Engine assembly (VAZ-21011)

Marks on the main bearing caps and the cylinder block reference number

The number of supports is calculated from the front of the engine.

Cylinder Head Bolt Tightening Sequence

Camshaft Bearing Housing Nut Tightening Procedure

Checking the alignment of the timing mark on the crankshaft sprocket with the mark on the cylinder block

The marks are indicated by arrows.

Checking the alignment of the timing mark on the camshaft sprocket with the mark on the bearing housing

1. Place the washed and cleaned cylinder block on the stand and tighten the missing studs.

2. Place the washed and cleaned cylinder block on the stand and tighten the missing studs.

3. Place liners without a recess on the inner surface in the middle bearing seat and in its cover, and liners with a recess in the remaining seats and corresponding covers (since 1987, the lower main bearing shells have been installed without a recess on the inner surface).

Attention! Lubricate the engine cylinders, as well as the pistons and seals, bearing shells and crankshaft thrust half rings with engine oil before installation.

4. Place the crankshaft in the main bearings and insert two thrust half rings, selected according to thickness according to the instructions, into the rear support sockets subsection 3.10.6.


5. Install the main bearing caps according to the marks (see fig. Marks on the main bearing caps and the conventional number of the cylinder block).

Attention! Install the main bearing caps into the previous block. For this purpose, the cylinder block and the caps belonging to it are marked with the same reference number (see Fig. Marks on the main bearing caps and the reference number of the cylinder block and Fig. Marking of the cylinder size group on the block and the conventional number of the cylinder block). Install the thrust half rings with the recesses towards the thrust surfaces of the crankshaft, and install a steel-aluminum half ring on the front side of the rear support, and a metal-ceramic half ring on the rear side (yellow color).

6. Place the seal holder gasket on the crankshaft flange and insert the front clutch housing cover mounting bolts into the holder sockets. Place the holder with the seal on the 41.7853.4011 mandrel and, moving it from the mandrel to the crankshaft flange, attach it to the cylinder block (the arrows indicate the protrusions for centering the holder relative to the crankshaft flange).

7. Install the front cover 6 using two centering bushings (see Fig. Removal the flywheel) clutch housing.

8. Install the flywheel on the crankshaft so that the mark (cone-shaped hole) near the rim was opposite the axis of the connecting rod journal of the fourth cylinder, lock the flywheel with the A.60330/R lock and attach it with bolts to the crankshaft flange.



9. Using the bushing from the A.60604 set, insert the pistons with connecting rods into the cylinders. The set contains bushings of nominal and repair piston sizes. Therefore, it is necessary to select a bushing suitable for the given size of the piston being installed. You can also use the adjustable bushing 67.7854.9517.

Attention! The pin hole on the piston is offset by 2 mm, so when installing the pistons into the cylinders, the "P" mark on the pistons must face the front of the engine.

10. Install the connecting rod liners and connecting rod caps. Connect the connecting rods to the crankshaft journals, install the caps and tighten the connecting rod bolts.

11. Install the sprocket onto the crankshaft. Install the oil pump drive shaft and secure with the thrust flange.

12. Install the cylinder head with the gasket, the exhaust manifold and the intake manifold on the block using two centering bushings.

13. Tighten in a specific sequence (see Fig. Cylinder Head Bolt Tightening Sequence) in two steps fastening bolts:

• pre-torque 33.3–41.16 N·m (3.4–4.2 kgf·m) bolts 1–10;
• finally tighten bolts 1–10 with a torque of 95.94–118.38 N·m (9.79–12.08 kgf·m) and bolt 11 with a torque of 31.36–39.1 N·m (3.2–3.99 kgf·m).

14. Turn the flywheel so that the mark on the crankshaft sprocket aligns with the mark on the cylinder block (see fig. Checking the alignment of the timing mark on the crankshaft sprocket with the mark on the cylinder block).

15. Install the sprocket on the camshaft assembled with the bearing housing and turn the shaft so that mark 1 on the sprocket is opposite mark 2 on the bearing housing (see fig. Checking the alignment of the timing mark on the camshaft sprocket with the mark on the bearing housing).

16. Remove the sprocket and, without changing the position of the shaft, install the bearing housing on the cylinder head and secure it by tightening the nuts in a certain sequence (see Fig. Tightening order of camshaft bearing housing nuts).

17. Install the chain guide on the cylinder head.

18. Install the camshaft timing chain:

• place the chain on the camshaft sprocket and insert it into the drive cavity, installing the sprocket so that the mark on it coincides with the mark on the bearing housing (see fig. Checking the alignment of the timing mark on the camshaft sprocket with the mark on the bearing housing). Do not tighten the sprocket bolt all the way;
• install the sprocket on the oil pump drive shaft, also without completely tightening the mounting bolt;
• install the chain tensioner shoe and tensioner without tightening the cap nut so that the tensioner spring can press the shoe; screw the chain limiting pin into the cylinder block;
• turn the crankshaft two turns in the direction of rotation to ensure the correct chain tension; check that the marks on the sprockets match the marks on the cylinder block (see fig. Checking the alignment of the timing mark on the crankshaft sprocket with the mark on the cylinder block) and on the bearing housing (see fig. Checking the alignment of the timing mark on the camshaft sprocket with the mark on the bearing housing).;
• if the marks match, then, having locked the flywheel with the A.60330/R lock (see Fig. Removal the flywheel), finally tighten the sprocket bolts, the chain tensioner cap nut and bend back the sprocket bolt lock washers; if the marks do not match, repeat the chain installation operation.

19. Adjust the clearance between the camshaft lobes and the valve drive levers.



20. Install the camshaft drive cover with the gasket and oil seal on the cylinder block without completely tightening the bolts and nuts. Using the 41.7853.4010 drift, center the position of the cover relative to the end of the crankshaft and finally tighten the nuts and bolts of its fastening (the arrows show the projections for centering the cover relative to the crankshaft pulley hub).

21. Install the crankshaft pulley and tighten the ratchet.

22. Lubricate the oil filter O-ring with oil and install the filter by hand-tightening it to the fitting on the cylinder block. Install the crankcase ventilation oil separator, breather cover and secure the oil separator drain tube retainer.

23. Install the oil pump and oil pan with gasket.

Install the coolant pump, alternator bracket and alternator. Place the belt on the pulleys and adjust the tension.

24. Install the heater radiator inlet pipe and outlet pipe on the cylinder head. Attach the heater radiator outlet pipe to the coolant pump and outlet manifold.

25. Install control instrument sensors.

26. Install the oil pump and distributor drive gear. Install the distributor and adjust the ignition timing. Screw in the spark plugs, install the 67.7812.9515 wrench on them and tighten with a torque wrench.

27. Install the fuel pump (see subsection 4.1.3).

28. Install the carburetor, connect the hoses to it and close it with a technological plug.

29. Install the cylinder head cover with gasket and fuel line bracket.

30. Pour oil into the filler neck on the cylinder head cover.