation of a head of cylinders.

Examine knots.

NOTE If it is necessary, to check and process a head of cylinders, remove from a head of cylinders everything the details established outside: chain drive, GRM case, block of cylinders, head of cylinders, support of a bent shaft, oil pallet, cover of a head of cylinders, pump of cooling liquid, thermostat case.

When replacing details consider various options of a design. To watch correctness of numbers of details and the catalog.

Replace a sealing ring of a bent shaft in front 1.

Grease sealing edges with silicone lubricant (white).

Shift on KM-960 devices.

By means of KM-960 adaptation hammer aflush.

Replace consolidation of the GRM case.

Apply silicone sealant on a joint of the block of cylinders and a support of a bent shaft.

NOTE Finish installation works within 10 min.

Separate the acting elastomer of consolidation of a head of the cylinder 1 and replace it with a strip of silicone sealant 2 mm thick.

NOTE If there is no acting elastomer, it is possible to put a strip of silicone sealant at once.

Establish a driving chain of a cam-shaft.

NOTE Track the correct landing of the directing plugs (arrow).

Install KM-953 adaptation.

Replace bolts.

5 shift a driving wheel.

Spread a gear wheel of the final camshaft.

Screw a bolt.

Establish a driving chain of a cam-shaft 3.

Insert into a driving chain of a cam-shaft a gear wheel of the inlet camshaft with a disk of the phase sensor.

Screw a bolt.

NOTE The disk of the phase sensor has to turn manually.

Establish a sled for a tension of a driving chain of a cam-shaft 6.

Tighten a bolt and tighten the moment of an inhaling 20 N · m.

NOTE You watch correctness of landing of a driving chain of a cam-shaft.

Establish the directing fillet of a driving chain of a cam-shaft 4.

NOTE You watch correctness of landing of a driving chain of a cam-shaft.

Tighten a bolt of 8 N · m.

Establish a level of an uspokoitel of a driving chain of a cam-shaft 2.

Tighten 2 bolts of fastening with the moment of 8 N · m.

Take out KM-955-1 adaptation.

Install the pump of cooling liquid.

NOTE You watch correctness of landing of the directing plugs (arrow)

1 replace consolidation.

Establish by means of short bolts of fastening.

Tighten 3 bolts of fastening of 8 N · m.

Install the GRM case.

NOTE Observe the sequence of an inhaling.

Twirl 21 bolts of fastening.

Tighten 5 bolts of fastening of 1 (M6) 8 N · m.

Tighten 14 bolts of fastening of 2 (M6) 8 N · m.

Tighten 2 bolts of fastening of 3 (M10) 35 N · m.

Establish a branch pipe of cooling liquid.

Replace consolidation of a branch pipe.

Tighten 3 bolts of fastening the moment of 8 N · m.

Lift the car.

Take out KM-952 adaptation.

NOTE The fixing tools cannot be used for keeping.

Establish a nave of a bent shaft.

NOTE Observe the assembly provision of a nave of a bent shaft – the mark has to specify up.

Replace a bolt.

Tighten a bolt of a nave of a bent shaft.

NOTE This procedure will require work of two people.

Hold naves by means of KM-956-1/KM-956-2 devices.

Tighten a bolt the moment of 150 N · m +45 °.

Remove KM-956-1/KM-956-2 devices.

Establish a pulley poliklinovy ременя a bent shaft.

Tighten 6 bolts of fastening the moment of 8 N · m.

Hold a bolt of a nave of a bent shaft.

Insert the KM-952 device.

Lower the car.

Install KM-9541 adaptation.

Turn a disk of the phase sensor 2, there will be yet no opportunity to install KM-954 adaptation on the GRM case.

Fix driving gear wheels of camshafts.

NOTE In the beginning tighten a bolt of a driving gear wheel of the inlet camshaft.

Tighten 2 bolts of fastening the moment of 210 N · m.

NOTE Driving gear wheels of camshafts and disk of the phase sensor tighten with the moment 10 N · m.

Support camshafts for a hexagon 1.

Take out the fixing tools.

NOTE The fixing tools cannot be used for keeping.

Tighten driving gear wheels of camshafts.

NOTE This procedure will require work of two people.

Bolts tighten the moment of 50 N · m +60 °.

NOTE In the beginning tighten a bolt of a driving gear wheel of the inlet camshaft.

Hold camshafts for a hexagon.

Turn a bent shaft (720 °).

Install KM-952, KM-953, KM-954 devices.

Take out the fixing KM-952, KM-953, KM-954 tools.

Lift the car.

Establish a carving stopper of a support of a bent shaft.

Replace a sealing ring.

Tighten a bolt of 50 N · m.

On the ECO model establish an engine cover below.

Lower the car.

Clean sealing surfaces of a head of cylinders, covers of a head of cylinders.

Establish a cover of a head of cylinders 1.

Replace consolidation 2 and a sealing ring.

Apply sealant (distance of 1-2 mm).

NOTE Installation works need to be finished within 10 min.

Tighten 13 bolts of fastening the moment of 8 N · m.

Establish 2 hoses of ventilation of a case of the engine.

Install the ignition module.

Turn off 2 pieces of KM-6009.

Tighten 2 bolts of fastening with the moment of 8 N · m.

Establish a plait of wires of a control system of the engine.

Lay a plait of wires.

Fix the channel for a plait of wires.

Connect 4 sockets of a plait of wires.

Connect plugs of the rechargeable battery.

Program volatile memory.

Close a cowl.