In detail: do-it-yourself overhaul of a vaz 2107 from a real master for the site my.housecope.com.
Overhaul of the engine, or the eyes are afraid, but the hands are doing.
Background. It all started, as you know, with the purchase of a "new" car in 2009. Car VAZ 21053 1997 color "safari" code 215 (for those who do not know - light beige). After the purchase, I skated no more than a couple of thousand kilometers and soon the move refused to pull normally. I checked the candles - relatively clean, adjusted the valves - it did not help. Having procured a homemade compression meter, and measured the compression, I was unpleasantly surprised.
The compression was as follows: 1 — 8; 2 — 8; 3 — 4,5; 4 — 8. Here it is a no brainer that only an autopsy will save the patient. Like many brothers in misfortune, he began by calling the services, and, having learned the cost of the repair (15-17 thousand rubles only for work), he unanimously decided to make repairs with the forces of his limbs and gray matter.
And so, the age-old question, to which I did not find a detailed answer on the forums: "Capital of the engine, what and how to do?".
I'll start, perhaps, with a list of special tools that you may need for this ritual: • set of heads; • a mandrel for piston rings (about 260 rubles, but you can collect it yourself from a sheet of tin); • mandrel for valve stem seals (20 rubles); • valve desiccant (80-100 rubles); • torque wrench (it is necessary to take such that the size of the square is the same as on the heads) (1300r); • micrometer (500-600 rubles); • mandrel of the clutch disc (50 rubles);
• a device for adjusting valves with a hour indicator (500-800 rubles); • two- or three-legged stripper (400-500 rubles).
For spare parts: • pistons; • piston rings; • main and connecting rod inserts; • crankcase gasket; • block laying;
Video (click to play).
Literature: • Repair manual for your car; • spare parts catalog (of course, rare in our days, but you can find it on the internet)
The engine capital has been completed. Now you need to drive the first 2500 km carefully without sudden accelerations, without overloading the engine. After driving 2500 km, change the engine oil. Look under the hood frequently to check the unit.
Advice for those who will disassemble the cylinder head. As you know, a regular drying agent is not a very convenient thing and easily flies out of the engagement on a hairpin. I advise you to tighten two nuts on the hairpin and clamp the grip of the device between them, then the chance of getting the device on the forehead will be minimal.
In order to save money, the owners often repair the VAZ 2107 engine with their own hands. The motor of this model has some features. Before repairing without a service station, you must familiarize yourself with the causes and methods of troubleshooting the VAZ 2107 engine.
Photo of the VAZ 2107 engine.
The VAZ 2107 "Classic" is equipped with a four-stroke inline engine with four cylinders. The engine, depending on the modification, can be made with a central mixing injection system (carburetor) or with a distributed injection system (injector). Depending on the modification, it can also develop from 68 to 74 horsepower.
Car engine maintenance must be carried out in accordance with the manufacturer's instructions, taking into account the operating conditions.
Lada 2107 is a rear wheel drive car. The connection of the engine with the variable gearbox is made in the longitudinal version. This design can make it difficult to completely dismantle the motor. Almost all of the interior engine compartment is used to house the engine, air filter and auxiliary systems. It also makes repairs difficult.
Dedicated car-tool.
The need to repair the motor can be caused by a number of reasons:
terms of Use;
planned wear of parts;
engine diagnostics;
unplanned breakdowns;
accidents and others.
The car was produced for about forty years. Due to the obsolescence of the design, there may be incompatibilities with a number of tools. In addition, full engine overhauls are carried out exclusively in private repair shops.
This increases the cost of the work so much that it may be easier to buy a new motor. If the breakdown is small and can be eliminated without complicated procedures, or it is possible to carry out partial overhaul, it is better to do everything yourself
The first thing you should pay attention to when there is a need for engine repair is the condition of the oil in the crankcase (color, turbidity and level). Engine oil in the engine lubrication system is the main indicator of the condition of the joints of engine parts.
Cloudy engine oil.
Clouding of the oil indicates the presence of running-in parts, blackening - about possible overheating or breakthrough of the flame from the combustion chamber into the crankcase. A drop in level may indicate leaks or frictional depletion in overtightened mates.
Checking the oil level is carried out on a cold engine when the vehicle is installed on a flat horizontal surface.
It is also necessary to check the level of antifreeze in the expansion tank. If the level drops, it could indicate overheating or a leak in the cooling system. If the level rises, then we can talk about problems with the thermostat - a device that, depending on the temperature of the coolant, regulates the speed of its movement in the cooling system.
