Car engine repair VAZ-21051 «Zhiguli»

Description of engine design
Longitudinal and cross-section of the 2105 engine Engine mount 1 – support casing; 2 – Front engine mount support; 3 – cylinder block flange; 4 – bracket; 5 – intermediate plate;...

Removal and installation the engine
1. Place the car on a lift or over an inspection pit, place chocks under the front wheels and lift the rear axle on one or both sides. 2. Remove the hood, disconnect the wires...

Disassembling the engine
Disassembling the front part of the engine 1 – top protective cover; 2 – tension roller; 3 – tension spring; 4 – camshaft drive belt; 5 – camshaft drive cover; 6 – oil pump and...

Engine assembly
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...

Engine bench testing
The repaired engine is subjected to bench tests (running-in) without load according to the following cycle: 820–900 min⁻¹ 2 min 1000 min⁻¹ 3 min 1500 min⁻¹ 4 min 2000 min⁻¹ 5 min...

Checking the engine on a car
Install the engine on the car, carefully check the correct installation. Let the engine run for a while, then check: check for coolant and fuel leaks in the pipe connections,...

Cylinder Block — Design Description
Main dimensions of the cylinder block The cylinder block is cast from special low-alloy high-strength cast iron. The cylinders are bored directly in the block and do not have...

General cleaning and inspection of the cylinder block
Wash the cylinder block thoroughly and inspect the oil passages. Blow and dry the cylinder block with compressed air, especially the oil passages. Inspect the cylinder block. If...

Checking the cylinder block for leaks
If there is a suspicion of coolant getting into the crankcase, then check the cylinder block for leaks on a special stand. To do this, having plugged the openings of the cooling...

Cylinders — Description and Testing
Measuring cylinders with a bore gauge 1 – bore gauge; 2 – setting the bore gauge to zero according to caliber 67.8125.9501 Cylinder Measurement Diagram A and B are the directions...

Parting plane with cylinder head
There may be deformations on the plane of the cylinder block-head joint. Therefore, check the plane of the joint using a ruler and a set of feeler gauges. The ruler is installed...

Pistons and connecting rods — design description
Main dimensions of piston, connecting rod, piston pin and piston rings Piston The piston is made of aluminum alloy and coated with a layer of tin to improve the running-in...

Pressing out the piston pin
The pin must be removed on a press using the A.60308 mandrel and a support with a cylindrical recess into which the piston is placed. Before pressing out the pin, remove the...

Cleaning pistons and connecting rods
Remove any carbon deposits that have formed on the piston crown and in the piston ring grooves, and remove all deposits from the piston and connecting rod oil passages. Carefully...

Selecting a piston for a cylinder
Calculated clearance between piston and cylinder (for new parts) is 0.05–0.07 mm. It is determined by measuring the cylinders and pistons and is ensured by installing pistons of...

Checking the clearance between the piston and the pin
Installing the piston pin The piston pin should be installed with a simple push of the thumb. Checking the piston pin fit The pin is pressed into the upper head of the connecting...

Checking the clearances between piston grooves and rings
Checking the clearance between piston rings and grooves 1 – piston ring; 2 – piston; 3 – set of feeler gauges Checking the height clearance Check the height clearance between the...

Checking the clearance between the bearings and the crankshaft
Measuring the width of the calibrated wire after flattening using a scale 1 – calibrated wire; 2 – insert; 3 – connecting rod bearing cap; 4 – scale for calibrated wire The...

Piston mass control
Scheme of metal removal from a piston to adjust its mass The arrows indicate the places where metal can be removed. The mass of pistons in one engine must not differ from each...

Assembly of the connecting rod and piston group
Installing the piston pin on the 02.7853.9500 tool for pressing it into the piston and connecting rod head 1 – device roller; 2 – piston pin; 3 – guide; 4 – stop screw Pressing...

Checking the piston pin press fit
Assembled piston-pin-connecting rod kit mounted on fixture A.95615 for pin pressing-out test 1 – indicator pin in contact with the end of the rod; 2 – the head of the rod in...

Parallelism of the axes of the lower head of the connecting rod and the piston pin
Checking the parallelism of the piston pin and connecting rod lower head axes 1 – assembled connecting rod-pin-piston kit; 2 – retractable knives; 3 – emphasis; 4 – caliber Before...

Crankshaft and flywheel — design description
Main dimensions of connecting rod and main journals of the crankshaft and their fillets Crankshaft The crankshaft is a five-bearing, cast iron crankshaft. The surfaces of the...

Cleaning the crankshaft lubrication system channels
To clean, remove the channel plugs. Then run through the plug sockets with the countersink A.94016/10, put on the spindle A.94016, thoroughly wash the channels with gasoline and...

Main and connecting rod journals
Permissible runout of the main surfaces of the crankshaft Diameters of connecting rod journals, mm Nominal Reduced 0,25 0,50 0,75 1,0 47,814 47,564 47,314 47,064 46,814 47,834...

