Attention: Before removing the pistons with connecting rods, remove the cylinder head.
Check with your fingernail for a bead at the top of the piston ring travel (about 5 mm below the top of the cylinder). If rollers have formed due to carbon deposits or wear of the cylinder walls, they must be completely removed using a special tool. If the rollers are not removed, then when removing the pistons with connecting rods, the piston can be damaged.
After the rollers have been removed, turn the engine over.
Loosen the mounting bolts and remove the oil pan (1) with padding.
Remove the oil receiver (arrow).
Remove the oil pump.
Remove the back cover (1).
Before removing the connecting rods, check their backlash with feeler gauges. Insert them between the first connecting rod and the shaft crank until all the play is taken out. If the play exceeds the limit repair value, then it is necessary to replace the connecting rods If new connecting rods are installed (or new crankshaft), the play may become less than the minimum allowable. In this case, the connecting rods must be machined - if necessary, consult a car workshop. Repeat the procedure for the rest of the connecting rods.
Check for identification marks on the connecting rods and connecting rod caps. If they are not visible, use a small punch to mark the appropriate number of marks on each connecting rod and cap (1, 2, etc. according to cylinder number).
Connecting rod marks 1.6 and 1.8 liter engine
Connecting rod marks 2.0 liter engine
A - color coding
Loosen each connecting rod cap nut in several half-turn increments until they can be twisted by hand. Remove the number 1 connecting rod cap together with the bearing shell - do not drop the shell.
Pull a piece of plastic or rubber hose over each connecting rod cap bolt so as not to damage the crankshaft journal and cylinder bore when the piston is pulled out.
Pull out the bearing shell and push the connecting rod with the piston out through the top of the engine. Push, resting on the wooden handle of the hammer against the connecting rod or piston.
Repeat this operation for the remaining connecting rods with pistons.
Assemble the connecting rods by installing the bearing shells and caps, and tighten the nuts with your fingers.