Other malfunctions of the VAZ 2107 engine and their characteristic manifestations can be found in special literature, engine repair instructions.
Before proceeding with the overhaul of the VAZ 2107 engine, it is strongly recommended that you familiarize yourself with the special literature in order to better understand the procedures performed.
Upon completion of the repair, the car must be run-in to run-in all parts. Usually the break-in takes place in the first 5,000 kilometers.
Engine prepared for overhaul.
Before the actual disassembly, the oil must be drained from the engine. To do this, warm up the motor to approximately operating temperature and turn it off. If there is a ditch, then the car is driven onto it.
If it is not possible to enter the ditch, it is necessary to place the car on a flat surface.
Place a 10-liter container made of heat-resistant material under the oil drain hole. Unscrew the plug and drain the oil.
Then drain the antifreeze from the cooling system through the drain hole at the bottom of the engine cooling radiator.
IMPORTANT! The oil can reach temperatures of about 100 degrees. If you try to start the car when the oil and antifreeze are drained, the engine will completely fail.
When all working fluids are drained, unscrew all supports and disconnect the flywheel-to-transmission bolted connections. Using a winch, remove the motor from the bonnet and place it on a stand for repair.
Dismantling the engine does not require a special approach: simple unscrewing of the threaded connections.
Photo of the removed cylinder head.
Everything is removed: the cylinder head, electrical components, including the starter and generator, connecting rods, crankshaft, oil pump and so on. As a result, a separately disassembled cylinder block and a crankshaft should remain. Removing the head and all elements is a simple procedure.
It will be difficult when assembling gas distribution and other engine mechanisms, which require precise matching of the position of the working parts. Installing the head will require compliance with timing marks and other mechanisms.
The removed cylinder head and crankshaft together with the purchased pistons are taken to the grinding specialist. The specialist makes all measurements, including all sizes of the crankshaft, for the subsequent boring of the engine. Boring is necessary to compensate for wear on non-replaceable parts.The specialist grinds to the dimensions of the already purchased pistons.
First of all, worn out plain bearings for the crankshaft bearings, piston rings (compression and oil scraper) need to be replaced. We need gaskets (under the block head and others) and oil seals - installing old ones with new working dimensions can lead to the formation of gaps through which oil and antifreeze will leak.
Consumables required for overhaul.
You also need to purchase rollers and a belt for a belt drive. If the drive is chain, you need to check the chain.
The temperature and pressure sensors in the lubrication system need to be replaced.
We need filters (air, oil filter and others), new oil and antifreeze.
The list of what is needed to repair an engine on a VAZ 2107 also includes all consumables and fasteners. For example, sealant or retaining rings. The need for them arises in the course of the repair and cannot be predetermined.
The cylinder head is a critical part of the engine. It contains the timing elements: valves, camshaft, drive gears and others. All parts must be free of visible defects, no noticeable wear, and also not hang out in the guides. In the case of the first repair (overhaul or planned after overhaul), replacement of the camshaft may not be necessary.
Before assembly, you need to make sure that the oil channels are clean, since one of the types of engine lubrication starts precisely from the head.
In addition, even the slightest blockage in the passages will melt the bearing shells, gaskets and other heat-sensitive parts.
Disassembled car engine.
The process of assembling an engine on a VAZ 2107 begins with the installation of a lubricated crankshaft on the supports. Care must be taken not to twist the liners. The accuracy is checked by the coincidence of their locks. The axial displacement is compensated for by half rings. As a result, the backlash should be barely felt by the hands.
After installation, the yokes are tightened. Each twisted yoke must be alternated with checking the smoothness of the crankshaft in the bearings.
The next step is to install the pistons in an assembly with rings (compression and oil scraper) and connecting rods. To do this, you need a mandrel, with which the rings are compressed before the piston is seated in the cylinder. After that, the connecting rod journal is aligned with the journal on the crankshaft. The yokes are twisted.
Next is the turn of the installation of the elements of the lubrication system and oil seals. They are pre-lubricated.
Many motorists, especially beginners, do not quite clearly understand what the repair of a VAZ 2107 engine, or any internal combustion engine, for example, a VAZ 21213, which is called "overhaul", or overhaul, is. Let us explain this using a simple “life situation”.
Your car is not new. You drove it, it "ate" an abundance of oil and gasoline, the engine had poor thrust and was noisy. Your car could not climb a long, steep hill in 4th gear. You had to switch to the third one, all the road users following you first signaled you, then overtook you.
