Attention: This chapter provides a general procedure for disassembling and assembling engines. For detailed information on checking individual engine components, see the following chapters.
Bulkhead six-cylinder engine series M30
Fix the removed engine. Drain the engine oil. Remove the ignition distributor cover with cables.
Remove the spark plugs. Remove the ignition distributor.
Rotate the engine until the #1 piston is at TDC and both valves are closed.
Lock the engine flywheel in this position.
Remove the chain tensioner from the right front.
Remove the chain sprocket on the camshaft and remove the chain.
Loosen cylinder head bolts (engine must be cold).
Remove the cylinder head along with the intake and exhaust manifolds.
Immediately remove any water in the cylinder bores.
Tilt the engine and remove the oil pan.
Remove the V-belt pulley from the front of the engine.
Remove the lower front cover.
After loosening the damper flange mounting nut, remove the flange, chain and chain gear from the crankshaft.
Remove the oil pump, water pump and oil filter caliper.
Remove clutch from flywheel and flywheel.
Remove the front cover under the flywheel.
Loosen the connecting rod bearing bolts and remove the bearing caps. Lay the covers so that they can be installed in the same position.
Remove the pistons with the connecting rods up.
Piston group elements
1 - piston;
2 - piston pin;
3 - oil scraper ring;
4 - compression ring.
Reinstall the connecting rod bearing caps and lightly tighten the bolts.
Remove the bearing shells from the crankshaft and install in the appropriate connecting rod bearing.
Loosen the main bearing cap bolts, remove the bearing caps.
Remove the crankshaft from the block.
Put all the parts so that they are not damaged.
Clear all details.
After all parts and assemblies are checked for wear, you can start assembling the engine.
Insert the main bearings into the bed of the block.
Insert the crankshaft into the block, lubricating the journals, and install the main bearing caps.
Tighten the bolts to 58-63Nm.
After tightening, check the ease of movement of the crankshaft. If it sticks, loosen the bearings one by one until the sticking bearing is found.
Insert the pistons with connecting rods into the cylinders.
Lubricate the connecting rod bearings and install the appropriate caps.
The arrow on the piston crown must point forward over the engine.
Tighten the connecting rod bolts to 52-57 Nm.
Use new bolts for each installation.
Check the stroke of the connecting rod. Install the rear cover with a new gasket.
Insert the chain drive wheel and put on the chain.
Install the oil pump. The linings for the pump are selected so that the chain has a play of 3-4 mm. The chain must not be too tight.
Install the chain guide and insert the movable tip.
Slide damper flange onto crankshaft and secure.
The nut is finally tightened after installing the flywheel.
Install the lower front cover with a new gasket.
Pull the chain up to the top hole and secure it with wire so it can't fall off.
Attach the damper and the new V-belt pulley to the flange.
Install the oil pan.
Install the flywheel on the drive shaft and tighten to 105 Nm. Use only new knurled bolts.
Fix the crankshaft through the flywheel and tighten the nut to 440 Nm.
Install the oil filter support and screw on the new filter by hand.
Clean the sealing surfaces of the cylinder head.
Position the new cylinder head gasket so that the TOP designation on the gasket is up and the FRONT mark is by the chain. Remove the pad from the packaging immediately before use, otherwise it will oxidize. Turn the crankshaft so that the piston of the first cylinder is in the TDC position.
Before installing the cylinder head, make sure that the valves of the first cylinder are closed.
Lay the cylinder head on the block and hand-tighten the bolts into the dry holes. For installation, the bolts should be slightly lubricated.
Tighten the bolts as follows:
- 1st reception - tighten the bolts with a force of 60 Nm.
- 2nd reception - hold on 33°.
- 3rd reception - after 25 minutes of warming up, tighten by an angle of 35°.
Install the chain with gear so that the dowel pin is at the bottom left when the threaded holes on the flange are vertical and horizontal.
Tighten the chain sprocket to 10 Nm.
Install the chain tensioner on the front cover and fill with oil.
Rotate the crankshaft two turns. Watch for ease of rotation. If resistance is felt, check the camshaft setting.
Turn the crankshaft to the TDC position of the piston of the first cylinder and check the installation of the camshaft.
Otherwise, install correctly.
Install the front cylinder head cover.
Install the distributor rotor flange to the camshaft and tighten the bolt with a new O-ring.
Install the ignition distributor.
Adjust valve clearance. Install the spark plugs and put on the ignition distributor cap.
Install the valve cover.
Install all accessories. Tighten the V-belt so that it is pressed through with a finger by 8-10 mm on the longest branch.
Bulkhead twelve-cylinder engine series M70
Fasten the engine.
Remove the intake air manifold.
Disconnect the pressure regulator vacuum hoses. Loosen the bolts securing the injection pipes and remove them together with the injection fans.
Disconnect the crankcase ventilation hose.
Remove the throttle fittings from the manifolds.
Loosen the intake manifold nuts.
Remove the protective bar of the earbuds.
Unscrew the manifold using a T-wrench with a swivel head.
Unscrew the distributor sliders.
Unscrew the nozzles of the runners from the camshafts.
Take out the polymer insert and unscrew the three bolts. Remove the cover.
Unscrew the rubber bearings from the valve covers.
