2.2.6. Repair of the engine (Z10XE, Z10XEP, without conditioner)

Remove the transmission from the engine.

Pick up the directing oil meter probe phone.

Turn out a bolt.

Dismantle heated a lambda sensor of regulation of composition of fuel mix.

Disconnect the socket of a plait of wires.

Release a plait of wires.

Carefully turn out a lambda sensor by means of KM-6129 adaptation.

Dismantle a guard of a final collector.

Turn off 2 bolts of fastening.

Dismantle a final collector.

Turn off 7 nuts of fastening.

Take out consolidation.

Lift the engine.

Install on the engine on KM-412-18 adaptation.

Tighten 4 bolts of fastening.

Fix the engine on KM-412 2 adaptation.

Tighten 8 threaded connections.

Install KM-2358 adaptation.

Merge engine oil.

Substitute the reception pallet.

Turn out a carving stopper of a drain opening.

Uncover the case of an oil filter.

Take out an insert of an oil filter.

Dismantle coupling.

Remove a flywheel.

Install KM-652 adaptation.

Turn off 6 bolts of fastening.

Dismantle KM-652 adaptation.

Remove the holder of the engine 1 on the right.

Turn off 3 bolts of fastening.

Wrap a carving stopper of a masloslivny opening.

Replace a sealing ring.

Tighten a bolt the moment of 10 N · m.

Remove the reception pallet for oil.

Take off a poliklinovy belt.

NOTE Mark the direction of rotation.

Pull the tension device of a poliklinovy belt in the direction of an arrow.

Insert the KM-955-2 device.

Remove from a pulley poliklinovy ременя a bent shaft.

Remove a pulley poliklinovy ременя the pump of cooling liquid.

Turn off 3 bolts of fastening.

Dismantle a pulley poliklinovy ременя a bent shaft.

Turn off 6 bolts of fastening.

Hold a bolt of a nave of a bent shaft.

Remove the tension device of a poliklinovy belt.

Turn off 2 bolts of fastening.

Dismantle plaits of wires of the engine.

Turn off a plait of wires of the generator.

Turn off 2 nuts.

Отболт you iteit a plait of wires of a starter.

Turn off 2 nuts 1.

Remove cable collars.

Dismantle the generator.

Turn off 2 threaded connections.

Dismantle a starter.

Turn off 2 bolts of fastening (arrow).

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

On the Z 10 XEP engine: dismantle a casing of a pipe of the fuel distributor.

Turn off 2 bolts of fastening.

Disconnect 12 sockets of a plait of wires of a control system of the engine.

Oil 6 pressure relay, sensor of temperature of cooling liquid 8, sensor of the camshaft 9, module of a butterfly valve 2, controller of engine management 12, valve of system of recirculation of OG 4, module of ignition 3, sensor of a detonation 10, sensor of a bent shaft 11, fuel nozzles 1.

Turn off a wire of mass of the controller of engine management 13.

Free the canal for a plait of wires 7.

Release a plait of wires – 4 holders 14.

Disconnect 3 hoses from the pump of cooling liquid.

Disconnect a hose of cooling liquid from a flange of cooling liquid of recirculation of exhaust gases.

Release a collar.

Dismantle the pump of cooling liquid 1.

NOTE At removal pay attention to the directing plugs.

Substitute the reception pallet.

Turn off 9 bolts of fastening.

NOTE Consider the different length of bolts of fastening (an arrow – short bolts).

Dismantle the ignition module.

Uncover the ignition module, having shifted it to the right.

Turn off 2 bolts of fastening.

Take out a cover by means of KM-6009 1 adaptation.

Uncover a head of the block of cylinders.

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

Release a collar.

Turn off 17 bolts of fastening.

Release a bolt of a nave of a bent shaft 1.

NOTE This work will require participation of two people.

Establish and hold KM-956-1/KM-956-2 devices.

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

Adjust camshafts.

Evenly turn a bent shaft by means of KM-956-1/KM-956-2 adaptation in the direction of rotation of the engine until KM-953 1 adaptation against the stop does not come into a camshaft groove.

Remove a nave of a bent shaft.

NOTE Observe the assembly provision of a nave.

Turn out a bolt.

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

Remove the oil pallet.

