Removal
1. Remove the timing belt, cylinder head and drive plate, gearbox mounting plate, oil pan.
2. Remove the oil seal housing and rear oil seal.
3. Remove the lower connecting rod head caps.
Note: Mark the main bearing caps so that they can be installed in the correct direction later.
4. Remove the main bearing caps and crankshaft. Arrange the liners according to the bearing cap numbers.
Examination
Crankshaft
1. Check the crankshaft main and connecting rod journals for damage, uneven wear, and cracks. Also check the cleanliness of the lubrication holes. Repair or replace any defective parts.
2. Check the main and connecting rod journals for out-of-roundness and taper.
Nominal values:
- Crankshaft journal diameter - 59.980-60.000 mm
- Crankshaft journal diameter - 49.980-50.000 mm
Main and connecting rod bearing shells
Visually inspect each bearing for delamination, melted areas, scoring, and improper contact. Replace defective bearings.
Measuring oil clearances
Check the oil clearance by measuring the crankshaft journal diameter and the bearing inner diameter. The clearance is obtained by calculating the difference between the measured diameters.
Nominal value:
- Oil clearance
- Crankshaft main bearings - 0.02-0.048 mm
- Connecting rod lower head liners - 0.02-0.046 mm
Method of using a plastic template
A plastic template can be used to measure gaps.
1. Remove oil, grease and dirt from the bearings and crankshaft journals.
2. Cut a piece of plastic template to a length equal to the width of the bearing shell and place it along the axis of the crankshaft journal away from the lubrication holes.
3. Install the crankshaft, bearing shells and caps and tighten them to the specified torque. Do not rotate the crankshaft during this operation. Remove the bearing caps. Using the scale printed on the template packaging, measure the thickness of the plastic template at its widest point.
If the clearance exceeds the permissible limit, the bearings should be replaced or smaller size repair bearings should be used. When installing a new crankshaft, use bearings of the nominal size.
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If even when replacing the liners it is not possible to obtain the nominal clearance value, the liners of the corresponding repair size should be ground.
Seal
Check the front and rear oil seals for damage and wear on the working edge. Replace any defective oil seals.
Drive plate
Replace a warped, damaged or cracked drive plate.
Installation
Main bearings
1. Install the main bearing with the groove into the cylinder block bed.
2. Install the main bearing shell without a groove into the main bearing cap bed.
3. Install the crankshaft. Apply engine oil to the main and connecting rod journals.
4. Bearing caps should be installed with the arrows pointing towards the front of the engine. Make sure the caps are positioned correctly according to their numbers.
5. Tighten the bearing cap bolts to the specified torque.
- Tightening torque: Main bearing cap bolts - 75-85 Nm.
7. The cover bolts should be tightened evenly in 4 or 5 steps until the required tightening torque is achieved.
8. Make sure that the crankshaft rotates easily and has normal axial clearance.
Crankshaft axial clearance:
- Nominal - 0.05-0.25 mm
- Limit - 0.3 mm
9. Using a special device (09321—33000), install the rear oil seal into its housing.
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10. Apply sealing material to the surfaces shown in the figure. Install the oil seal assembly to the cylinder block.
- Tightening torque: Oil seal housing bolts - 10-12 Nm.
11. Tighten the gearbox mounting plate to the specified torque.
- Tightening torque: Gearbox mounting plate bolts - 10-12 Nm.
12. Tighten the drive and adapter plate mounting bolts.
- Tightening torque: Drive and adapter plate bolts - 73-77 Nm.
