When cleaning the sealing surfaces, do not use sharp objects to avoid damaging the aluminum parts. Assembly is carried out in the following order:
- insert the bearing shells and pressure plates into the cylinder block, lubricate the shells well and place the crankshaft on them. The lubrication holes in the shells and in the cylinder head should be in line. Turn the shaft several times so that the shells are well installed;
- Place three regular liners and one flanged liners over the crankshaft main journals. The liners should fit snugly on the journals;
Fig. 332. Places of sealant application
- clean both halves of the crankcase. Apply sealant to the cylinder block surfaces. It is applied to the separating surfaces in the places shown in Fig. 332. Pay special attention to the specified dimensions;
Note: The lower part of the crankcase must be installed within 4 minutes after applying the sealant.
- check that all the adjusting pins are in the lower part of the crankcase and install the crankcase. Press the crankshaft from below and put half of the pressure plate. Tighten the screws, do not lubricate them;
Fig. 333. Sequence of tightening the screws of the lower part of the crankcase
- tighten all screws in the sequence shown in Fig. 333 with a tightening torque of 4 Nm. Screws 1 to 16 must be replaced. Tightening of individual screws is carried out in 4 stages:
Stage 1 - screws 1-8 with a torque of 25 Nm;
Stage 2 - screws 9-16 with a torque of 40 Nm;
Step 3 - Tighten screws 1–16 a quarter turn (90°);
Stage 4 - screws 17–22 with a torque of 25 Nm;
- after tightening all the screws, turn the crankshaft several times to identify the jammed areas. To turn, screw a screw into the front of the crankshaft or two screws into the rear flange of the shaft and turn the shaft with an inserted screwdriver;
- remove all squeezed out sealant and turn the shaft so that the journal of the piston being installed is at BDC;
- install the pistons in the same way as for a 16-valve engine. The arrow on the piston bottom should point to the front of the engine; the recesses and grooves in the connecting rod bearing cap must be on the same side; the connecting rod bearing cap screws should always be replaced. The cap is tightened in 3 stages:
Stage 1 - 23 Nm;
Stage 2 - 43 Nm.
Step 3 - turn a quarter turn (90°);
- after installing all connecting rods and pistons, check the axial clearance of the connecting rod bearings on the connecting rod journals of the crankshaft (see installing pistons on a 16-valve engine). In addition, all the checks mentioned in the same section should be carried out before completing the installation of the pistons. Then the crankshaft should be turned again to fix the clamping mechanism;
- install the oil pump. When tightening the screws, looking at the pump, first tighten the lower screw on the right, then the upper screw on the right, the lower screw on the left and the upper screw on the left. All screws are tightened to a torque of 10 N·m;
Fig. 334. Fastening the lubrication plate to the open crankcase
- install the lubrication plate (Fig. 334). First tighten the screws to a torque of 5 Nm, then tighten them another 45° (one eighth of a turn);
- Fix the oil pump receiver screen together with the inlet pipe in two places on the flange and in one place in the middle. Before installation, lubricate the new sealing ring with oil. Tighten the screws with a torque of 10 N·m;
- install the oil separator with a new gasket and tighten the screws to a torque of 10 Nm;
- install the console for mounting the power steering pump and tighten the screws to a torque of 47 Nm. Provide the console with adjusting pins;
- Put a new cylinder block gasket and install the cylinder block. Screw in the screws with washers one by one and tighten them securely. Both cylinder heads are installed in the same way. Tightening of all screws is performed in several stages:
Fig. 335. Cylinder head screw tightening sequence (both heads)
1st stage - in the sequence shown in Fig. 335 with a torque of 40 Nm;
2nd stage - in the sequence shown in Fig. 335, tighten without using a torque wrench by a quarter of a turn;
Fig. 329. Sequence of unscrewing the cylinder head screws. Both heads are unscrewed in the same way
3rd stage - in the sequence shown in Fig. 329, loosen by one turn;
4th stage - in the sequence shown in Fig. 335 with a torque of 40 Nm;
