Removing the air filter housing
Open the hood.
Components removed when dismantling the air filter: 1 - fastening bolt; 2 - intake manifold; 3 – a socket of a plait of wires of the gauge of the mass expense of air; 4 - air filter housing
Note. Before the test procedure, warm up the engine to operating temperature (oil temperature - 80°C).
Turn away a fastening nut and disconnect a mass wire from the storage battery.
Remove the air filter housing and intake manifold.
Disconnect the MAF sensor harness connector.
Unscrew the mounting bolt, remove the clamp and the intake pipe of the air filter.
Removing the front toothed belt cover
Unscrew the two mounting bolts, disconnect the upper latch and remove the front toothed belt cover (top).
Fastening of a forward cover of a gear belt: 1 – a forward cover of a gear belt; 2 - fastening bolts; 3 - latches
Note. Pull the front cover of the toothed belt up, by the ledge (arrow in the picture).
Remove the ignition module cover in the direction of the arrow shown on it.
Removing the cover of the ignition module: 1 - mounting bolts
Note. Mark the position of the arrow on the cover.
After unscrewing the 2 bolts, remove the spark plugs using the KM 6009 special tool.
Remove the coolant expansion tank cap.
Remove the dipstick.
Raise the vehicle.
Removing the right engine baffle
Remove the 4 mounting bolts and remove the right engine mudguard.
Remove the two rivets mounted on the body.
Components removed when dismantling the cylinder head cover: 1 - right engine mudguard; 2 - fastening bolts; 3 - rivets
Setting the crankshaft to top dead center (TDC) piston of cylinder No. 1
Turning the engine crankshaft in the direction of rotation, set the piston of cylinder No. 1 to the top dead center position (TDC) (label 1).
Lower the car.
Setting the crankshaft to top dead center (TDC) piston of cylinder No. 1: 1 - marks
Put 3 marks on one of the camshaft gears and align the marks on both wheels.
Combination of marks on the gears of the camshafts: 1 - marks
Each mark must be offset by 90°relative to the adjacent mark.
Connect the pressure drop tester to the compressed air supply.
Calibrate the pressure drop tester.
Engage first gear and parking brake.
Note. The wheels must be in contact with the ground.
Screw the connecting piece into the threaded hole of the spark plug of cylinder No. 1.
Apply compressed air to the cylinder.
Pressure drop test
Determine the value of the pressure drop.
The maximum allowable pressure difference between the cylinders is approximately 10%.
The maximum pressure loss in the cylinder is 25%.
Note. Watch for any visible compressed air leaks in the intake and exhaust manifolds and crankcase.
Note. Pay attention to bubbles in a broad tank of a cooling liquid.
Rotate the crankshaft 180°in the direction of engine rotation (corresponds to 90°rotation of the camshaft gear) and set the piston of cylinder No. 3 to the position of top dead center (TDC) (pre-marked).
Connect a pressure drop tester.
Screw the fitting into the threaded hole of the No. 3 cylinder spark plug and apply compressed air to the cylinder.
Determine the value of the pressure drop.
The maximum allowable pressure difference between the cylinders is approximately 10%.
The maximum pressure loss in the cylinder is 25%.
Rotate the crankshaft 180°in the direction of engine rotation (corresponds to 90°rotation of the camshaft gear) and set the piston of cylinder No. 4 to top dead center (TDC) (pre-marked)
Connect a pressure drop tester.
Screw the fitting into the threaded hole of the No. 4 cylinder spark plug and apply compressed air to the cylinder.
Determine the value of the pressure drop.
The maximum allowable pressure difference between the cylinders is approximately 10%.
The maximum pressure loss in the cylinder is 25%.
Rotate the crankshaft 180°in the direction of engine rotation (corresponds to 90°rotation of the camshaft gear) and set the piston of cylinder No. 2 to the position of top dead center (TDC) (pre-marked)
Connect a pressure drop tester.
Screw the fitting into the threaded hole of the No. 2 cylinder spark plug and apply compressed air to the cylinder.
Determine the value of the pressure drop.
The maximum allowable pressure difference between the cylinders is approximately 10%.
The maximum pressure loss in the cylinder is 25%.
Installing components
Raise the vehicle.
Install the engine mudguard.
Lower the car.
Insert the dipstick into the hole.
Install the coolant expansion tank cap.
Install the spark plugs using the KM 6363 special tool and tighten to 25 Nm.
Install the ignition module by replacing the 4 gaskets.
Tighten the two mounting bolts to 8 Nm.
Install the ignition module cover.
Install the front toothed belt cover.
Attention! Check that the cover is installed correctly.
Tighten the two cap screws to 6 Nm.
Install the air filter housing, tighten the mounting bolt and secure the clamp with a torque of 3.5 Nm.
Install the intake pipe.
Connect the air flow sensor harness connector.
Connect the battery.
Tighten the terminal nut.
Program the transition memory.
Close the hood.
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