Install a clean block on the stand and wrap the missing studs in it.
Lubricate the bearing shells and thrust washers of the crankshaft, as well as the pistons and seals, with engine oil. When assembling the engine after repair, install new crankshaft oil seals.
Lay loose leaves without a groove on the inner surface in the middle bearing seat and in its cover. Place liners with a groove in the remaining nests of the cylinder block, and liners without a groove in the corresponding covers.
Lay the crankshaft in the main bearings and insert two thrust half rings into the sockets of the rear support (pic. 2-17).
Pic. 2-17. Installation of persistent half rings on the rear support.
Warning. The half rings must face the grooves towards the thrust surfaces of the crankshaft (on the side of the grooves, an anti-friction layer is applied to the surface of the half-ring).
Place a steel-aluminum half ring on the front side of the rear support, and a metal-ceramic half ring on the back side (yellow color).
Install the main bearing caps in accordance with the marks on their outer surface (pic. 2-18). Tighten the cap screws.
Pic. 2-18. Marks on main bearing caps (bearings are counted from the front of the engine).
Check the axial free play of the crankshaft. To do this, mount the indicator on a magnetic stand and insert the ends of two screwdrivers as shown in fig. 2-19. While moving the shaft with screwdrivers, measure the axial free play of the shaft with an indicator. It should be within 0.06-0.26 mm. If the free play is greater, then bring it back to normal by replacing the old half rings with new ones or by installing half rings of increased thickness.
Pic. 2-19. Checking the axial free play of the crankshaft.
Establish on a flange of a cranked shaft a lining of the holder of a back epiploon, and in sockets of the holder (pic. 2-20) insert the clutch housing front cover bolts. Install the holder with the oil seal on the crankshaft flange, attach to the cylinder block.
Pic. 2-20. The holder of a back epiploon of a cranked shaft. The arrows show the protrusions for centering the holder relative to the crankshaft flange.
Install on two centering sleeves (pic. 2-21) front cover 6 (see fig. 2-11) clutch housing. Attach the cover with nuts to the rear oil seal holder.
Pic. 2-21. Clutch dowel pins (black arrows) and centering sleeves of the clutch housing (white arrows).
Install the flywheel on the crankshaft so that the mark (cone-shaped hole) near the rim was against the axis of the connecting rod journal of the fourth cylinder, block the flywheel with the retainer A.60330 / R and bolt it to the crankshaft flange.
Insert the pistons with connecting rods into the cylinders using a piston ring crimping bush (pic. 2-22).
Pic. 2-22. Piston installation with piston rings using a ring crimping bush and cylinder head centering sleeves (shown by arrows).
Warning. The pin hole on the piston is offset from the axis by 1.2 mm, therefore, when installing the pistons in the cylinders, the arrow on the piston crown must point towards the camshaft drive.
Install the bearings in the connecting rods and connecting rod caps. Install the connecting rods and caps on the crankshaft journals and tighten the connecting rod bolts. Connecting rod caps must be installed so that the cylinder number on the cap is opposite the cylinder number on the bottom end of the connecting rod.
Install the sprocket on the crankshaft. Install the oil pump drive shaft and secure with the thrust flange.
Install two centering bushes in the cylinder block (see fig. 2-22) and install the cylinder head gasket over them.
Warning. When assembling the engine, always install a new gasket under the cylinder head. The use of a used gasket is not permitted.
Before installing the gasket, all oil must be removed from the mating surfaces of the block and cylinder head. The gasket must be clean and dry. Oil contact with the gasket surface is not allowed. If oil gets in, degrease the gasket.
Turn the crankshaft so that the pistons are in the middle of the cylinders.
Install the two centering bushings on the block cylinder head assembly with valves.
Pic. 2-23. The order of tightening the cylinder head bolts.
Tighten bolts of fastening of a head of cylinders in the sequence specified in fig. 2-23. To ensure a secure seal and avoid tightening the bolts during vehicle maintenance, tighten the cylinder head bolts in four steps:
- 1st step - tighten bolts 1-10 to 20 Nm (2 kgf·m);
- 2nd step - tighten bolts 1-10 to 69.4-85.7 Nm (7.1-8.7 kgf·m), and bolt 11 - with a torque of 31.36-39.1 Nm (3.2-3.99 kgf·m);
- 3rd reception - tighten the bolts 1-10 by 90°;
- Step 4 - Tighten bolts 1-10 again by 90°.
