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

Removal
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.

Installation of the engine
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.