Note: The shafts and the housing are marked (DR, DN).
2. Align the marks and install the driving and driven gears of the balance shafts.
3. Install the rear cover (B) of the balance shaft housing. Tightening torque of the mounting bolts is 8-12 Nm.
4. Install the gear plate (A). Tightening torque of the mounting bolts is 8-12 Nm.
5. Align the timing marks. Install the balance shaft drive gear (A) and the idler gear (B).
- Tightening torque of mounting bolts A: 39-43 Nm, B: 60-64 Nm.
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6. Install the front cover (A) of the balance shaft housing.
- Tightening torque of mounting bolts 8-12 Nm.
7. Install the compression rings.
8. Install the piston and connecting rod with the marks towards the drive belt.
9. Install the piston into the cylinder using a ring compressor.
10. Apply engine oil to the mounting bolts, then install the connecting rod caps.
11. Install the oil injectors and tighten the mounting bolts to a tightening torque of 9-13 Nm.
12. Apply engine oil to the main bearing shells.
13. Install the half rings into the middle main bearing.
14. Install the crankshaft into the cylinder block so that the second and third connecting rod journals are facing upward.
15. Apply engine oil and install the half rings into the middle main bearing.
16. Apply sealant (LOCTITE 5205, DREIBOND 5105 or HYLOMAR 3000) to the mating surface with the block and install the ladder frame. Tightening torque of the mounting bolts is 28-32 Nm + 120° (15 mm), 33.7-37.7 Nm (12 mm).
17. Turn the crankshaft clockwise.
18. Using a calibrated plastic strip, measure the clearance in the crankshaft main bearings.
19. Install the piston pin connecting rod.
20. Install the crankshaft gear. The tightening torque of the mounting bolt is 185-195 Nm.
Note: Align the alignment marks.
21. Install the oil receiver (A) on the oil pump housing (B). Tightening torque of the mounting bolts: bolt A 10-12 Nm, bolt B 34-38 Nm.
Note: The bolts must be tightened first.
22. Apply sealant to the mating surface of the crankcase with the cylinder block. Tighten the crankcase mounting bolts in three passes with a tightening torque of 10-12 Nm.
23. Install the water pump.
24. Install the automatic tensioner of the camshaft drive toothed belt. The tightening torque of the locking bolt is 10-12 Nm.
25. Install the air conditioning compressor (A).
26. Install the cooling system pipes, the hydraulic booster pump, connect the crankshaft position sensor and the oil pressure sensor. Then install the cylinder head assembly.
27. Install the feeler gauge and timing belt.