2. Install the grease jets relief valve.
3. Install oil jets.
4. Install the main and thrust bearings.
(1) Remove dust, dirt and oil from the contact surfaces under the bearings in the cylinder block and main bearing caps.
(2) Install thrust bearings on both sides of housing No. 3 of the cylinder block.
Insert the thrust bearing into the cylinder block with the oil groove towards the crank arm.
(3) When installing the main bearings, pay attention to the direction.
Install main bearings with lubrication holes and a groove on the side of the cylinder block, and without lubrication holes and grooves on the side of the covers.
Lubricate the inner surfaces with engine oil before installing the bearings. Do not apply oil to the outside, but clean it thoroughly.
When installing, align the tabs on the bearings to prevent rotation.
Make sure the oil holes in the cylinder block and crankshaft line up with the holes in the bearings.
5. Install the crankshaft in the cylinder block.
Turn the crankshaft by hand and make sure it turns freely.
6. Install the main bearing caps.
There are markings on the main bearing caps.
Install the covers on the corresponding necks with the front mark towards the front of the engine.
Note: The cylinder block and main bearing caps are made as one piece and must only be replaced as a set.
7. Check the difference in diameters of the main bearing cap set bolts (see section «Diameter difference of main bearing cap bolt».
8. Tighten the main bearing cap set bolts in the following order.
(1) Apply engine oil to the threaded portions of the set bolts and bolt holes.
(2) Tighten the set bolts in the order shown in the figure to a torque of 24.5-30.4 Nm (2.5-3.1 kg m).
Note: The cylinder block and main bearing caps are made as one piece and must only be replaced as a set.
7. Check the difference in diameters of the main bearing cap set bolts (see section «Diameter difference of main bearing cap bolt».
8. Tighten the main bearing cap set bolts in the following order.
(1) Apply engine oil to the threaded portions of the set bolts and bolt holes.
(2) Tighten the set bolts in the order shown in the figure to a torque of 24.5-30.4 Nm (2.5-3.1 kg m).
After tightening the main bearing cap bolts, turn the crankshaft to make sure it turns freely.
Check crankshaft side clearance (see section «Crankshaft side clearance»).
9. Check the connecting rod bolt diameters (see section «Outer diameter of connecting rod bolts»).
10. Install the pistons on the connecting rods.
(1) Using circlip pliers, place the circlip into the groove on the back of the piston.
Insert the ring firmly into the groove.
(2) Install the piston on the connecting rod.
Use a hair dryer or similar device to heat the piston (up to 60-70°С) and insert the piston pin into the piston and connecting rod from the front of the piston towards the rear.
Assemble the piston and connecting rod so that the gear mark on the piston head and the cylinder number mark on the connecting rod are as shown.
(3) Install the circlip on the front of the piston.
See p. (1) to install retaining rings.
After installation, make sure the connecting rod moves freely.
11. Install the piston rings using a piston ring expander.
Attention: Do not damage the piston.
Install the first and second compression rings with the mark up.
Tags:
- First compression ring: R
- Second compression ring: 2R
Position the piston ring locks at a 120°angle.
Note: It is sufficient to move the piston ring locks by 120°.
12. Install bearings in caps and connecting rods.
When installing connecting rod bearings, apply engine oil to the inside surfaces of the bearings. Do not apply oil on the reverse side, but wipe it thoroughly.
When installing, align the tab on the bearing with the notch on the connecting rod.
13. Install the piston and connecting rod assembly to the crankshaft.
Bring the crankpin of the connecting rod to be installed to BDC.
Check the connecting rod cylinder number corresponding to its installation location.
Using a compressor to compress the piston rings, insert the piston with the front mark on the piston head towards the front of the engine.
14. Install the connecting rod cap.
Check the connecting rod cylinder number and cap cylinder number.
Align the front mark on the cover towards the front of the engine.
15. Tighten the connecting rod nuts in the following order.
(1) Apply engine oil to the threads and seating surfaces of the connecting rod bolts and nuts.
(2) Tighten the nuts with a force of 28.4-30.4 Nm (2.9-3.1 kg m).
(3) Fully loosen the nuts to 0 Nm.
(4) Tighten the nuts with a force of 18.6-20.6 Nm (1.9-2.1 kg m).
(5) Tighten the nuts by 120-125" (norm 120°).
Attention: Check the tightening angle with a goniometer or protractor. Avoid Estimating Tightening Angle «approximately» without the use of tools.
After tightening all bolts, check that the crankshaft rotates freely.
Check the side clearances of the connecting rods (see section «Checking the side clearance of the connecting rod»).
16. Install the rear oil seal into the rear oil seal holder.
Use a 105mm diameter drift and press in the oil seal to the size shown in the illustration.
Press in without distortion.
17. Install the rear oil seal retainer.
Apply Three Bond 1207 Sealant in a continuous bead (KR510 00150) as shown in the figure.
18. Install the guide bush.
Press the bushing in using a drift with a diameter of approximately 33 mm.
Install the guide bushing with the chamfer facing the crankshaft.
19. Install the injection pump bracket.
Install insulators in the shape of the cylinder block together with brackets and fix.
Align the brackets with the pins on the cylinder block.
The two bolts next to the pins are longer than the other two bolts.
Make sure the injection pump pin protrudes by the amount shown below.
- Standard protrusion: 14.0±1.0mm
20. Install all parts in the reverse order of disassembly.
Tighten the bracket bolts to the following torques.
A/C compressor bracket bolts:
: 56,9-65,7 N-m (5.8-6.7 kg m)
Alternator Bracket Bolts:
: 56,9-65,7 N-m (5.8-6.7 kg m)
21. Remove the engine from the stand in the reverse order of installation.
22. Install the drive disc.
Install the drive disc and booster disc as shown in the illustration.
Tighten the mounting bolts while securing the crankshaft with the gear lock (special tool).
Tighten the bolts evenly diagonally.