Note. The shafts and body are marked (DR, DN).
2. Align the marks and install the drive and driven gears of the balance shafts.
3. Install the back cover (IN) balance shaft housings. The tightening torque of the mounting bolts is 8-12 Nm.
4. Install the stove (A) gears. The tightening torque of the mounting bolts is 8-12 Nm.
5. Align the alignment marks. Install the balance shaft drive gear (A) and intermediate gear (IN).
- The tightening torque of the mounting bolts A: 39-43 Nm, B: 60-64 Nm.
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6. Install front cover (A) balance shaft housings.
- The tightening torque of the mounting bolts is 8-12 Nm.
7. Install compression rings.
8. Install the piston and connecting rod with marks to the drive belt.
9. Install the piston into the cylinder using a ring compressor.
10. Apply engine oil to the mounting bolts, then install the connecting rod caps.
11. Install the oil nozzles and tighten the mounting bolts with a tightening torque of 9-13 Nm.
12. Apply engine oil to the main bearing bushings.
13. Install the half rings in the middle root support.
14. Install the crankshaft in the cylinder block so that the second and third connecting rod journals point upwards.
15. Apply engine oil and install the half rings in the middle main bearing.
16. Apply sealant (LOCTITE 5205, DREIBOND 5105 or HYLOMAR 3000) on the mating surface with the block and install the ladder-type frame. Tightening torque of mounting bolts 28-32 Nm + 120° (15 mm), 33.7-37.7 Nm (12 mm).
17. Turn the crankshaft clockwise.
18. Using a calibrated plastic strip, measure the clearance in the crankshaft main bearings.
19. Install the piston pin connecting rod.
20. Install the crankshaft gear. The tightening torque of the fastening bolt is 185-195 Nm.
Note. Align alignment marks.
21. Install oil receiver (A) on the oil pump housing (IN). The tightening torque of the fastening bolts is bolt A 10-12 Nm, bolt B 34-38 Nm.
Note. The bolt must be tightened first.
22. Apply sealant to the mating surface of the crankcase with the cylinder block. Tighten the crankcase mounting bolts in three steps to a tightening torque of 10-12 Nm.
23. Install water pump.
24. Install the camshaft timing belt automatic tensioner. The tightening torque of the locking bolt is 10-12 Nm.
25. Install the air conditioning compressor (A).
26. Install the pipes of the cooling system, the hydraulic booster pump, connect the crankshaft position sensor and the oil pressure sensor. Then install the cylinder head assembly.
27. Install the feeler gauge and timing belt.