Note:
- 1. Thoroughly clean all parts before assembly.
- 2. Immediately before assembly, apply fresh engine oil in a thin layer to all friction surfaces.
- 3. When assembling, replace all gaskets, o-rings and seals with new ones.
1. Connect piston and connecting rod. Using a hydraulic press, press in the connecting rod pin, while the marks on the piston (A) and on the rod (IN) must be on one side, and when installed directed towards the front of the engine (side with drive belts).
2. Install discs and oil scraper ring expander. Using a piston ring expander, install the lower and upper compression rings with the alignment mark up. Separate the compression ring locks as far apart as possible, making sure that they are not in the same plane as the locks of the oil scraper ring discs and the piston pin.
3. Install the connecting rod bearings so that the tabs on the bearings fit into the corresponding grooves in the connecting rod cap and connecting rod.
4. Install the bearing shells of the main bearings.
Note. The upper bearing shells of the main bearings No. 1, 2, 3, 4 have an oil groove and hole, the lower shells do not.
Align the tabs on the upper bearing shells (A) with recesses in the sockets of the cylinder block and insert the liners with light pressure.
Align the tabs in the lower bearing shells (A) with recesses in the sockets of the covers of the main bearings (IN) and insert the inserts with a slight pressure.
5. Install two thrust bearings (A) on the sides of the main bearing No. 3 of the cylinder block with oil grooves outward.
6. Insert crankshaft (A) into the cylinder block.
7. Install the bearing caps of the main bearings in their place in the cylinder block.
8. Apply a thin coat of engine oil to the threads of the main bearing cap bolts, and tighten in two steps:
Stage I - tighten the bolts of the bearing caps of the main bearings in a certain order to a torque of 30 Nm.
Stage II - tighten the bolts by 60°-65°.
Note. If the threaded part of the bolts is damaged or the bolts themselves are deformed, replace them with new ones.
9. Check the ease of rotation of the crankshaft.
10. Check the axial clearance of the crankshaft.
Note. Before installing the pistons with connecting rods in the cylinders, apply engine oil to the cylinder bore and to the piston rings.
11. Remove the connecting rod caps and put pieces of rubber hose on the threaded part of the connecting rod bolts.
12. Install a piston ring compressor on the piston and, making sure that the connecting rod bearing is installed correctly, push the piston with the connecting rod into the cylinder using a wooden hammer handle.
Note. When moving the piston into the cylinder, support the piston ring compression tool so that the piston rings do not open prematurely.
13. After the piston rings are in the cylinder, make sure. that the connecting rod hit the crankshaft journal.
14. Remove the hose sections from the threaded part of the connecting rod bolts and lubricate the bolts with engine oil. Install the connecting rod caps with bearing shells and tighten the bolts to a torque of 50-53 Nm.
15. Apply sealant to the stuffing box (A) and install it on the cylinder block. Tighten the mounting bolts (IN) torque 10-12 Nm.
Note. Use sealant M724-40A or similar. Make sure the surface is clean and dry before applying the sealant.
16. Apply a small amount of engine oil to the rear oil seal seat. Using a special tool (09231 - 21000) and a hammer, press in a new oil seal.
17. Install the front housing.
18. Install the oil pickup (A) with new gasket (IN) and tighten the bolts (WITH) torque 15-22 Nm.
19. Apply MS 721-40A sealant or similar to the clean and dry crankcase joint surface.
Note: To prevent oil leakage, apply sealant to the threaded holes before tightening the bolts. Tighten the bolts no later than 5 minutes after applying the sealant, otherwise remove the sealant from the holes and apply fresh sealant again. After assembling the engine, wait at least 30 minutes before adding engine oil to the engine.
20. Install crankcase (A) on the engine and tighten the mounting bolts to a torque of 10-12.
21. Install water pump.
22. Apply THREE BOND TV2403 or similar sealant to the threaded part of the oil pressure sensor (A) and tighten the sensor to a torque of 15-22 Nm.
23.Install knock sensors (A). Tightening torque for knock sensors: 17-26 Nm.
24. Install a new O-ring on the dipstick. Apply engine oil to the O-ring and screw in the dipstick (A) into the cylinder block.
25. Install the cylinder head.
26. Install drive belts.
27. Install flange (vehicles with automatic transmission). The tightening torques for the flange bolts are 120-130 Nm.
28. Install flywheel (vehicles with manual transmission).