Warning. Cylinder head bolts may only be reused if the bolt shaft has extended to no more than 117 mm. If the bolt is longer, replace it with a new one.
Before assembling the engine, pre-lubricate the threads and bolt heads by dipping them in engine oil. Then allow excess oil to drain, after holding the bolts for at least 30 minutes. Remove oil from the bolt holes in the cylinder block.
Turn the flywheel so that the mark on the crankshaft sprocket aligns with the mark on the cylinder block (pic. 2-24).
Pic. 2-24. Check that the alignment mark on the crankshaft sprocket matches the mark on the cylinder block.
Check if the camshaft bearing housing dowels are in place (pic. 2-25). Install the sprocket on the camshaft assembled with the bearing housing and rotate the shaft so that the mark on the sprocket is against the mark on the bearing housing (pic. 2-26). Remove the sprocket and, without changing the position of the shaft, install the bearing housing on the cylinder head so that the mounting sleeves enter the bearing housing seats. Secure the bearing housing by tightening the nuts in the sequence shown in fig. 2-27.
Pic. 2-25. Mounting sleeves for the camshaft bearing housing.
Pic. 2-26. Checking that the alignment mark on the camshaft sprocket matches the mark on the bearing housing:
1 - mark on the asterisk;
2 - mark on the bearing housing.
Pic. 2-27. The procedure for tightening the camshaft bearing housing nuts.
Install the chain guide on the cylinder head.
Install the camshaft drive chain:
- put the chain on the camshaft sprocket and insert it into the drive cavity, installing the sprocket so that the mark on it matches the mark on the bearing housing (see fig. 2-26). Do not overtighten the sprocket bolt;
- install the sprocket on the oil pump drive shaft, also without finally tightening the fastening bolt;
- install the chain tensioner shoe and hydraulic tensioner;
- install the hydraulic tensioner tube;
- check the alignment of the marks on the sprockets with the marks on the cylinder block and on the bearing housing (see fig. 2-24 and 2-26);
- if the marks match, then locking the flywheel with lock A.60330/R (see fig. 2-9), finally tighten the sprocket bolts, bend the sprocket bolt lock washers; if the marks do not match, then repeat the chain installation operation.
Install the camshaft cover (pic. 2-28) with a gasket and an oil seal on the cylinder block, without finally tightening the fastening bolts and nuts. Center the position of the cover relative to the end of the crankshaft and finally tighten the nuts and bolts of its fastening.
Pic. 2-28. Camshaft drive cover. The arrows show the protrusions for centering the cover relative to the crankshaft pulley hub.
Install the crankshaft damper and secure it with the nut.
Install the power steering pump bracket with pump assembly.
Install the oil filter with gasket by hand screwing it to the fitting on the cylinder block. Install the crankcase breather oil separator, breather cap and attach the oil separator drain tube retainer.
Install oil pump 1 (pic. 2-29) and oil sump with gasket.
Pic. 2-29. Oil pump installation:
1 - oil pump;
2 - drain tube retainer;
3 - oil separator drain pipe.
Install the coolant pump, alternator bracket and alternator. Install the belt on the pulleys and adjust its tension following the recommendations outlined in subsection «Accessory Drive Belt Tension Adjustment».
Install the air conditioning compressor and its drive belt on the engine following the recommendations set out in subsection «Air conditioning system».
Install the heater core feed pipe and exhaust pipe to the cylinder head.
Install the exhaust manifold to the cylinder head 2 (pic. 2-9), screen 6 and inlet pipe 1.
Install the starter guard on the engine.
Install control gauges.
Install the oil pump drive gear and gear retainer. Screw in the spark plugs and tighten them with a torque wrench.
Install the cylinder head cover with gasket, engine shield and accelerator cable brackets.
Install the ignition coil and knock sensor.
Install the fuel rail on the inlet pipe and fix it with bolts 3 (see fig.2-8). Connect the wiring harness to the injectors. Lubricate the injector O-rings with engine oil before installing the fuel rail.
Connect the fuel supply pipe to the rail.
Install the gasket on the inlet pipe, receiver 6 (see fig. 2-6), engine shield bracket, and install the five nuts.
Connect the throttle pipe with gasket to the receiver.
Connect the coolant inlet and outlet hoses, crankcase ventilation hose to the throttle pipe.
Pour engine oil into the engine through the opening on the cylinder head cover.