Removing the air filter housing
Note. Before the test procedure, warm up the engine to operating temperature (oil temperature - 80°C).
Open the hood.
Components removed when dismantling the air filter: 1 - bolt for fastening the lower rubber support; 2 – a plait of wires of the gauge of the mass expense of air; 3 – fuel tank ventilation line; 4 – a hose of ventilation of the engine; 5 - air intake hose; 6 - inlet pipe
Remove the air filter housing.
Disconnect the mass air flow sensor harness.
Disconnect the fuel tank vent line.
Disconnect the engine ventilation hose from the air intake hose.
After removing the clamp, disconnect the air intake hose from the throttle pipe.
After removing the clamp, disconnect the air filter housing.
Loosen the bottom rubber mounting bolt and remove it.
Disconnect the intake pipe.
Removing the ignition module
Remove the ignition module wiring harness.
Remove the ignition module cover from the cylinder head cover in the direction of the arrow.
Loosen the two fixing screws.
Components removed when dismantling the ignition module: 1 – cover of the ignition module; 2 - special tool; 3 – a plait of wires of the module of ignition; 4 - ignition module; 5 - fastening bolts; 6 – a cover of a head of the block of cylinders
Separate the ignition module from the spark plugs using the KM 6009 2 special tool.
Removing the camshaft sensors
Disconnect the camshaft sensor, film mass air flow sensor, oil pressure sensor, and coolant temperature sensor connectors.
Disconnect wiring from cylinder head cover.
Take her back.
Components removed when dismantling the camshaft sensors: 1 - camshaft sensor connector; 2 – a socket of the gauge of the mass expense of air; 3 – a socket of the gauge of pressure of oil; 4 – a socket of the gauge of temperature of a cooling liquid; 5 - wiring
Removing the cylinder head cover
Remove the two clamps and disconnect the engine hoses from the cylinder head cover.
Disconnect the ignition module harness connector.
Remove the ignition module cover from the cylinder head cover in the direction of the arrow.
Loosen the two fixing screws.
Separate the ignition module from the spark plugs using a special tool KM 6009 3.
Remove from the cylinder head.
Turn away 13 bolts of fastening.
Remove gasket residue and clean sealing surfaces.
Remove spark plugs with special tool KM-194-E.
Components removed when dismantling the cylinder head cover: 1 - cover of the ignition module; 2 - engine hoses; 3 – a plait of wires of the module of ignition; 4 – a socket of a plait of wires of the module of ignition; 5 - ignition module; 6 - fastening bolts; 7 - special tool
Components removed when dismantling the cylinder head cover: 1 - right engine mudguard; 2 - fastening bolts; 3 - rivets
Attention! Open the lid carefully and slowly. There is a risk of burns.
Turn away a cover of a broad tank of a cooling liquid.
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.
Setting the crankshaft to top dead center (TDC) piston of cylinder No. 1
Use the bolt on the crankshaft hub to set the crankshaft to top dead center (TDC) piston of cylinder #1 in the direction of engine rotation.
The mark on the crankshaft pulley must align with the lip on the housing.
Setting the crankshaft to top dead center (TDC) piston of cylinder No. 1: 1 - cams of cylinder No. 1; 2 - ledge; 3 - label
Note. In this position, the cams of cylinder No. 1 are at TDC (both cams point outward).
Shift the marks on the belt pulley by 180°relative to the TDC mark of the first cylinder (arrow).
Lower the car.
Connect the pressure drop tester to the compressed air supply.
Calibrate the pressure drop tester.
Screw the connector into the spark plug hole of cylinder no. 1 and connect the pressure drop tester to the connector (in accordance with the manufacturer's instructions).
Select a gear and apply the handbrake.
Note. All wheels must touch the ground.
Recommended tightening torques for threaded connections
* two passes
** use new bolts
On an automatic transmission, move the selector lever to position «P».
Check the pressure drop in cylinder #1.
Read the pressure drop reading on the tester as a percentage.
Note. Pay attention to any noise from air leakage from the intake manifold, exhaust system or crankcase, as well as bubbles in the expansion tank of the cooling system.
Set the crankshaft to the ignition position in cylinder No. 3 (TDC).
Check the pressure drop in cylinder #3.
Set the crankshaft to the ignition position in cylinder No. 4 (TDC).
Check the pressure drop in cylinder #4.
Set the crankshaft to the ignition position in cylinder No. 2 (TDC).
Check the pressure drop in cylinder #2.
Compare your results.
The maximum pressure spread between individual cylinders is approximately 10%.
The maximum pressure drop in an individual cylinder must not exceed 25%.
Installing components
Raise the vehicle.
Attach the right engine mudguard.
Tighten 4 bolts.
Install two rivets.
Lower the car.
Install the coolant expansion tank cap and dipstick.
Install the spark plugs with the KM-194-E special tool into the cylinder head and tighten to 25 Nm.
Installing the cylinder head cover
Install the cylinder head cover.
Replace seal.
Attention! Perform assembly within 10 minutes of seal installation.
Installation of a cover of a head of the block of cylinders: 1 – a cover of a head of the block of cylinders; 2 - seal
Apply a layer of silicone sealant (gray) approx. 2 mm thick (size I) at the junction of the synchronization housing and the cylinder head.
Attention! Visually inspect the bolts and ensure that the seal is not damaged. If necessary, replace the bolts with new ones.
Tighten 13 mounting bolts to 8 Nm.
Install the ignition module.
Connect the module to the spark plugs.
Tighten the two mounting bolts to 8 Nm.
Install the ignition module cover to the cylinder head cover.
Connect the ignition module harness connector.
Attach the wiring harness to the cylinder head cover.
Connect the connectors of the camshaft sensor, mass air flow sensor, oil pressure sensor and coolant temperature sensor.
Install the air filter housing on the wheel arch and tighten the mounting bolt.
Attach the air intake hose to the throttle module and secure the clamp.
Attach the engine ventilation hose to the air intake hose and secure the clamp.
Connect the harness connector to the mass air flow sensor.
Connect the fuel tank vent tube.
Close the hood.
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