Withdrawal
1. Remove the toothed belt, front cover, flywheel, cylinder head and oil pan.
2. Remove the rear cover from the cylinder block and the crankshaft rear O-ring.
3. Turn away nuts and remove covers of rods.
Attention! Mark the crankshaft main bearing caps in order to install them in their places and in the same position.
4. Turn out bolts and remove a basic cover of radical bearings of a cranked shaft and a cranked shaft.
Examination
1. Check the crankshaft main and connecting rod bearing journals for wear and wear. Check crankshaft oil holes for blockage.
2. With a micrometer, measure the diameters of the crankshaft journals in two diametrically opposite directions. If there is a taper or ovality, regrind the crankshaft.
- Main journal diameter: 60.002-60.020 mm
- Connecting rod diameter: 50.008-50.026 mm
Connecting rod and main bearing shells
Check the connecting rod and main bearings for localized corrosion, wear, or other damage. If necessary, replace the liners.
Measuring the clearance of main and connecting rod bearings
To measure the clearance of the main and connecting rod bearings, measure the diameters of the crankshaft journals and the corresponding inner diameters of the bearings. The clearance value is the difference between the inner diameter of the bearing and the corresponding diameter of the crankshaft journal.
- Crankshaft main bearing clearance: 0.024–0.042 mm
- Crankshaft connecting rod bearing clearance: 0.024–0.042 mm
Plastigauge Method
The most accurate and convenient measurement of the clearance of main and connecting rod bearings using a plastic calibrated Plastigauge rod
1. Clean the main and connecting rod journals of the crankshaft from grease, and blow the lubrication holes with compressed air.
2. Establish loose leaves of radical bearings on the block of cylinders of the engine. Cut pieces of the plastic Plastigauge rod equal to the width of the bearings and place them along the axis on the crankshaft main bearing shells.
3. Install the crankshaft on the main bearing shells in the cylinder block. Install the main bearing shells and bearing cap as marked. Tighten the crankshaft main bearing cap bolts in sequence. Do not rotate the engine crankshaft when measuring the crankshaft main bearing clearance. Turn out bolts and remove a basic cover of radical bearings of a cranked shaft. Measure the width of the deformed Plastigauge with a measuring template and determine the gap.
Oil seal rings
Check the front and rear oil seals for damage or wear on the sealing lips. If there are any defects, replace the O-ring.
Bearing cover
After installing the bearing cap, turn the crankshaft to make sure it turns easily and smoothly and that its end play is within specification. Axial play of the crankshaft: 0.09 - 0.32 mm.
Drive plate
Replace deformed, damaged or cracked drive plate.
Flywheel
1. Check the condition of the surface of the flywheel in contact with the clutch disc. If there is significant wear, replace the flywheel.
2. Check the runout of the flywheel surface in contact with the clutch disc. Runout: 0.13 mm3.
3. Check the condition of the flywheel ring gear for damage and wear and replace if necessary.
Installation
1. Install the upper main bearing shells with oil supply grooves on the engine block. When reinstalling the earbuds, install them in the same places they were before removal.
2. Install the non-groove main bearing shells into the crankshaft main bearing cap.
3. Install the lower center main bearing without groove. Install the upper center grooved main bearing.
4. Before installing the crankshaft, apply a thin film of clean engine oil to all sliding surfaces. Install the crankshaft onto the main bearing shells in the cylinder block.
5. Install the base cover using Loctite 5205.
6. Torque tighten the base plate mounting bolts. Tightening torque: – 15 mm: 28–32 turn 120°– 12 mm: 33.7–37.7.
7. Tighten the bolts in 4 or 5 passes.
8. Turn the crankshaft and check that it rotates easily and smoothly. Install the dial gauge tip on the front end of the crankshaft. Move the crankshaft along the axis until it stops and set the dial gauge to zero. Move the crankshaft along the axis to the other side until it stops and read the values of the axial play on the indicator scale.
9. Lubricate the outer surface of the new O-ring with engine oil. Using the special tool 09231-21000, install the O-ring until it stops in the seat of the cover.
Vehicles with manual transmission
10. Install flywheel and bolt to specification. Tightening torque: 70–80 Nm.
Vehicles with automatic transmission
11. Install drive plate and bolt to specification. Tightening torque: 70–80 Nm.