Stage 5 - in the sequence shown in Fig. 335, tighten without using a torque wrench another quarter turn (90°);
Stage 6 - in the sequence shown in Fig. 335, tighten again by a quarter of a turn (90°) without using a torque wrench;
- to install the left drive chain, set the crankshaft to the required position. To do this, screw the shock absorber screw with the washer into the crankshaft and turn the shaft to the right until the woodruff key is set to approximately the 11 o'clock position;
- insert well-lubricated valve lifters into the corresponding holes;
- place both camshafts in the left cylinder head and align the drive gear marks with the upper edge of the cylinder head:
Fig. 336. Installation of camshafts in the left cylinder head: 1 — adjustment mark of the intake camshaft; 2 - adjusting mark of the exhaust camshaft
1) Set the adjustment mark 1 (Fig. 336) of the intake camshaft to the "9 o"clock" position;
2) Set the adjustment mark 2 of the exhaust camshaft to the "12 o"clock" position;
- install the left camshaft bearing caps according to the cap designation. The caps are marked with marks from "1L" to "9L". The "1L" cap is on the side with four bearing caps on the drive gear side, the "5L" cap is on the other side near the drive gear. Lubricate the surfaces of the caps well. First install the "1L" and "5L" caps. The screws are not tightened;
- Place both camshafts in the right cylinder block and turn until the timing marks on the drive gears are aligned with the top edge of the cylinder head. This is done in the same way as in Fig. 336, but note the following differences:
1) Turn the lower shaft (exhaust camshaft) so that the adjustment mark is set to the "12 o"clock" position;
2) Turn the upper shaft (intake camshaft) so that the adjustment mark is set to the "3 o"clock" position;
Note: With four camshafts and two cylinder heads, it is easy to make a mistake during assembly. For this reason, we recommend that you perform another comprehensive check after installation and alignment of the adjustment marks.
- install the right camshaft bearing caps according to the cap designation. These caps are marked with marks from "1R" to "8R". The "5R" cap is located at the top right next to the drive gear. Behind it are the "6R" to "8R" caps. The "5R" cap is located on the opposite side next to the drive gear. Behind it are the "2R" to "4R" caps. First, install the "1R" and "5R" caps. The screws are not tightened at this stage;
Fig. 337. Location of timing marks for camshaft drive gears and copper-colored chain links (left chain)
- Fit the left camshaft timing chain. This chain has copper-coloured links which must be aligned with the timing marks of both camshaft timing gears and the crankshaft timing gear. Fit the crankshaft timing gear onto the shaft (timing mark on the outside) and position the chain. Fit the guide plate (made of black material) located on the right side and tighten to a torque of 25 Nm. Fig. 337 shows the chain lying on the camshaft timing gears, which also applies to the right camshafts. After fitting, check the following again:
1) Both copper-colored chain links must be positioned exactly opposite both timing marks on the camshaft drive gears;
Fig. 338. Crankshaft drive gear and copper-colored link of the left chain (A). In the right chain, the timing mark is located on the reverse side (B)
2) the copper-colored link on the reverse side must be aligned with the timing mark of the crankshaft drive gear (Fig. 338, A);
- install the chain pressure plate on the other side, mount the tensioner, which is still under pre-tension, and tighten to 25 Nm, then press the pressure plate firmly against the chain. Hold the plate in this position and remove the locking pin from the tensioner. The tensioner is now pressed against the pressure plate and provides the required chain tension;
- mount the drive chain on the right side as described above. The guide bar for this chain is light in colour. Again, align all the timing marks with the copper-coloured links. In doing so, pay attention to Fig. 338, B, as these marks are located in different places. Looking at the chain, tighten the guide bar on the right side with a torque of 25 Nm. The installation of the pressure bar and tensioner is similar and has already been described above;
