The composition of the crank mechanism
1. Oil seal
2. Front crankcase cover
3. Gasket
4. Oil receiver
5. Drain plug
6. O-ring
7. Oil pan
8. Root cap
9. Main bearing
10. Crankshaft
11. Thrust bearing
12. Cylinder block
13. Rear oil seal housing
14. Flywheel
15. Torque converter drive plate
16. Washer
17. Back plate
The composition of the connecting rod and piston group
1. Piston rings
2. Piston
3. Piston pin
4. Connecting rod
5. Connecting rod bearing
6. Connecting rod bearing cap
Disassembly
1. Remove the flywheel (manual transmission) or torque converter drive plate (automatic transmission). Tightening torque: 117-127 Nm.
2. Install the motor workbench.
3. Remove the timing belt.
4. Remove the cylinder head.
5. Remove the dipstick tube to check the oil level (1). Tightening torque: 12-15Nm.
6. Remove the knock sensor (2). Tightening torque: 17-27 Nm.
7. Remove the oil pressure sensor (3). Tightening torque: 15-22 Nm.
Note: When installing, apply sealant MS 721-39 or TB 2310/2350 to 2-3 threads of the sensor.
8. Remove the coolant pump.
9. Remove the oil pan.
10. Remove 2 screws (4) and remove the oil receiver (5) with gasket (6). Tightening torque: 15-22 Nm.
11. Check up a backlash of a rod.
12. Check up a backlash in rod bearings.
13. Remove carbon deposits from the top of the cylinder. Push the piston assembly with connecting rod and connecting rod bearing upper shell through the top of the cylinder.
Note: Keep the connecting rod and connecting rod bearing cap together for proper reassembly.
14. Remove a forward cover of the block of cylinders.
15. Remove 5 screws (7) and remove the crankshaft rear oil seal housing (8).
16. Carefully remove the crankshaft (9) from the cylinder block.
Note: Keep the main bearing shells in the order in which they were removed.
17. Try moving the piston back and forth on the piston pin. If there is even a slight gap, replace the piston and piston pin.
18. Using a puller, remove both compression rings. Remove the discs and oil ring expander by hand
19. Using a press, press out the piston pin and remove the piston from the connecting rod.
Assembly
Note: Before reassembly, thoroughly wash all parts and apply clean engine oil to the running surfaces of the parts. Replace all gaskets, o-rings and seals.
20. Using a press, assemble the piston with the connecting rod. Make sure that the marks on the connecting rod and piston are facing the timing belt.
21. Manually install the oil ring expander and two discs. Using a suitable tool, install the compression rings with the marks up.
22. Arrange locks of piston rings in the specified way.
- 1. 1st compression ring
- 2. 2nd compression ring
- 3. The upper part of the oil scraper ring
- 4. The lower part of the oil scraper ring
23. Align the protrusion of the earbuds (10) with grooves in the connecting rod cap (11) and install the inserts.
24. Install the top bearings (12) crankshaft main bearings (however, do not install the center main bearing shell), by aligning the tabs on the bushings with the notches on the cylinder block.
Note: The upper main bearing shells are lubricated
25. Install the lower crankshaft main bearing shells by aligning the tabs on the shells with the notches on the covers.
26. Install the top liner (13) central main bearing No. 3.
27. Install the crankshaft in the cylinder block.
28. Install the main bearing caps.
29. Using a torque wrench, tighten the screws (14) caps of main bearings in the specified sequence in 2 stages. Tightening torque: 54-69 Nm.
Note: Apply clean engine oil to the threads and under the heads before installing the screws.
30. Check the ease of rotation of the crankshaft
31. Check up an axial run-up of a cranked shaft.
Note: Apply a light coat of engine oil to the piston rings and cylinder walls before installing the pistons.
32. Install the piston ring compressor, place it on the cylinder block and install the piston into the cylinder, lightly tapping with a wooden hammer handle. After the tool is released, check the alignment of the connecting rod with the crankshaft and fully push the piston into the cylinder.
33. Apply engine oil to the bolt threads and tighten the connecting rod cap nuts. Tightening torque: 32-34 Nm.
34. Check up an axial run-up of rods.
Note: Clean the surfaces of the rear oil seal housing and cylinder block. Before applying the sealant, remove all foreign particles from the surface.
35. Apply MS 721-40A or Loctite 5900 to the surface of the rear seal housing between the outer and inner edges. The sealant layer should be located on the inside of the screw holes.
Note: Install the stuffing box within 5 minutes of applying the sealant.
36. Install the stuffing box and tighten the 5 mounting screws. Tightening torque: 10-12 Nm.
Note: Before installing, apply engine oil to the lips of the oil seal.
37. Using a suitable mandrel, install the rear oil seal into the housing.
38. Further assembly is carried out in the reverse order.