Withdrawal
1. Remove the toothed belt, cylinder head 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.
4. Turn out bolts and remove covers of radical bearings of a cranked shaft.
5. Remove a gear rotor of the gauge of an angle of rotation of a cranked shaft.
Attention! Mark the crankshaft main bearing caps in order to install them in their places and in the same position.
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. In the presence of development or ovality, regrind the crankshaft. Regrinding the crankshaft journals only to the next repair size.
Diameter of crankshaft main journals, mm:
- 1.3L engine: 50
- 1.1L engine: 42
The diameter of the connecting rod journals of the crankshaft, mm:
- 1.3L engine: 45
- 1.1L engine: 38
Ovality and taper of the crankshaft journals: no more than 0.01 mm
Inserts of main and connecting rod bearings
Check the connecting rod and main bearings for localized corrosion, flaking, melting, wear, or other damage. If necessary, replace the liners.
Measuring the clearance between bearing shells and crankshaft journals
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.
Nominal clearance values on engines 1.3 l, mm:
- clearance between liners and main journals No. 1, 2.4, 5 of the crankshaft: 0.028–0.046
- gap between the liners and the main neck No. 3 of the crankshaft: 0.034–0.52
- clearance between the liners and connecting rod journals of the crankshaft: 0.024–0.042
Nominal clearance values on engines 1.1 l, mm:
- clearance between liners and main journals No. 1,2, 3, 4, 5 of the crankshaft: 0.020–0.038
- clearance between the liners and connecting rod journals of the crankshaft: 0.012–0.041
Measuring main and connecting rod bearing clearance using Plastigage plastic caliper
Checking the clearance between the liners and the crankshaft journals can be done using a plastic calibrated Plastigage 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.
Install the crankshaft onto the main bearing shells in the cylinder block. Install the remaining main bearing shells into the crankshaft main bearing caps. Position the lengths of the Plastigage plastic dipstick on the crankshaft main bearing journals.
3. In accordance with the markings, install the main bearing caps. In a certain sequence, tighten the crankshaft main bearing cap bolts. Do not rotate the engine crankshaft when measuring the crankshaft main bearing clearance. Turn out bolts and remove covers of radical bearings of a cranked shaft. Using a measuring gauge, measure the width of the deformed Plastigage plastic rod and determine the gap.
If the clearance exceeds the maximum allowable value, regrind the crankshaft journals and use oversized repair liners.
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.
Crank angle sensor rotor
1. Remove the crank angle sensor rotor.
2. Check the crankshaft angle sensor rotor for damage, cracks and wear.
3. Check the clearance between the crank angle sensor rotor and the crank angle sensor.
Gap between crank angle sensor rotor and crank angle sensor: 0.5–1.5 mm.
Note.
- 1. Measure the installation depth of the sensor, i.e. the distance from the top of the rotor teeth of the crank angle sensor to the surface of the cylinder block mating with the plane of the gearbox.
- 2. Calculate the difference between the length of the crank angle sensor and the distance obtained.
- 3. The length of the sensor is equal to the distance between the end of the sensor and the inner point of the contact surface.
Selection of main bearing shells
1. Check the crankshaft hole size code in the cylinder block.
Note.
- Write down the letter code for the size of the crankshaft hole in the cylinder block.
- The reading order is from left to right, with the first code corresponding to the size of the front hole in the cylinder block.
2. Check the crankshaft journal diameter size code.
1.3L engine
Note. Record the crankshaft journal size letter code located on the crankshaft counterweight.
The reading order is from left to right, with the first code corresponding to the size of the front crankshaft journal.
Engine 1.1L
Note. Write down the letter code for the size of the diameter of the crankshaft main journal, located on the places painted with paint in the places shown in the figure.
3. According to the table, select the thickness of the main bearing shells.
Installation
1. Install the upper main bearing shells to the engine block. When reinstalling the earbuds, install them in the same places they were before removal.
2. 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.
3. Install the remaining main bearing shells into the crankshaft main bearing caps. Install the crankshaft main bearing caps as marked with the arrow' on each cap pointing towards the crankshaft pulley. In a certain sequence, in 2 or 3 stages, tighten the crankshaft main bearing cap bolts in the following order: center, No. 2, No. 4, front and rear.
Torque:
Main bearing cap bolts:
- 1.3L engines: 55–60 Nm
- 1.1L engines: 50–55 Nm
Connecting rod cap bolts:
- 1.3L engines: 32–35 Nm
- 1.1L engines: 20–23 Nm
4. Turn the crankshaft and check that it rotates easily and smoothly. Using a feeler gauge inserted between the thrust shoulder of the central bearing and the crankshaft, check the end play of the crankshaft.
Axial play of the crankshaft:
- 1.3L engines: 0.05–0.175 mm
- 1.1L engines: 0.05–0.25 mm
5. Lubricate the outside of the new rear O-ring with engine oil. Using the special tool 09231–22000, install the O-ring until it stops in the rear cover slot.
6. Install rear o-ring cover, gasket and tighten bolts. At installation grease working edges and an external surface of a sealing ring with pure engine oil.
7. Install the back cover of the unit and tighten the bolts.
8. Install the connecting rod caps.
9. Install the flywheel, front cover, oil pan and toothed belt.