Disassembly
1. Remove the toothed belt pulleys, front cover, flywheel, flywheel rim and oil pan.
2. Remove the rear plate and rear oil seal.
3. Remove the connecting rod caps.
- Rated value: The outer diameter of the crankshaft main journal is 56.995 mm.
Note. Mark the crankshaft main bearing caps, this will allow them to be installed in their places in the correct position.
4. Remove the main bearing caps and crankshaft.
Examination
Crankshaft
1. Check the main and connecting rod journals of the crankshaft for damage, uneven wear, cracks. Check if it's clogged lubrication holes. Correct or replace any defective parts.
2. Check the out-of-roundness and taper of the main and connecting rod journals of the crankshaft.
Rated value:
- The outer diameter of the crankshaft journal is 56.995 mm
- The outer diameter of the connecting rod journal of the crankshaft is 44.980-44.995 mm
Main and connecting rod bearings
Visually inspect each bushing for peeling, melted areas, nicks, and bad contacts. Replace defective earbuds.
Oil clearance measurement
Check the oil clearance by measuring the outside diameter of the crankshaft journals and connecting rod journals and the inside diameter of the bearings. The gap is obtained by calculating the difference between the measured outer and inner diameters.
Rated value:
Oil clearance:
- Indigenous liners of a cranked shaft — 0,02-0,05 mm
- Connecting rod bearings - 0.02-0.05 mm
Plastic template method
A plastic template can be used to measure the gap.
1. Remove oil, grease and dirt from bearings and crankshaft journals.
2. Cut a piece of plastic template equal to the width of the liner and place it along the axis of the neck away from the oil holes.
3. Install the crankshaft, liners and bearing caps and tighten them to the required torque. Do not rotate the crankshaft while performing this operation.
Remove bearing caps. Using the scale printed on the plastic template package, measure the thickness of the plastic template at its widest point.
If the gap exceeds the repair tolerance, the liner must be replaced or a smaller liner must be used.
When installing a new crankshaft, use liners of nominal size. If you cannot obtain the nominal clearance even after replacing the bearings, grind the main journals and crankpins to a smaller size and install bearings of the appropriate size.
Oil seals
Check the front and rear bearings for damage and lip wear. Replace defective seal.
Adapter plate
Replace a deformed, damaged or cracked adapter plate.
Installation
Main bearings
1. Install the main bearing with a groove in the bed of the cylinder block.
2. Install main bearing without groove.
3. The top and bottom center bearing shells are not grooved.
4. Install the crankshaft. Apply engine oil to his necks.
5. The covers should be installed with the arrow pointing towards the front of the engine. The cap numbers must match the cylinder numbers.
6. Torque tighten the cap bolts in the following sequence: center, #1, #2, front, and rear.
- Tightening torque: Main bearing cap bolts - 50-55 Nm
7. Before tightening to the required torque, the cover bolts should be tightened evenly in 4-5 steps.
8. Make sure the crankshaft rotates easily and has adequate end play.
9. Using a special tool (09231-32000), install the oil seal in its housing.
10. Install the oil separator in the body with the 4 mm oil hole facing down (to the oil sump mounting surface).
11. Install a new packing box gasket and packing box.
12. Attach the rear plate to the cylinder block.
13. Install the flywheel and tighten the bolts to the required torque.
Check the clutch mounting surface for wear.
- Wear - Max. 0.1 mm
- Tightening torques Flywheel bolts - 130-140 Nm
14. When using an automatic transmission, install the adapter and drive plates and tighten the bolts to the required torque.
- Tightening torque: Drive plate mounting bolts - 130-140 Nm.