Elements of the gas distribution mechanism of the M70 series engine
Remove valve covers.
Remove the top timing gear cover.
Remove the valve levers with a tool. To do this, install the appropriate cams vertically above the valves.
Remove the hydraulic valve lifters. They must be kept vertically to prevent oil from escaping.
Remove the distributors. Set the piston of the first cylinder to the ignition position.
Loosen the locknut, loosen the set bolt. Turn out a locking bolt, take out the piston of a tension. Remove the center bar of the amplifier.
Unscrew the chain sprocket for cylinders 1-6.
Loosen the bolt of the left damper bar and pull the bar up.
Loosen the chain sprocket bolts and remove the sprocket.
Remove the oil lines from the cylinder heads.
After removing the camshaft bearing caps, remove the crankshaft camshafts Remove the rear of the top timing gear box.
The box is located in the center of the cylinder heads on the guide bushings.
Remove the coolant manifold between the cylinder heads at the rear.
Remove the alternator.
Remove the damper, to do this, block the flywheel with a tool.
Loosen damper bolts and remove damper.
Unscrew the damper hub from the crankshaft.
Remove the hub with a tool. Remove the cylinder heads.
Remove the water pump.
Press the pump bolts away from the holder block.
Remove the oil pan.
Loosen the oil pump chain sprocket nuts. Take off the star.
Remove the oil pump.
Remove the lower timing gear cover. To do this, remove the reference signal sensor.
Unscrew the mounting bolts and remove the cover.
Release the connecting rod bearing caps and remove the pistons together with the connecting rods.
Mark the installation position of the connecting rods, if the pistons are separated from the connecting rods, also mark the installation position.
Connecting rods and covers are marked with numbers.
The numbers should be opposite each other.
Remove the chain sprocket from the crankshaft using a puller.
Unscrew the flywheel and clutch disc from the crankshaft.
Remove the rear bearing cover.
Remove the main bearing cap and remove the crankshaft.
After all the details have been checked, assemble the engine.
Insert the crankshaft into the lubricated bearings of the block.
Install the main bearing cap with the bushings fully screwed in.
Screw in the inner bearing bolts by hand.
Tighten the bolts in two steps:
- 1st reception - tighten with a force of 20 Nm.
- Step 2 - Tighten 70°.
Tighten the support bushings of the outer bolts to 10 Nm.
Tighten the outer bolts to 34 Nm.
Tighten the oil pump mounts to 34 Nm.
After tightening, check the ease of movement of the crankshaft. If it sticks, loosen the bearings one by one until the sticking one is found.
Install the rear bearing cap.
Heat the chain sprocket to 150-200°C and put it on the crankshaft.
Install pistons with connecting rods. When installed, the pistons should be in position as shown.
Install the connecting rod caps and tighten in two steps:
- 1st reception - with a force of 20 Nm,
- 2nd reception - tighten by 70.
Insert the chain and install the timing gear box (tensioner strap installed).
Install the oil pump chain.
Install the upper part of the oil sump.
Screw the flywheel to the crankshaft with a force of 100 Nm and fix in the TDC position of the piston of the first cylinder.
Completely screw in the oil pump bearing bushings and install the pump.
Install the chain sprocket. Tighten the nut to 28 Nm.
Rotate the support bushes so that the chain can have 7+1 mm slack.
Tighten the support bolt to 24 Nm.
Press in the damper hub. Tighten the bolt to 440 Nm.
Screw the damper with a force of 24 Nm.
Install the generator.
Measure the protrusion of the piston with a tool.
Install the device with the base on the block and set the scale to «0».
Move the device to point A and turn the crankshaft to set the highest point.
Move the instrument to point B and determine the value.
Size A+B will give a performance.
This measurement is carried out on 6 pistons.
The average value of the size will determine the thickness of the gasket.
Select the appropriate gasket. Install gaskets.
Install both cylinder heads.
Install the rear of the upper timing gear box with guide bushings. Tighten the bolts by hand.
After tightening the head, tighten to 10 Nm.
Tighten the cylinder head bolts as follows:
- 1st reception - 30 Nm - 15 minute pause.
- Step 2: Rotate 120°.
Cylinder head bolt tightening sequence
Turn the engine to the TDC of the first cylinder and fix the flywheel.
Install both camshafts as shown and tighten the bearing caps to 15 Nm.
Set the camshaft to the required position using the tool.
Install the sprocket chain against the direction of travel so that it can be tensioned in the groove area.
Lightly tighten the sprocket nuts.
Install the damper bars and tighten the chain sprockets in the installation position.
Chain fittings
Install the chain tensioner.
Loosen the set screw completely.
Rotate the engine one revolution in the direction of travel. Measure A.
Push the tensioner bar all the way against the force of the spring.
Measure dimension B. The difference should be A-B = 6±0.5 mm. Install the set screw and tighten the lock nut.
Turn the crankshaft to TDC on the number one cylinder and use a feeler gauge to check the position of the camshaft.
Insert hydraulic tappets.
Insert the guide plates into the valve heads. Insert levers. Install oil lines.
Install the cylinder head covers.
Center the ignition distributor cap with a feeler gauge and tighten the fastener.
Install adapter with guide pin.
Further assembly is carried out in the reverse order of removal.