Main bearing shells
Determining the gap on the scale 1 – scale; 2 – calibrated wire Do not perform any adjustment operations on the liners. If there are any scuffs, scratches or deviations in the...

Flywheel — Checking the condition
Flywheel 1 – mounting surface to the crankshaft flange; 2 – clutch mounting surface; 3 – supporting surface of the driven clutch disc The flywheel surfaces mating with the...

Checking the axial clearance of the crankshaft
The axial movement of the crankshaft is limited by two thrust half rings installed on both sides of the rear main bearing. A steel-aluminum half ring is installed on the front...

Cylinder head and valve mechanism
Main dimensions of valves and guide bushings The cylinder head is common to all four cylinders and is cast from an aluminum alloy. The main dimensions of the cylinder head,...

Removal the cylinder head on a car
The cylinder head is removed from the engine on the car if it is not necessary to remove the engine itself to fix the malfunction or if it is only necessary to remove carbon...

Installing the cylinder head
1. Install the gasket and cylinder head on the cylinder block and tighten in the specified sequence (see Fig. Cylinder Head Bolt Tightening Sequence ) in two stages, tighten the...

Disassembly and assembly of the cylinder head
Valve Mechanism Parts 1 – valve; 2 – retaining ring; 3 – guide bushing; 4 – oil deflector cap; 5 – outer spring support washer; 6 – inner spring support washer; 7 – inner spring;...

Cleaning the cylinder head
1. Install the head on the stand A.60353. 2. Remove carbon deposits from the combustion chambers and from the surface of the exhaust ports with a wire brush driven by an electric...

Checking and grinding valve seats
Intake valve seat profile I - new saddle; II – saddle after repair Exhaust valve seat profile I - new saddle; II – saddle after repair The shape of the valve seat chamfers is...

Valves — Check for wear
1. Remove carbon deposits from the valves. Check if the stem is deformed and if there are any cracks on the plate; if damaged, replace the valve. 2. Check whether the working...

Valve guide bushings
Pressing out guide bushings 1 – mandrel A.60153/Ya Check the clearance between the guide bushings and the valve stem by measuring the diameter of the valve stem and the guide...

Oil deflector caps of guide bushings
The oil deflector caps must not have any separation of the rubber from the fittings, cracks or excessive wear of the working edge. When repairing an engine, it is recommended to...

Valve Levers — Checking
Check the condition of the working surfaces of the lever in contact with the valve stem, the camshaft cam and the spherical end of the adjusting bolt. If these surfaces are scored...

Valve springs — checking
Basic data for checking the outer valve spring Basic data for checking the internal valve spring Lever Spring Test Scheme A – size in free state; B – size under load Make sure...

Cylinder Head Gasket — Check
The surfaces of the gasket must not have any damage. They must be smooth, without dents, cracks, swellings and fractures. Peeling of the facing material from the reinforcement is...

Checking the cylinder head for leaks
Checking the tightness of the cylinder head on the device A.60334 1, 2, 4 – plugs; 3 – fixture plate; 5 – flange with water supply nipple Hydraulic test for tightness of the...

Camshaft and its drive
Main dimensions of the camshaft and bores in the camshaft bearing housing The camshaft is cast iron and rotates on five bearings in an aluminum cast bearing housing mounted on the...

Adjusting the clearance between the levers and the camshaft cams
Checking the clearance between the levers and camshaft cams with a feeler gauge A.95111 1 – adjusting bolt; 2 – adjusting bolt lock nut Adjust the gaps on a cold engine, having...

Adjusting the tension of the camshaft drive belt
1. Remove the upper protective cover 8 (see Fig. Camshaft Drive Diagram ). 2. Loosen bolts 6 securing bracket 11 of the tension roller and turn the crankshaft with a wrench two or...

Replacing the camshaft drive belt
1. Remove fan drive belt 2 and upper protective cover 8 (see Fig. Camshaft Drive Diagram ). 2. Turn the crankshaft and align the "C" mark on pulley 1 of the crankshaft with the...

Checking the technical condition of the belt
1. The surface of the toothed part must have a clear tooth profile, without wear, folds, cracks, undercuts and delamination of the fabric from the rubber. 2. There should be no...

Checking the belt tensioning mechanism
Basic data for checking the tension spring The working surface of the tension roller must be smooth, without nicks and burrs. The ball bearing of the tension roller must rotate...

Checking the camshaft
The bearing journals of the camshaft must not have any scoring, nicks, scratches, or aluminum drag from the bearing housings. The working surfaces of the cams must not have wear...

Checking the camshaft bearing housing
Wash and clean the camshaft bearing housing and oil supply passages. Check the diameter of the holes in the bearings. If the gap between the camshaft journals and the bearings...

Assembly of the camshaft bearing housing
Installing the camshaft oil seal holder A – lower plane of the holder; B – lower plane of the camshaft bearing housing 1. Secure the camshaft bearing housing to the assembly jig....

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