VAZ 2101, 2102
1. Specifications
2. Operation and service
3. The engine
3.1. Features of the device
3.2. Possible malfunctions of the engine, their reason and elimination methods
3.3. Removal and engine installation
3.4. Engine dismantling
3.5. Engine assemblage
3.6. Bench tests of the engine
3.7. Engine check on the car
3.8. The block of cylinders
3.9. Pistons and rods
3.10. A cranked shaft and a flywheel
3.11. A head of cylinders and клапанный the mechanism
3.12. A camshaft and its drive
3.13. Cooling system
3.14. Greasing system
4. Fuel system
5. Ignition system
6. Start and gymnastics system
7. Transmission
8. A running gear
9. A steering
10. Brake system
11. An electric equipment
12. A body
13. Features of repair
14. Appendices


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3.5. Engine assemblage

Labels on covers of radical bearings and conditional number of the block of cylinders

Cчет support it is conducted from a forward part of the engine.

Order of a tightening of bolts of a head of cylinders

Order of a tightening of nuts of the case of bearings of a camshaft

Check of coincidence of an adjusting label on an asterisk of a cranked shaft with a label on the block of cylinders

Labels are specified by arrows.

Check of coincidence of an adjusting label on an asterisk of a camshaft with a label on the case of bearings

1 – a label on an asterisk;

2 – a label on the case of bearings

PERFORMANCE ORDER
1. The washed up and cleared block of cylinders establish at the stand and wrap absent hairpins.
2. The washed up and cleared block of cylinders establish at the stand and wrap absent hairpins.
3. Lay in a nest of the average bearing and in its cover loose leaves without bore on an internal surface, and in other nests and corresponding covers – loose leaves with bore (since 1987 the bottom loose leaves of radical bearings are established without bore on an internal surface).

The prevention

Engine cylinders, and also pistons and epiploons, loose leaves of bearings and persistent half rings of a cranked shaft before installation grease with engine oil.


4. Lay in radical bearings a cranked shaft and insert into nests of a back support two persistent half rings which have been picked up for a thickness as directed of subsection 3.10.6.
5. Establish covers of radical bearings according to labels (Label fig. see covers of radical bearings and conditional number of the block of cylinders).

The prevention

Covers of radical bearings establish in the former block. For this purpose the block of cylinders and covers belonging to it are marked by identical conditional number (Label fig. see covers of radical bearings and conditional number of the block of cylinders and fig. Marks of dimensional group of cylinders on the block and conditional number of the block of cylinders). Persistent half rings establish dredging to persistent surfaces of a cranked shaft, and from the forward party of a back support put a steel-aluminium half ring, and from the back party – ceramic-metal (yellow colour).


6. Put on a flange of a cranked shaft a lining of the holder of an epiploon, and in nests of the holder enclose bolts of fastening of a forward cover картера couplings. Put on the holder with an epiploon on оправку 41.7853.4011 and, having moved it with оправки on a flange of a cranked shaft, attach to the block of cylinders (cтрелками ledges for a centering of the holder concerning a flange of a cranked shaft are specified).
7. Establish on two aligning plugs a forward cover 6 (fig. flywheel Removal see) картера couplings.
8. Establish a flywheel on a cranked shaft so that the label (cone-shaped лунка) about a rim was against an axis шатунной necks of the fourth cylinder, block clamp А.60330/R a flywheel and attach its bolts to a flange of a cranked shaft.
9. By means of the plug from set А.60604 insert into cylinders pistons with rods. In a set there are plugs nominal and the repair sizes of pistons. Therefore it is necessary to pick up the plug, suitable for the given size of the established piston. It is possible to apply also the adjustable plug 67.7854.9517.

The prevention

The aperture for a finger on the piston is displaced on 2 mm, therefore at installation of pistons the label «П» on pistons should be turned into cylinders to a forward part of the engine.


