Identification marks and markings for correct piston and connecting rod position
1 – designation of the piston diameter, 2 – designation of the direction of installation in the cylinder (the arrow should be directed towards the valve timing drive), 3 – designation of the direction of installation of the connecting rod relative to the piston (the letter "F" should be directed in the same direction as the arrow on the bottom of the piston), 4 – designation of the cylinder number, 5 – designation of the length of the connecting rod, 6 – designation of the mass of the connecting rod
Places of application of sealing paste on the surface of the engine cylinder block
1. Install the crankshaft thrust half rings into the sockets in the middle main bearing, directing the oil grooves of the half rings outward of the main bearing.
2. Insert the main bearing shells.
3. Lubricate the main and connecting rod journals of the shaft and the main bearing shells with oil.
4. Install the crankshaft on the main bearing shells in the engine cylinder block.
5. Install the main bearing caps (with arrows on the caps pointing towards the timing drive) together with the liners.
6. Lubricate the threads of the new main bearing cap bolts with oil.
7. Tighten the main bearing cap bolts to the specified torque.
8. If the piston rings were removed, install them on the pistons with the inscription "TOP" facing the bottom of the piston.
9. Place the ring locks at an angle of 120°.
10. Lubricate the smooth surface of the cylinders, the side surface of the pistons and the piston rings with oil.
11. Install the half bearings into the connecting rod bases.
12. Install the piston-connecting rod assemblies in the cylinders, paying attention to the installation marks (see Fig. Identification marks and marks for the correct position of the piston and connecting rod):
- the connecting rod and cover are marked with the number of the cylinder in which they are installed (cylinder No.1 on the timing drive side);
- the arrow on the bottom of the piston and the letter "F" on the side surface of the connecting rod journal must be directed towards the valve timing drive;
- the connecting rods are divided into four selection groups, differing in the distance between the axes of the head and base holes; this allows to limit to a minimum the difference in the piston protrusion above the upper plane of the cylinder block (and thus the difference in the compression ratio in individual cylinders); the selection group of the distance between the centers of the connecting rods is designated by the letters "A", "B", "C" and "D" stamped on the caps of the connecting rods (the letter "A" refers to the shortest connecting rods);
- the cranks are divided into two selection groups depending on their weight: "light" and "heavy"; all connecting rods in an engine must belong to the same mass group.
13. Insert the half bearing shells into the connecting rod caps.
14. Lubricate the connecting rod bearings and shaft journals with oil.
15. Install the connecting rod caps, paying attention to their designation (see Fig. Identification designations and marks for the correct position of the piston and connecting rod).
16. Insert new connecting rod cap bolts and lubricate their threads with oil.
17. Tighten the connecting rod cap bolts to the specified torque.
18. Lubricate the circular gasket of the oil supply line to the oil pump with oil.
19. Install the oil supply line and check if the gasket is in the proper place.
20. Install the crankshaft rear cover together with a new gasket reaching the bottom plane of the engine cylinder block.
21. Using tool 21.148 and the mounting bolt, install the crankshaft pulley, the front plate of the cylinder block together with a new gasket.
22. Lubricate the front journal of the crankshaft and the O-ring of the pulley with oil.
23. Install the pulley on the crankshaft, making sure that the keyway with the key in the neck is exactly opposite the groove in the pulley.
24. Lubricate the intermediate shaft and bearing bushings in the cylinder block, as well as the front support plate, with oil.
25. Install the intermediate shaft together with the support plate into the cylinder block.
26. Lubricate the indicated areas (see Fig. Areas of application of sealing paste on the surface of the engine cylinder block): with a thin layer of sealing paste and install the oil pan together with a new gasket.
27. First insert the four oil pan mounting bolts into the corners of the oil pan, tighten them by hand, then insert and tighten the remaining oil pan mounting bolts by hand.
28. Tighten the bolts – except for the bolts in the corners of the pan – to the appropriate torque.
29. Tighten the bolts at the corners of the oil pan to the specified torque.
30. Install the coolant pump with a new gasket.
31. Pour about 10 cm³ of oil into the oil pump.
32. Install the oil pump.
33. Screw on the oil filter.
34. Install the engine cylinder head (see subsection 3.2.1.4.4).
35. Install the generator.
36. Install the fuel pump (see subsection 3.2.1.3.3)
37. Install the pulley onto the crankshaft.
38. Install the flywheel onto the crankshaft.
39. Install the clutch on the flywheel.
40. Install the starter.
41. Install the exhaust manifold.