- check again that the woodruff key on the crankshaft is set to the 11 o'clock position and insert the tappets into the left cylinder head;
Fig. 339. Sequence of tightening the camshaft bearing cap screws: A - for the left cylinder head; B - for the right cylinder head
- tighten the camshaft bearing cap screws (Fig. 339) to a tightening torque of 10 Nm;
- turn the crankshaft in the manner described above so that the segment key is set to the "3 o"clock" position;
- lubricate the tappets and insert into the right cylinder head;
- tighten the screws of the right camshaft bearing caps in the sequence shown in the right Fig. 339 to a torque of 10 N·m;
Fig. 340. Places of sealant application
- install the pulse ring on the crankshaft with the blue mark in the groove and apply sealant (6 mm wide) in the places indicated in Fig. 340. The steering gear housing cover must be screwed on within 6 minutes after applying it;
- install new sealing rings for the steering gear housing cover and tighten it evenly around the circumference with a torque of 25 Nm;
- install the crankshaft position sensor with a new sealing ring (10 Nm) and install the cable clamp;
- install the front crankshaft seal ring;
- install the crankshaft belt pulley, hold the shaft, and screw in the screws in four steps:
Stage 1 - 120 Nm;
Step 2 - Loosen the screw one full turn;
Stage 3 - 50 Nm;
Stage 4 - turn 90°;
- mount the power steering pump with the holder and tighten the screws to a torque of 25 Nm. Then tighten the pin screws to a torque of 10 Nm, tightening the long pins first;
- install the power steering pump belt pulley and tighten the screws to a torque of 25 Nm;
- Place a new sealing ring and install the rear camshaft ring retainer with adjusting pins on the cylinder block. Tighten the screws to 10 Nm. Insert the camshaft sealing ring as described above. The same subsection describes the process of installing the belt pulley on the camshaft;
- screw in the spark plugs and tighten to 15 Nm;
- install the cylinder head covers as described above in the relevant subsection;
- mount the oil pan as described in the relevant subsection and screw on the heat-protective metal sheet (10 Nm);
Fig. 341. Installed oil radiator (1) and switch (2) with hydraulic drive
- lubricate the oil cooler sealing ring, O-ring and oil filter sealing ring with engine oil and mount the oil cooler. Tighten the fastening in the middle to 57 N·m. Lubricate the switch 2 (Fig. 341) with a hydraulic drive with sealant and screw it next to the oil cooler 1 (14 N·m). After installing the radiator, you can install the oil filter;
- screw on the left exhaust manifold with the neutralizer and a new sealing ring (20 Nm);
- install the generator suspension bracket (25 Nm) and install the generator. Tighten the lower screws to 47 Nm, the upper screws to 25 Nm;
- install the rear crankshaft oil seal ring as described above in the relevant subsection;
- place the intermediate engine plate and install the flywheel. Lubricate the screws with sealant and, with the flywheel fixed, tighten them evenly, crosswise, with a torque of 80 N·m;
- install the liquid pump. Tighten the screws evenly to a torque of 10 Nm and tighten them another quarter turn in the final position. Connect the cooling system hoses to the pump;
- install the coolant connecting pipe with new O-rings between the two cylinder heads. Lubricate them with grease. Tighten the screws with a torque of 10 Nm;
- lay the drive belt of the liquid pump. To do this, turn the tensioner to the right, lay the belt with the pulley and release the tensioner;
- tighten the engine lifting eye (12 Nm), screw in the dipstick guide tube with a new, oil-lubricated sealing ring (10 Nm) and install the coolant distribution pipe (10 Nm);
- install the thermostat housing with the coolant hose;
- install the lower part of the intake manifold with new gaskets. The guide grooves of the gaskets must be directed downwards. From the middle to the edges, tighten the screws evenly to a torque of 10 N·m;
- install all cable connectors (connect plugs) and secure the wires with appropriate clamps;
- Install the upper part of the intake manifold as described earlier in the relevant subsection. Use new gaskets. They should also be facing downwards.
Perform all other work in the reverse order of removal.
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