All parts must be cleaned before assembly.
1. Using a plastic gauge, determine the clearances in all crankshaft bearings. See "Selection of connecting rod bearing liners using a plastic gauge" and "Selection of main bearing shells using a plastic gauge".
2. Check the radial runout of the rear sealing journal of the crankshaft with the bearings installed.
3. Check the axial run-out of the crankshaft.
4. Check the runout of the surface of the journal of the middle main bearing of the crankshaft.
5. Apply a thin layer of engine oil to the crankshaft bearing shells.
6 Install the crankshaft.
7. Apply sealing compound to the rear main bearing cap.
8. Install the crankshaft main bearing caps No.1-4.
9. Install the main bearing cap No.5. Make sure that the sealant evenly seals the joints between the cap and the cylinder block.
Caution: Do not reuse old crankshaft main bearing bolts.
10. Tighten the crankshaft main bearing cap screws:
- tighten the screws to 50 Nm;
- tighten to an angle of 45° + 15°.
11. Install the connecting rod bearing shells into the connecting rods and into the connecting rod bearing caps.
12. Install the connecting rod bearing caps.
Caution: Do not reuse old connecting rod bearing cap screws.
13. Tighten the connecting rod bearing cap screws to a torque of 25 Nm.
14. Tighten the connecting rod bearing cap screws to an angle of 30° + 15°.
15. Install the oil pump.
16. Tighten the oil pump screws to 10 Nm
17. Install the oil receiver.
18. Tighten the oil receiver screws to a torque of 10 Nm.
19. Install the oil pan gasket.
20. Install the oil pan no later than 5 minutes after applying the sealant gasket.
21. Tighten the oil pan bolts to 10 Nm.
22. Install the crankshaft toothed pulley.
23. Install the rear part of the timing belt cover.
24. Tighten the rear timing belt cover screws to 10 Nm.
25. Install the automatic timing belt tensioner.
26. Tighten the timing belt automatic tensioner screw to a torque of 20 Nm.
27. Tighten the camshaft timing pulley screw to a torque of 45 Nm.
28. Install the timing belt.
29. Adjust the tension of the camshaft drive toothed belt.
30. Install the valve cover with gasket.
31. Tighten the camshaft cover screws to 10 Nm.
32. Install the lower part of the timing belt housing.
33. Tighten the timing belt cover lower part screws to 10 Nm.
34. Install the power steering pump.
35. Tighten the power steering pump screws to 25 Nm.
36. Install the upper part of the timing belt cover.
37. Tighten the timing belt cover upper part screws to 10 Nm.
38. Install the rear crankshaft oil seal using a drift.
39. Install the flywheel.
40. Tighten the flywheel mounting screws to a torque of 35 Nm.
41. Tighten the flywheel mounting screws to an angle of 30° + 15° (see figure T250 2.069).
42. Install the engine into the vehicle.
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