And somehow you decided to “save money” on the purchase of engine oil. The path is not short, and the oil decreases very noticeably. You bought cheap oil from the market, put it in the engine and forgot. But on the way I had to skid. The engine began to overheat, it is evening time, the place is wild. You have a "classic", not a VAZ 21213. There is no distribution box. You jerked off the gas pedal, and at first speed, finally, left. On the way to the house, the knocking intensified, the oil pressure lamp began to burn constantly, I had to go on "suction", and when entering the garage, the car completely stalled.
In the workshop, it was found that:
the camshafts are scarred and chipped, with coarse burrs.
The splines on the shaft of the oil pump are cut off almost completely, while the entire crankcase and filter of the oil pump is clogged with shavings and metal debris.
The following happened: during the forced operation of a hot engine, the engine oil lost its lubricating properties, and intensively rubbing parts instead of lubrication were worn off, and at the end the engine even "jammed".
Significant funds were spent on repairs. The following was done:
replaced the cylinder head,
the chain is tightened,
new oil pump delivered,
completely changed oil with engine flushing,
replaced the oil filter,
many gaskets had to be changed,
the ignition moment was re-set, at the same time new high-voltage ignition wires were purchased (the wire from the coil was supplied from the VAZ 21213);
new candles were installed;
replaced the generator relay;
timing chain tightened, tensioner and damper adjusted.
Should we consider that a major overhaul has been carried out?
The answer is no. Just as the machine before “ate bad oil a lot and well,” so it will consume good oil on an increased scale. Just as she did not ride up the hill before the accident, so she also drives badly after repairs.
Overhaul of a car engine is the repair that is carried out due to the loss of thrust and engine power - namely, a decrease in torque,
What are the ways to identify the loss of power? Simple ways are as follows:
Excessive consumption of oil and gasoline;
Decrease in acceleration dynamics with a well-adjusted carburetor, this applies to all "classics" and to the VAZ 21213;
The appearance of black smoke and soot in the exhaust, traces of oily soot at the end of the exhaust pipe.
What can simulate the need for a major overhaul?
In the event that the gasket slightly does not correspond to the dimensions of the cylinder, for example, a gasket from the VAZ 21213 is supplied. Sometimes it happens that a similar picture develops if the cylinder head gasket is broken. In this case, there may be a decrease in power output and compression. It may give the impression that a major overhaul is needed;
Sometimes the head bolts are not tightened correctly after opening, as a result of which a skew is created;
In the event that the gasket slightly does not correspond to the dimensions of the cylinder, for example, a gasket is supplied from the VAZ 21213.
Loss of power is a consequence of incomplete adherence of the pistons to the cylinder walls, or a decrease in compression. It is the reduction in compression, wear of the piston rings and an increase in the diameters of the working volumes of the cylinders that require major overhaul.
Good compression is especially important in small gears when the engine is delivering high power. This allows, for example, VAZ 21213 to overcome off-road.
Remember: the main thing in an overhaul of the engine is the repair of the cylinder block.
The stages of cylinder block repair are as follows:
Troubleshooting - or measuring the compression number in each cylinder;
Disassembly of the block and careful measurement of planes and dimensions;
Boring a block for new dimensions, and honing surfaces - or changing the geometry of cylinders;
Checking dimensions, machining planes, grinding and honing the crankshaft (main and brass journals) - in this and the previous paragraphs, the overhaul consists in its essence;
Balancing the crankshaft with the flywheel and clutch basket;
Selection of new piston rings for new sizes;
Assembly, performance testing and measurement of compression after repair.
For those who decided to make a major overhaul on their own, so that only spare parts are bought (since they will take more than tens of thousands of rubles for just one job in a car service), we will briefly describe only the disassembly and the process of removing the cylinder block (the approach is almost the same for the VAZ 2107 and VAZ 21213):
Only now, when the garage has become like a spare parts warehouse, can you unscrew the crankshaft pulley mount, clutch housing screws, large nuts (2) from the engine mountings, and, with the help of a partner, hang it on a beam, gently lift it above the engine compartment and remove the engine.
After that, the clutch is removed, the oil filter, the flywheel, the timing chain, the crankshaft star are also removed, and only after that you can begin to assess the condition of the crankshaft, its necks, liners, and also start working with the cylinder block, evaluating the future overhaul.
In the event that you are not afraid even of the preparatory volume of work, then we can safely recommend that you carry out an overhaul of the engine with your own hands.
In addition, you should find a service station where they will bore the cylinder block, grind the crankshaft, perform press fitting and other operations.
Thus, without serious auto repair shops equipped with machine tools, it is still impossible to carry out a major overhaul with your own hands alone.