Note: Connecting rod bearings 1 through 4 on engines built after May 1998 are marked on the timing side. On these engines, connecting rods and connecting rod bearing caps are not interchangeable, as each bearing cap only fits a specific connecting rod. The bearing cap and connecting rod marking instructions can be ignored if the engine was built after this date.
Perform installation in the following order:
Fig. 76. Removing or installing piston rings with pliers
- install the piston rings on the piston as shown in Fig. 76. If you do not have pliers, select three thin metal strips and install the rings (Fig. 82);
Fig. 82. Removing and installing piston rings using metal plates
- distribute the metal strips at regular intervals around the circumference of the piston and place the lower ring on the strips. One strip should be located exactly under the ring lock to avoid scratches;
- carefully push the piston ring down until it is level with its groove and remove the metal strips to allow the ring to fit into the groove;
- install the second and third rings in the same way on the piston;
- you can also carefully put the rings on with your hands without any tools, but both ends of the ring should be closed, as they can scratch the piston. It is important to remember that piston rings break very easily if pliers are not used;
- lubricate the piston rings with engine oil and turn them to the positions indicated above;
- Insert the piston and connecting rod from above into the cylinder block. The arrow on the piston pin should point towards the front of the engine;
Fig. 83. Installing pistons
- Compress the piston rings with a suitable band clamp as shown in Fig. 83. If this is not available, a very wide hose clamp can be used. Before installation, lubricate the piston and bore well with engine oil;
- turn the crankshaft so that the first and fourth connecting rod journals of the crankshaft are at BDC;
- insert the insert into the lower connecting rod head and carefully push the piston with the connecting rod, simultaneously guiding the connecting rod bearing onto the connecting rod journal of the crankshaft. Check again that the inscription "Front" points to the front of the engine. From the crankcase side, check that the connecting rod markings are on one side of the engine (as they were marked during engine disassembly). As the piston rings slide into the cylinder, the clamping band will slide off them, then it can be removed;
Note: On 1.8 litre engines produced since May 1998, the recess in the piston crowns must be on the intake side.
- Install the connecting rod bearing cap with the inserted liner. Make sure that the caps are installed on the connecting rod that belongs to them. Check whether the cap numbers are on the same side as the numbers on the connecting rods. In addition, the brand name (may not be on all engines) should be on the valve timing side. Insert both guide pins into the small connecting rod head (if any) into engagement with the connecting rod bearing cap;
- tighten the connecting rod bearing cap. First tighten both screws (always use new screws) to the initial torque and from this position tighten them a quarter of a turn. For tightening torques, see the appendix. Turn the crankshaft several times and return the first piston to BDC again. Install the second piston with the crankpin of the crankshaft set at BDC;
- turn the crankshaft until the crankpins of the crankshaft of the second and third cylinders are at BDC, and install both pistons and connecting rods in the manner described above.
After installation, please check the following again:
- all arrows on the pistons must point towards the front of the engine (on the 1.8-liter engine produced from May 1998, also check the recesses in the piston crowns);
- the connecting rod numbering by cylinders must be on the same side, the connecting rod and connecting rod bearing cap numbers must match;
- each connecting rod on the crankshaft journal should have a small lateral clearance if the connecting rod bearing is slightly moved in different directions in the axial direction.
Carry out all further work in the same way as when installing the crankshaft.