Note:
- Wash all parts before assembly.
- Before installing parts, apply a thin layer of engine oil to all friction surfaces.
- Replace all gaskets, o-rings and seals.
1. Assemble the piston with the connecting rod.
Using a hydraulic press, press the piston pin into the piston.
Make sure that the piston and connecting rod alignment marks are directed towards the timing chain.
2. Install piston rings.
Install the oil scraper spacer with two side rails, by hand.
Using the tool, install the two compression rings with the identification marks facing up.
Position the piston rings so that the locks are located as shown in the figure below.
3. Install the connecting rod bearing shells.
Align the protrusion on the earmold (A) with a selection on the connecting rod and connecting rod cap (IN).
Install the connecting rod bearings and connecting rod cap as shown.
4. Install the main bearing shells.
Note: The upper main bearing shells installed in the cylinder block have recesses for supplying engine oil, the lower ones do not have recesses.
Align the tabs on the bearings with the recesses on the cylinder block. Install the bearings in the five bearings of the crankshaft (A), as it shown on the picture.
Align the tabs on the bushings with the recesses on the main bearing caps. Install the earbuds.
5. Install the thrust bearings on the 3rd support. The bushings must be installed in recesses from the support, as shown in the figure.
6. Install the crankshaft in the cylinder block.
7. Establish covers of radical bearings on the block of cylinders.
8. Establish bolts of fastening of covers of radical bearings.
Note:
- Tightening torque: 14.7 Nm + (27.5-31.4 Nm) + (120-125°).
- The main bearing cap bolts are tightened in two steps.
- If any defects are found in the bolts, they must be replaced with new ones.
Apply a light coat of engine oil to the threaded portion of the boots.
Install and tighten the 10 mounting bolts in two steps, in the sequence shown in the figure.
Check and make sure the crankshaft rotates smoothly.
9. Check up an axial backlash of a cranked shaft.
10. Establish pistons in gathering with rods.
Note: Before installing the pistons in the cylinders, apply a light coat of engine oil to the grooves under the rings and cylinder bore.
Remove the connecting rod caps and put a rubber hose on the threaded part of the connecting rod bolts.
Install the piston ring compression tool. Then install the piston in the cylinder and, applying light blows with the wooden handle of the hammer, insert it into the cylinder.
Stop when the spring compressor is released. Check the correct installation of the connecting rod relative to the crankshaft.
Install the connecting rod caps and tighten the mounting bolts.
Note: Tightening torque: (17.7 - 21.6 Nm) + tighten by 88-92°.
Attention. Always use new bolts.
11. Apply sealant to the cylinder block crankcase connector surface as shown in the illustration.
Note: THREE-BOND 1217H or Loctite 5900 sealant must be applied. Crankcase must be installed within 5 minutes of sealant application. Apply sealant to the threaded portion of the bolt holes.
12. Install crankcase (A) to the cylinder block. Tighten the fastening bolts with the tightening torque: step 1: 8.8 - 9.8 Nm, step 2: 17.7 -20.6 Nm, step 3: 27.5 - 31.4 Nm.
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13. Install a new rear oil seal.
Apply a thin coat of engine oil to the sealing surface.
Using a special tool (09231-Н1100, 09214-ЗК100) and a hammer, press in a new oil seal.
14. Install the balance shaft module (oil pump).
15. Install the water pump.
16. Install the crankshaft position sensor (A) and cover (IN) sensor.
Note: Tightening torque: (A): 9.8- 11.8 Nm.
17. Install the oil pressure switch.
Apply glue MS 721-39 (B) 2 or 3 threads.
Install the oil pressure gauge (A).
Note: Tightening torque: 7.8-11.8 Nm.
18. Install knock sensor (A).
Note: Tightening torque: 18.6 - 23.5 Nm.
19. Install the oil dipstick.
Install a new o-ring on the dipstick.
Apply engine oil to the O-ring.
Install dipstick (A) with bolt.
Note: Tightening torque: 7.8-11.8 Nm.
20. Install integrated tensioner bracket (A).
Note: Tightening torque: 39.2-44.1 Nm.
21. Install the cylinder head.
22. Install the timing chain.
23. Install the oil pan.
Using a blade or scraper, remove the old sealant from the gasket surface.
Note:
- Check that mating surfaces are clean and dry before applying sealant.
- Apply sealant with an even bead placed between the edges of mating surfaces.
- Use LOCTITE 5900H or THREEBOND 1217H.
Note:
- To prevent oil leakage, sealant must be applied inside the bolt holes.
- Install the parts within 5 minutes after applying the sealant.
- After assembly, wait 30 minutes, then fill with oil.
Install the oil pan (A). Screw in the bolts and tighten in several approaches.
21. Install the cylinder head.
Note:
Torque:
- M9 (IN): 30.4-34.3 Nm.
- MB (WITH): 9.8-11.8 Nm.
24. Remove the engine stand.
25. Install the drive (A) (Automatic transmission).
Note: Tightening torque: 117.7-127.5 Nm.
Install flywheel (IN) (Manual Transmission).
Note: Tightening torque: 117.7-127.5 Nm.
Note:
- Always use new bolts (WITH) flywheel mounts (drive disk).
- Apply sealant to the threads of the new bolts (8mm from the bottom of the bolt). Sealant: Three bond 2403, Loctite 200 or 204.
- Screw in and tighten 7 bolts.