Turn the engine on 180 °.

Turn off 14 bolts of fastening.

Remove consolidation of the oil pallet.

Remove the GRM case.

Turn the engine on 90 °.

Turn out 15 bolts of fastening (arrow).

Consider length of bolts of fastening.

Do not damage the sensor of the camshaft 1.

Poddnte also take a sealing ring of the GRM case.

NOTE Do not damage a sealing surface.

Dismantle the chain drive.

Release bolts of driving gears of the camshaft.

Hold camshafts for a hexagon.

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 and driving gear wheels of camshafts.

Take out a driving chain of a cam-shaft 4 with a driving wheel 6. Take consolidation of the GRM case.

Dismantle a head of the block of cylinders.

Turn the engine on 90 °.

Dismantle KM-953 adaptation.

Turn off 10 bolts of fastening.

NOTE Release hairpins of a head of cylinders in that order: – release hairpins of a head of cylinders (90 °); – release hairpins of a head of cylinders (180 °); – take out hairpins of a head of cylinders.

Enclose a head of the block of cylinders in wooden blocks.

Take out consolidation of a head of the block of cylinders.

Dismantle the case of an oil filter.

Turn off 3 bolts of fastening.

Dismantle the detonation sensor.

Turn out a bolt.

Remove a maslootrazhatel.

Turn the engine on 180 °.

Turn off 6 bolts of fastening.

Dismantle the sensor of provision of a bent shaft.

Turn out a bolt.

Dismantle the block of cylinders.

Install KM-2358 adaptation.

Suspend the engine on the crane.

Remove KM-412-18 adaptation.

Install the block of cylinders.

Install KM-412-18 adaptation on the engine. Tighten 4 bolts of fastening.

Dismantle KM-2358 adaptation.

Press 6 guides of sleeves by means of KM-427 adaptation in the block of cylinders.

Dismantle the soaking-up oil pipeline 1.

Turn off 4 bolts of fastening.

Remove a sealing ring 2.

Clean the sealing surfaces of the block of cylinders and a head of cylinders, covers of a head of cylinders, cases of an oil filter, a support of a bent shaft, the GRM case, the oil pallet, the pump of cooling liquid and a final collector.

Examine knots of the power unit.

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

By means of a lekalny ruler and the caliber probe check flatness of a head of the block of cylinders.

Stop a bent shaft.

Remove a carving stopper 1.

Insert the KM-952 2 device on its place.

Evenly turn a bent shaft until adaptation is not captured.

Establish a maslootrazhatel.

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

Install the case of an oil filter.

Turn the engine on 180 °.

Replace consolidation.

Tighten 3 bolts of fastening the moment of an inhaling of 20 N · m.

Replace an insert of an oil filter.

Establish a cover of the case of an oil filter.

Replace a sealing ring.

Tighten bolts of fastening of a cover the moment of 10 N · m.

Adjust camshafts.

Insert the KM-953 device.

Turn camshafts for a hexagon.

Take out KM-953 adaptation.

Establish a head of the block of cylinders.

Replace consolidation.

NOTE Marking of "OPEN/TOP" has to specify up. Replace bolts of fastening of a head of the block of cylinders.

By means of a lekalny ruler level a head of cylinders in relation to the block of cylinders.

Tighten 10 bolts of fastening the moment of 25 N · m + 60 ° + 60 °+60 °.

NOTE Observe the sequence of an inhaling of bolts.

Establish a driving chain of a cam-shaft.

Install KM-953 adaptation.

Replace consolidation of the GRM case.

NOTE You watch correctness of landing (arrow).

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 the moment of an inhaling of 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.

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

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

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.

Weaken a tension of the tension device of a chain.

Take out KM-9551 adaptation.

When replacing details consider various options of a design. You watch correctness of numbers of details.

Install the pump of cooling liquid.

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

1 replace consolidation.

Fix the pump by means of short bolts of fastening 2.

Tighten 3 bolts of fastening of 8 N · m.

Dismantle a branch pipe of cooling liquid, открутитв 3 bolts of fastening.

Install the GRM case.

Screw bolts.

NOTE Observe the sequence of an inhaling

Tighten 5 bolts of fastening (M6) the moment of 18 N · m.

