General information about the 1.6 liter gasoline engine Engine identification data The engine identification data is located on the cylinder block between the exhaust manifold and the flywheel. The data can either be contained on a separate plate affixed with rivets or...
Preparation for repair Note: All work on the engine must only be carried out by qualified personnel. When carrying out repairs on a vehicle, the basic safety rules must be observed. The quality of the repair depends primarily on the care with...
Compression test 1. Remove the spark plugs. 2. Connect the compression gauge (1). K7M engine (8 valves) K4M engine (16 valves) 3. Connect the diagnostic scanner to the car and run the following commands: RZ003: engine adaptation (ENGINE...
Engine attachments Attachment drive belt Attachment Drive Belt Replacement Attention: Wear protective gloves when performing work. To avoid damage to the crankshaft pulley, do not start the engine with the attachment drive belts removed....
Removal and installation of the compressor of the conditioner Caution: Take precautions when handling refrigerant (see chapter 21 "Air conditioning system''). Note: To remove the air conditioning compressor, a special station is needed to empty and recharge the air conditioning...
Removal and installation of the power steering pump 1. Place the vehicle on a two post lift. 2. Disconnect the negative battery terminal. 3. Place the hose clamp (Ms. 583) to the low pressure pipe at the pump. 4. Remove the implement drive belt. 5. Disconnect the high...
Removal and installation of a multipurpose support Removing 1. Place the vehicle on a two post lift. 2. Disconnect the negative battery terminal. 3. Unscrew the fastening bolts and remove the engine protective tray. 4. Remove the implement drive belt. 5. Remove the...
Removal and installation of the power unit assembly Engine K7M: 1. Cylinder head mounting support. 2. Front side spar. 3. Engine with gearbox assembly. 4. Jet thrust of the engine. 5. Engine thrust support. 6. Gearbox support. 7. Elastic transmission support on the body....
Repair of the engine removed from the car Installing the engine on the assembly stand Attention: For safe work with the engine removed from the vehicle, it is recommended to use a special assembly stand. Attention: It is strictly forbidden to apply any pressure...
Removing components from the top of the engine 1. Remove the timing belt. 2. Remove ignition coils. 3. Remove intake manifold. 4. Remove rocker cover. 5. Remove the cylinder head. 6, Remove the exhaust manifold. 7. Remove the throttle valve. 8. Remove the cooling...
Removing components from the bottom of the engine 1. Remove the generator. 2. Remove the air conditioning compressor. 3. Remove the power steering pump. 4. Remove the multifunction support. 5. Remove the water pump inlet. 6. Remove knock sensor (3). 7. Remove the...
Preparing engine parts for assembly Parts that must be replaced with new ones: all seals, damaged cooling system hoses, drive belts, drive belt tensioners and rollers, crankshaft pulley bolt, camshaft sprocket bolt, exhaust manifold nuts exhaust manifold...
Installing the components of the lower part of the engine 1. Install the cylinder block. Note: When replacing the cylinder block, crankshaft, or main bearing shells, a thickness class must be determined for each bearing shell for each crankshaft bearing journal to ensure...
Installing Top Engine Components 1. Check the technical condition of the valves and install the valves on the cylinder head. Note: When replacing valves, be sure to select new valves with the same parts catalog numbers as previously installed. Failure...
Completion of engine repair 1. Remove the engine from the assembly stand. 2. Install the flywheel (see chapter " Clutch "). 3. Install clutch discs (see chapter " Clutch "). 4. Install flywheel locking tool (Mot. 582-01) to the cylinder block. 5....
Engine components that can be reused when replacing an engine Preparing the old engine for return to the factory for further restoration 1. Clean the engine. 2. Drain engine oil and coolant. 3. Fix the old engine on the stand. 4. Install plastic plugs and caps. 5. Place the entire...
Gas distribution mechanism drive Removal and installation of a gear belt of a drive of the gas-distributing mechanism, K7M engine (8 valves) Removing the timing belt 1. Place the vehicle on a two post lift. 2. Disconnect the negative battery terminal....
