Disassembly and assembly of the VAZ 2108 / VAZ 2109 / VAZ 21099 engine

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Engine disassembly

Place the washed and cleaned engine on a disassembly stand and drain the oil from the crankcase. Disassemble in the following order.

Rice. 2.11. Removing the carburetor: 1 – fuel supply hose; 2 – hose of the engine crankcase ventilation system; 3 – carburetor; 4 – coolant supply hose; 5 – spacer; 6 – heat insulating screen; 7 – coolant drain hose; 8 – vacuum selection hose to the vacuum regulator

Remove hose 1 () going from the fuel pump to the carburetor, and hose 2 of the crankcase ventilation system; remove hoses 4 and 7 for supplying and draining fluid from the cooling system to the carburetor and hose 8 for the vacuum regulator of the ignition sensor-distributor.

Remove carburetor 3 with spacer 5 and heat-insulating screen 6.

Rice. 2.12. Removing the fuel pump and ignition distributor: 1 – ignition distributor; 2 – bracket for fastening high-voltage wires; 3, 5 – sealing rings; 4 – housing of auxiliary units; 6 – heat-insulating spacer; 7 – pusher; 8 – fuel pump

Remove the high voltage wires and ignition distribution sensor 1 () with o-ring 3 and bracket 2. Remove the fuel pump 8 with heat-insulating spacer 6, pusher 7 and gaskets. Remove the housing 4 of the auxiliary units with the sealing ring 5.

Rice. 2.13. Removing the generator: 1 – tension bar; 2 – generator; 3 – generator mounting bracket; 4 – generator drive belt; 5 – generator drive pulley

Rice. 2.20. Flywheel locking with clamp 67.7820.9526

Remove the tension bar 1 () and the generator drive belt 4. Remove the generator and its mounting bracket 3. Lock the flywheel with clamp 67.7820.9526 (see), unscrew the bolt securing pulley 5 (see) of the generator drive and remove the pulley.

Rice. 2.14. Removing the camshaft drive: 1 – front protective cover; 2 – rubber seal; 3 – toothed belt; 4 – camshaft pulley; 5 – spacer ring; 6 – tension roller;

7 – tension roller axis; 8 – crankshaft toothed pulley

Remove the front cover 1 () of the timing belt. Unscrew the nut securing the tension mechanism. Loosen and remove the timing belt. Remove the tension roller 6 with the axis 7 and the spacer ring 5. Lock the camshaft pulley 4, unscrew the bolt securing it and remove the pulley. Remove toothed pulley 8 from the crankshaft.

Rice. 2.15. Removing the coolant pump: 1 – rear protective cover of the toothed belt; 2 – coolant pump; 3 – gasket

Unscrew the bolts securing the coolant pump 2 (). Unscrew the bolt and nut securing the rear cover 1 of the toothed belt and remove it. Remove the coolant pump with gasket 3 from the socket in the cylinder block.

Rice. 2.16. Removing the intake pipe and exhaust manifold: 1 – oil pressure warning lamp sensor; 2 – inlet pipe; 3 – warm air intake; 4 – bracket for the supply pipe of the coolant pump; 5 – exhaust manifold; 6 – gasket

Remove the intake pipe 2 () and the exhaust manifold 5 with gaskets 6, warm air intake 3 and bracket 4. Unscrew the oil pressure warning lamp sensor 1 from the cylinder head.

Rice. 2.17. Removing cooling system components: 1 – coolant temperature indicator sensor; 2 – outlet pipe of the cooling jacket; 3 – hose for supplying fluid from the heater; 4 – fluid drainage hose to the heater; 5 – supply pipe of the coolant pump; 6 – thermostat

Remove hoses 3 and 4 () for supplying and discharging coolant to the heater. Disconnect the hoses from thermostat 6 and remove it. Remove inlet pipe 5 of the coolant pump and outlet pipe 2 with gasket.

Using wrench 67.7812.9514, unscrew sensor 1 of the coolant temperature indicator and the spark plug.

Rice. 2.18. Removing the oil filter using tool A.60312

Using tool A.60312 (), remove the oil filter with gasket. Disconnect the crankcase exhaust ventilation hose from the pipes on the cylinder head cover and on the cylinder block. Remove the oil level indicator.

Remove the cylinder head cover. Unscrew the cylinder head bolts and remove it complete with the camshaft. If necessary, disassemble the cylinder head as indicated in the “Cylinder Head” subsection.

Rice. 2.19. Removing the oil pump: 1 – oil pump; 2 – oil pump gasket; 3 – oil pump receiver; 4 – crankcase gasket; 5 – crankcase

Turn the engine over with the crankcase up and remove the oil sump 5 () with gasket 4. Remove the receiver 3 and the oil pump 1.

Unscrew the nuts of the connecting rod bolts, remove the connecting rod caps and carefully remove the pistons with connecting rods through the cylinders.

Lock the flywheel with clamp 67.7820.9526 (), unscrew the flywheel mounting bolts, remove the bolt washer and the flywheel from the crankshaft. Remove the crankshaft rear oil seal holder with gasket.

NOTE
If complete disassembly of the engine is not required, you can remove the cylinder head complete with pipelines and auxiliary units.

Remove the main bearing caps along with the lower bearings. Remove the crankshaft from the bearing housings, and then the upper bearings and thrust half-rings from the middle support.

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Signs of piston wear

On average, a piston replacement on a VAZ 2109 is required every 150,000 km

The car owner should pay attention to warning signs that indicate the need to change the rings

  1. The car began to require more fuel.
  2. Compression measurements showed a value of less than 10 atmospheres.
  3. There is less engine oil.
  4. Replacing oil seals does not help eliminate oil leaks.

The VAZ 2109 piston group is a set consisting of a piston, piston rings mounted on it, a piston pin and its fasteners. There are three grooves on the surface of the piston for rings.

The oil scraper is responsible for removing excess oil from the cylinder walls, thereby reducing fuel consumption. Only a film a few microns thick is left inside the cylinder liner to lower the piston. Well, the pin, which is inserted transversely inside the piston cavity, attaches the connecting rod to the piston.

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How to determine a motor malfunction

The engine of a VAZ 2109 car, together with the gearbox and clutch, constitute a power unit, which makes up a single unit located on three rubber-metal elastic supports fixed in the engine compartment. Some faults can be diagnosed independently:

  • Increased clearances in the assembly, very early ignition or insufficient oil pressure are indicated by a metallic, dull sound of the crankshaft main bearings.
  • A large gap in the bearings or insufficient oil pressure can be indicated by a sharp knock in the connecting rod bearings.
  • Replacement of pistons or piston rings will be necessary when the piston knocks, which is caused by its beating in the cylinder.
  • A broken valve spring or mismatched clearances can be characterized by a uniform, constant knocking sound in the valves. To identify worn elements, you need to perform a visual inspection of the unit.
  • The ingress of foreign particles under the oil pressure valve and failure of the oil pump can be determined by insufficient oil pressure at idle when the engine is warm. When using low-quality motor oil, such problems may also arise.
  • Excessive pressure in the oil lubrication system indicates that the pressure relief valve is stuck or its spring is too stiff. After replacing the appropriate elements, this problem is eliminated.
  • An increase in oil consumption can be caused by increased wear of piston rings, engine seals, valve stems, guide bushings, and oil seals.

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