Tighten 14 bolts of fastening (M6) the moment of 28 N · m.

Tighten 2 bolts of krepleniya (M10) 3 the moment of 35 N · m.

Establish a branch pipe of cooling liquid.

Check, clear sealing surfaces.

Replace a sealing ring.

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

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

Grease sealing edges with silicone lubricant (white).

Install KM-960 2 adaptation and press a sealing ring of a bent shaft.

Take out KM-952, KM-953 devices.

NOTE The fixing tools cannot be used for keeping.

Establish a nave of a bent shaft.

Observe the assembly provision of a nave of a bent shaft 2, the mark has to specify up.

Replace a bolt of a nave.

Hold a nave 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 1.

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.

Insert the KM-953 device in a flute of camshafts.

Install KM-954 1 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 Driving gear wheels of camshafts and disk of the phase sensor tighten with the moment 10 N · m.

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

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

Support camshafts for a hexagon 1.

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

Tighten driving gear wheels of camshafts.

Tighten 2 bolts of fastening 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.

Check installation of phases of gas distribution.

Install the oil pallet.

Tighten 14 bolts of fastening the moment of 10 N · m.

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

Replace a sealing ring.

Tighten a fastening bolt the moment of 50 N · m.

Install the detonation sensor.

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

Install the sensor of provision of a bent shaft.

Replace a sealing ring.

Tighten a fastening bolt the moment of 8 N · m.

Establish a cover of a head of the block of cylinders 1.

Turn the engine on 180 °.

Replace consolidation 2, a sealing ring.

Apply sealant (distance of 1-2 mm).

NOTE Finish installation works within 10 min.

Tighten 17 bolts of fastening the moment of 8 N · m.

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

Fix a collar.

Install the ignition module.

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

Establish hoses of cooling liquid.

On the pump of cooling liquid and on the valve of recirculation of OG fix collars.

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

Lay a plait of wires.

Connect 13 sockets of a plait of wires.

Attach a wire of mass of the controller of management of the engine.

Tighten a fastening nut.

Fix the channel for a plait of wires.

Fix a plait of wires.

On the Z 10 XEP engine: establish a casing of a pipe of the fuel distributor.

Tighten 2 bolts of fastening.

Establish a starter.

Turn the engine on 90 °.

Tighten 2 bolts of fastening the moment of 25 N · m.

Install the generator.

Tighten 2 threaded connections the moment of 35 N · m.

Establish a plait of wires of the engine.

Turn the engine on 90 °.

Fix plaits of wires of the generator and a starter and tighten 4 nuts of fastening.

Install the tension device of a poliklinovy belt.

Turn the engine on 180 °.

Bolt (M8) tighten the moment of an inhaling of 20 N · m.

Bolt (M10) tighten the moment of an inhaling of 55 N · m.

Establish a pulley poliklinovy ременя the pump of cooling liquid.

Tighten 6 bolts of fastening the moment of an inhaling of 20 N · m.

Establish a poliklinovy belt.

NOTE Observe the direction of rotation and assembly situation.

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

Take out KM-955-2 adaptation.

Establish the holder of the engine on the right.

Tighten 2 bolts of fastening the moment of 60 N · m.

Establish a flywheel.

Clear 6 threaded connections in cranked to a shaft.

Replace fastening bolts.

Tighten 6 bolts of fastening the moment of 35 N · m +60 °.

Block a flywheel by means of KM-652 adaptation.

Establish coupling.

Fill in engine oil.

Check and, if necessary, modify the level of engine oil.

Disconnect the engine from KM-412 adaptation.

Turn off 8 threaded connections.

Dismantle KM-412-18 adaptation.

Turn off 4 bolts of fastening.

Establish a final collector.

Replace consolidation.

Replace nuts.

Tighten 7 nuts of fastening the moment of an inhaling of 20 N · m.

Establish a guard of a final collector.

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

Establish heated a lambda sensor of regulation of composition of fuel mix.

Apply on a carving assembly paste (white).

Tighten a lambda sensor the moment 40 N · m.

Connect the socket of a plait of wires.

Fix a plait of wires.

Establish the directing oil meter probe tube.

Replace 2 sealing rings.

Tighten a bolt the moment of 8 N · m.

Install the transmission on the engine.