10. Establish loose leaves in rods and covers of rods. Connect rods to necks of a cranked shaft, establish covers and tighten шатунные bolts.
11. Establish on a cranked shaft an asterisk. Establish the platen of a drive of the oil pump and fix a persistent flange.
12. Establish on two aligning plugs on the block a head of cylinders with a lining, with final kollekto-rum and the inlet pipeline.
13. Tighten in certain sequence (fig. the Order of a tightening of bolts of a head of cylinders see) in two steps fastening bolts:
      – Preliminary the moment 33,3 41,16 Н·м (3,4–4,2 кгс·м) bolts 1–10;
      – Definitively moment 95,94–118,38 Н·м (9,79–12,08 кгс·м) bolts 1–10 and the moment 31,36–39,1 Н·м (3,2–3,99 кгс·м) a bolt 11.
14. Turn a flywheel so that the label on an asterisk of a cranked shaft has coincided with a label on the block of cylinders (cм. Fig. Check of coincidence of an adjusting label on an asterisk of a cranked shaft with a label on the block of cylinders).
15. Establish an asterisk on a camshaft collected with the case of bearings, and turn a shaft so that the label 1 on an asterisk was against a label 2 on the case of bearings (Check of coincidence of an adjusting label fig. see an asterisk of a camshaft with a label on the case of bearings).
16. Remove an asterisk and, without changing shaft position, establish the case of bearings on a head of cylinders and fix, tightening nuts in certain sequence (fig. the Order of a tightening of nuts of the case of bearings of a camshaft see).
17. Establish on a head of cylinders успокоитель chains.
18. Establish a chain of a drive of a camshaft:
      – Put on a chain an asterisk of a camshaft and enter into a drive cavity, establishing an asterisk so that the label on it has coincided with a label on the case of bearings (Check of coincidence of an adjusting label fig. see an asterisk of a camshaft with a label on the case of bearings). A bolt of an asterisk do not tighten against the stop;
      – Establish an asterisk on the platen of a drive of the oil pump, also without tightening definitively a fastening bolt;
      – Establish a boot натяжителя chains and натяжитель, without tightening колпачковую a nut that the spring натяжителя could press a boot; wrap in the block of cylinders a restrictive finger of a chain;
      – Turn a cranked shaft on two turns in a rotation direction to provide the necessary tension of a chain; check up coincidence of labels on asterisks with labels on the block of cylinders (cм. Fig. Check of coincidence of an adjusting label on an asterisk of a cranked shaft with a label on the block of cylinders) and on the case of bearings (Check of coincidence of an adjusting label fig. see an asterisk of a camshaft with a label on the case of bearings).;
      – If labels coincide, that, having blocked a flywheel clamp А.60330/R (fig. flywheel Removal see), definitively tighten bolts of asterisks, колпачковую a nut натяжителя chains and unbend lock washers of bolts of asterisks; if labels do not coincide, repeat operation on chain installation.
19. Adjust a backlash between cams of a camshaft and levers of a drive of valves.
20. Establish a cover of a drive of a camshaft with a lining and an epiploon on the block of cylinders, without tightening definitively bolts and fastening nuts. Оправкой 41.7853.4010 centre position of a cover concerning the end of a cranked shaft and tighten definitively nuts and bolts of its fastening (arrows ledges for a centering of a cover concerning a nave of a pulley of a cranked shaft are shown).
21. Establish a pulley of a cranked shaft and wrap a ratchet.
22. Oil a sealing ring of the oil filter and establish the filter, manually having tightened it to the union on the block of cylinders. Establish a ventilation oil separator картера, a cover сапуна and fix a clamp of a drain tube of an oil separator.
23. Establish the oil pump and oil картер with a lining.
Establish the pump of cooling of a liquid, an arm of the generator and the generator. Put on a belt pulleys and adjust its tension.
24. Establish on a head of cylinders bringing tube of a radiator of a heater and a final branch pipe. Attach to the pump of a cooling liquid and a final collector taking away tube of a radiator of a heater.
25. Establish gauges of control devices.
26. Establish a gear wheel of a drive of the oil pump and the ignition distributor. Establish the distributor of ignition and adjust the ignition moment. Wrap spark plugs, establish on them a key 67.7812.9515 and tighten динамометрическим a key.
27. Establish the fuel pump (subsection 4.1.3 see).
28. Establish the carburettor, attach to it hoses and close its technological заглушкой.
29. Establish a cover of a head of cylinders with a lining and an arm топливопровода.
30. Fill in oil in a mouth on a cover of a head of cylinders.

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3.4. Engine dismantling
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3.6. Bench tests of the engine