Engine Overhaul Specifications All dimensions, diameters and gaps are in mm. Z24 engines Oil pressure: At idle no less than 0.6 kgf/cm 2 At 3000 rpm 2.8 - 4.0 kgf/cm 2 Compression (at 350 rpm)...
General information about engine overhaul This part of the Chapter discusses in detail the procedure for performing such work as dismantling the power unit from the car and overhauling the internal parts of the...
Checking compression in the engine cylinders 1. The results of the compression test in the engine cylinders allow us to judge the condition of the engine parts (pistons, rings, valves and cylinder head gaskets). To...
Dismantling the power unit — safety measures The engine is removed from the engine compartment as part of the power unit by lifting, so lifting equipment must be designed for the weight of the engine and gearbox...
Engine — removal and installation 1. On vehicles with a 4x2 formula, the engine is removed together with the gearbox. On vehicles with 4x4 transmission formula (transmission) detached from the engine,...
Engine overhaul — general information When performing a major overhaul, it is recommended to check, repair or replace the alternator, starter and ignition distributor. Preliminary volume of work and costs...
Engine Rebuild — Alternatives If the condition of the crank mechanism and the cylinder block is unsatisfactory, it is more cost-effective to replace worn parts with remanufactured ones, which are...
Engine overhaul — disassembly procedure The following engine disassembly procedure is recommended: cylinder head covers intake and exhaust manifolds Timing belt covers (on V6 engines) or front cover Camshaft...
Cylinder head — disassembly 1. To disassemble the cylinder head, it is necessary to remove all valves and valve train parts. The description assumes that the camshafts and rocker rollers have...
Cylinder head — cleaning and condition check 1. Thorough head cleaning (or heads) cylinders and parts of the valve mechanism with a subsequent check will allow to estimate the amount of work to repair the valves...
Cylinder head — assembly 1. Make sure the cylinder head is clean. 2. Install spring washers. 3. Press the new oil seals onto the guide bushings using a mandrel or tool (photo). Rotation of the...
Connecting rod and piston group — dismantling Attention! Before removing the pistons and connecting rods, remove the cylinder head, oil pan and oil pump. 1. Remove the shoulder at the top of the cylinder (photo)....
Crankshaft — dismantling Comment. The crankshaft can only be removed after the engine has been removed from the vehicle. Remove the flywheel first (or master disk), idler pulley, chain, sump,...
Cylinder block — cleaning Attention! If the plugs of the cooling system channels fall into the channel of the cylinder block, then it is usually impossible to remove them. 1. Drill holes in the...
Cylinder block — condition check 1. When external defects are found (cracks and chips), repair or replace the unit. It is recommended to check for internal defects in the cylinder block, for which it is...
Connecting Rods and Pistons — Checking Condition 1. Carefully clean the pistons from carbon deposits and carefully remove the rings. 2. Remove carbon deposits from the piston ring grooves (photo). 15.2a Clean the...
Crankshaft — condition check 1. Wash the crankshaft with solvent and dry, clean the oil channels, necks and remove burrs (photo). 16.1 Deburr the edge of the oil hole 2. Check the condition of the...
Main and connecting rod bearings — check and selection 1. The main and connecting rod bearings during the overhaul of the engine are subject to mandatory replacement, however, the bearings that were in operation should be...
Engine Overhaul — Assembly Procedure 1. The following assembly order is recommended On 4-cylinder engines Piston rings Crankshaft and main bearings Pistons with connecting rods Rear crankshaft oil seal...
Piston rings — installation 1. Before installing new piston rings, check the clearance at their joints. It is understood that the gap between the ring and the seat of the groove has already been...
Rear oil seal — installation On 4-cylinder engines 1. Lubricate the oil seal, put it on the crankshaft and carefully press it in with a mandrel or with light blows on the soft spacer. On V6 engines...
Starting the engine after repair and running in 1. After assembly is complete, double check the oil and coolant levels. 2. With the spark plugs turned out and the ignition system and fuel pump turned off, turn the...