Note:
- Wash all parts before assembly.
- Before installing parts, apply a thin layer of engine oil to all friction surfaces.
- Replace all gaskets, o-rings and seals.
1. Assemble the piston with the connecting rod:
Before pressing the piston pin, the pin and connecting rod surfaces must be lubricated.
Attention. Be careful not to damage the piston pin when pressing.
Using a hydraulic press, press the piston pin into the piston.
Make sure that the piston and connecting rod alignment marks are directed towards the timing chain.
2. Install piston rings:
Install the oil scraper ring and spring by hand.
Using the special tool, install the two compression rings so that their ends are positioned as shown in the figure (ring #1 should be on the opposite side of ring #2, and the oil scraper ring should be on the opposite side of the spring.)
3. Install the connecting rod bearing shells:
Align the protrusion on the earmold (A) with a selection on the connecting rod and connecting rod cap (IN).
Install the connecting rod bearings and connecting rod cap as shown.
After installing the bearings, apply a coat of engine oil.
4. Install the crankshaft main bearing shells:
Note: The upper main bearing shells installed in the cylinder block have recesses for supplying engine oil, the lower ones do not have recesses.
Align the tabs on the bearings with the recesses on the cylinder block. Install the bearings in the five bearings of the crankshaft (A), as it shown on the picture.
Align the tabs on the bushings with the recesses on the main bearing caps. Install the earbuds.
After installing the main bearings, apply a coat of engine oil.
5. Install the thrust bearings on the fourth leg. Install 2 thrust bearings (IN) on both sides of the No. 4 journal in the cylinder block to allow the oil groove (A) was outside.
6. Install the oil nozzle (A).
Note: Tightening torque: 8.8-12.7 Nm.
7. Install the crankshaft in the cylinder block.
8. Install covers (IN) main bearings and tighten the cap bolts.
Note:
- The bearing cover bolts must not be reused.
- Make sure the main bearing caps are installed in the correct order.
- The main bearing cap must be installed with the arrow pointing towards the front of the engine.
- First tighten all main bearing cap bolts to the specified torque, then tighten all bolts to the specified angle.
Apply a light coat of engine oil to the threaded portion of the boots.
Tighten all bolts to the specified torque in numerical order.
Tighten all bolts to the specified angle in numerical order.
Note: Tightening torque: 49.0 Nm + turn 120°.
Make sure the crankshaft turns smoothly.
9. Check up an axial backlash of a cranked shaft.
10. Install pistons with connecting rods:
Note: Before installing the pistons in the cylinders, apply a light coat of engine oil to the grooves under the rings and cylinder bore.
Install the piston ring compression tool. Then install the piston in the cylinder and, applying light blows with the wooden handle of the hammer, insert it into the cylinder,
Stop installation when the spring compressor is released. Check the correct installation of the connecting rod relative to the crankshaft.
Install the connecting rod caps and tighten the mounting bolts.
Note: Tightening torque: 27.5-31.4 Nm + tighten 88-92°.
Note:
- The connecting rod cap bolts must not be reused.
- Continue applying downward force to the piston ring compressor to prevent the rings from expanding before entering the cylinder.
11. Check up an axial backlash between the piston and a rod.
12. Install the ladder frame (A).
Note: Tightening torque: 19.6-26.5 Nm.
13. Install the oil pump module.
14. Install the new rear oil seal housing assembly and encoder:
Install the special tool on the crankshaft (09231-1M200, 09231-H110) (A).
Press the rear oil seal housing by hand (IN), then tighten the bolts.
Note. Tightening torque: 9.8-11.8 Nm
Install encoder (A).
Attention
- Apply a coat of engine oil to the seal before installing the rear oil seal housing assembly.
- Be careful not to damage or kink the seal.
- Remove harmful materials from the crankshaft flange and use a special tool to prevent seal damage and kinking.
- Fully insert the dust cover into the hole in the cylinder block and complete the assembly with the sensor wire.
- The rear seal housing must not be reused.
- When working with the special tool, avoid contact with foreign substances.
- When installing the rear oil seal housing, do not hold it by the lip.
15. Install flywheel (vehicles with manual transmission).
Note: Tightening torque: 117.7 - 127.5 Nm.
16. Install the drive (IN) and intermediate plate (A) (vehicles with automatic transmission).
Note: Tightening torque: 117.7-127.5 Nm
17. Install the coolant pump.
18. Install the high pressure fuel pump.
19. Install the cylinder head.
20. Install the timing chain.
21. Install the intake and exhaust manifolds.
22. Remove the engine from the stand.
23. Establish the engine in gathering with a transmission.