Cylinder head Valve clearance adjustment K7M engine (8 valves) Adjustment values Adjusting clearance on a cold engine, mm: Inlet valves: 0.10-0.15 mm; Exhaust valves: 0.25 - 0.30 mm (no valve replacement); Exhaust valves: 0.20 - 0.25...
Rocker cover Removal and installation, K7M engine (8 valves) Removing 1. Disconnect the battery. 2. Disconnect: air filter housing, ignition coil unit 3. Disconnect the EVAP tube from the holder at the point (1). 4. Disconnect the...
Removal and installation of the cylinder head, K7M engine (8 valves) Removing 1. Place the vehicle on a two post lift. 2. Drain the coolant through the bottom hose using a hose clamp pliers (Mot. 1448). 3. Remove the battery. 4. Unscrew the fastening bolts and remove the engine...
Removal and installation of the cylinder head, K4M engine (16 valves) Removing 1. Place the vehicle on a two post lift. 2. Disconnect the battery. 3. Remove: right front wheel accessory drive belt, crankcase protection. 4. Drain the liquid from the engine cooling system. 5. Remove: nuts...
Disassembly and assembly of the cylinder head, K7M engine (8 valves) Attention: It is strictly forbidden to apply any pressure to the engine oil pan. Damage to the sump can also cause various damage to the engine itself due to: blocking the oil intake; increasing the engine oil level...
Disassembly and assembly of the cylinder head, K4M engine (16 valves) Disassembly 1. Drain the coolant from the engine cooling system. 2. Remove the air filter unit. 3. Remove the attachment drive belt. 4. Remove the crankshaft pulley. 5. Remove the timing belt. 6. Remove ignition coils....
Cleaning the cylinder head Attention: Do not scratch the aluminum contact surfaces, any damage to the contact surfaces may cause leakage. Use safety goggles with side protection and sealed gloves (nitrile type). Do not allow cleaning agent to...
Camshafts Removal and installation of a camshaft, K7M engine (8 valves) Note: The cylinder head must be removed to remove and install the camshaft. Removing 1. Remove the cylinder head from the engine. 2. Place the cylinder head...
Front camshaft seals K7M engine (8 valves) Removing 1. Place the vehicle on a two post lift. 2. Disconnect the battery. 3. Disconnect: right front wheel right pendulum suspension support, accessory drive belt, timing belt. 4. Remove (1)...
Pistons and connecting rods Removal and installation of pistons with connecting rods 1. Place the vehicle on a two post lift. 2. Disconnect the negative battery terminal. 3. Remove the engine protection tray. 4. Drain the coolant from the engine...
Removal and installation of the crankshaft Attention: It is strictly forbidden to apply any pressure to the engine oil pan. Damage to the sump can also cause various damage to the engine itself due to: blocking the oil intake; increasing the engine oil level...
Checking the crankshaft and selecting the main bearing shells A. Crankshaft identification stamp Deciphering the identification stamp of the crankshaft: 1. Size groups of crankshaft main journals. 2. Dimensional groups of connecting rod journals of the crankshaft. 3. Dimensional...
Cylinder block Dismantling of the block of cylinders 1. Remove the power unit assembly (engine with gearbox) from the car. 2. Disconnect the gearbox from the engine (see chapter " Transmission "). 3. Remove the attachment drive belt....
Front crankshaft oil seal Removing 1. Place the vehicle on a two post lift. 2. Disconnect the battery. 3. Remove: right front wheel. timing belt, crankshaft toothed pulley. 4. Press out the front crankshaft oil seal using the tool (Mot. 1577)....
Rear crankshaft oil seal Removing 1. Place the vehicle on a two post lift. 2. Disconnect the battery. 3. Disconnect: gearbox, clutch, engine flywheel. Pressing out the stuffing box 4. Press out the crankshaft rear oil seal using the tool...
Special tools and fixtures Name of tool and fixtures Catalog number TDC locating pin Mot. 1489 Drive Belt Tension Checker (frequency indicator) Mot. 1715 TDC locating pin Mot. 1983 Hose clamp pliers Mot. 1448 Hose clamps Ms. 583 Hose clamp pliers...