Design and technical characteristics. General information A four-stroke, five-cylinder, in-line, liquid-cooled gasoline engine is located along the longitudinal axis of the car with an inclination to the right. The engine uses a valve...
Specifications of the cylinder block The cylinder block is sleeveless, cast iron. In the lower part of the cylinder block, there are six supports for the crankshaft main bearing shells. The main bearing caps are...
Technical characteristics of the crank mechanism Crankshaft Crankshaft steel, forged. The shaft is six-bearing. The upper main bearing shells have oil grooves. On the cheeks of the shaft there are ten counterweights, forged...
Technical characteristics of the gas distribution mechanism The engine uses a valve timing mechanism with an overhead camshaft, which, like the water pump, is driven by a toothed belt from the crankshaft pulley. Belt tension is provided...
Specifications of the lubrication system All models have a pressure lubrication system. Under vacuum, oil is sucked in through the oil receiver mesh filter from the oil sump and pumped by an internal gear oil pump...
Specifications of the cooling system The engine uses a liquid cooling system with forced circulation of liquid. The cooling system includes cooling jackets, a radiator, an expansion tank, a centrifugal water pump, a...
Power System Specifications The engine of the WN·model is carbureted, the engine of the JS model is with a fuel injection system. Fuel tank The plastic fuel tank is located in front of the rear axle. Fuel...
Specifications of the ignition system The ignition system is non-contact, including a distribution sensor with a built-in electronic control pulse sensor, an ignition coil and a switch. Ignition distributor Bosch...
Tightening torques of the main threaded connections, kgf.m Cylinder head bolts: 1st reception: 4.0; 2nd reception: 6.0; Step 3: turn 180°. Bolt of fastening of a gear pulley of a cranked shaft: 35,0. Water pump mounting bolt: 2.0. Bolt of...
Design of hydraulic pushers The hydraulic pusher consists of two main moving parts: the pusher itself 2 (see picture), which simultaneously serves as a plunger during operation, and cylinder 4. Under the...
The principle of operation of hydraulic pushers Starting valve lift At the moment the camshaft cam hits the valve stem, the check valve closes the chamber and the pressure in it increases. An increase in pressure does not...
Checking the technical condition of hydraulic pushers The design of the hydraulic pusher is non-separable and cannot be repaired. Start the engine and let it run until the cooling fan is turned on for the first time. Maintain the...
WN Engine Fuel Pump The fuel pump is fastened with two nuts through a heat-insulating spacer and an o-ring. Pump housing and cover are one-piece, i.e. The design of the fuel pump is non-separable and...
Carburetor Pierburg 2B5 Features of the device and calibration data of the Pierburg 2V5 carburetor are given in the subsection « Design and specifications ». The principle of operation of the carburetor...
Checking and adjusting the system «K-Jetronic» Throttle valve adjustment Note. The throttle valve opening is adjusted at the factory and cannot be changed in operation. However, if the stop screw is accidentally turned, the...
Removal and installation of the sensor-distributor ignition Removing Disconnect the spark plug wires and ignition coil wire from the ignition distributor. Unfasten the spring clips and remove the cover of the sensor-distributor. Disconnect...
Removing and installing the camshaft drive belt Removing Loosen the alternator mounting bolts and, depending on the configuration, the power steering pump mounting bolts. Remove the alternator drive belt and, depending on the...
Cylinder head Removing the cylinder head Disconnect the wire from the negative battery terminal. Drain the fluid from the cooling system by disconnecting the supply hose from the radiator and...
Installing the cylinder head Clean the removed parts and determine their technical condition by visual inspection. Clean the connector surfaces using suitable detergents. Do not use abrasive materials or...
Disassembly and repair of the cylinder head When disassembling the cylinder head, put marks on the removed parts in order to put them in their original places during assembly. Remove bearing caps No. 1 and 3 (the reading is...
Cylinder head assembly Install the valve spring support washers and insert the valves into the valve guides. Using a VW 10 204 mandrel, press new valve stem seals onto the valve guides, after putting...
Removal and installation of the engine Removing Disconnect the wire from the negative battery terminal. Remove the hood. Remove the plug from the expansion tank. Disconnect the radiator supply hose from the thermostat...
Engine disassembly Note. When disassembling, put marks on the parts that are suitable for further use, so that during assembly, install them in their original places and in their original position....
Engine Assembly Checking cylinder diameters Accurately measure cylinder diameters. Measurements to be made with a caliper in three belts as in the transverse direction «A», and in the...
Removal and installation of the oil pump Removing Disconnect the wire from the negative battery terminal. Loosen the alternator mounting bolts and, depending on the configuration, the power steering pump and remove the...
Coolant replacement There are no holes for draining the coolant from the cooling jacket on engines. Remove the expansion tank cap. Disconnect the coolant supply hose from the thermostat housing and...
Removal and installation of the water pump Removing Drain the coolant from the system. Set the crankshaft of the engine to the position corresponding to the TDC of the piston of the 1st cylinder. Disconnect the wire from...