Assembly and engine installation

Installing gearbox

Before assembling the engine, perform the following steps:

- Clean the socket main bearing shells. Make sure that the parts are clean and undamaged;

- Pay special attention to cleaning soot in the lock socket inserts;

- Check the label on the cylinder block and crankshaft.

Moreover, for the reliable operation of the engine is necessary to classify the crankshaft bearing.

Each main bearing socket marked cylinder number and the letter denoting the class of the cylinder block and crankshaft (Fig. 4.56).

Install in the engine block only the main bearings, selected in accordance with Table. 4.2.

Engine balance of assembly:

1) Apply polimerizuyuschusya uncured paste (P / N 1161 059-9) in the intermediate section. Cover the surface completely, but avoiding smudges that mastic was not included in the channels and holes for bolts. Use a roller with short bristle 951 1205;

2) Install bearing shells in the intermediate section. The surface of the bearing housings should be dry;

3) liberally lubricate the bearing shells and thrust pads.

4) Install the crankshaft. The shaft can not rotate as long as the intermediate section is secured in its place;

5) set the intermediate section. Tighten bolts of the intermediate section and the crankshaft 5 receptions. Check out the performance of each round, before proceeding to the next. The maximum permissible length of M10 - 118 mm:

- Tighten all screws M10 20 N ?� m;

- Tighten the M10 bolts to 45 N ?� m;

- Tighten the screws M8 torque 24 Nm;

- Tighten the bolts M7 torque 17 Nm;

- Tighten the screws M10 90 ?�;

6) Make sure that the crankshaft rotates smoothly, without jamming;

7) Measure the axial clearance using a dial gauge, magnetic plates and magnetic stand (Fig. 4.57). The axial clearance must be 0,08-0,19 mm;

8) Install the crankshaft rear oil seal;

9) Lubricate the surface of the interface: the neck and shaft sealing lips of oil seal. Slide the gland on the mandrel;

10) press-fit the oil seal (Fig. 4.58) to lock the plug in the crankshaft. If crankshaft has signs of wear, drive in the gland is deeper than it was located before;

11) assemble pistons and rods;

12) Put the retaining ring piston pin and make sure that it snaps into the groove. The cut of a lock ring should be turned down;

13) Install the piston rings (Fig. 4.59);

14) using the device for compression of piston rings, set the ring so that their castles were separated by an angle of about 120 ?�;

15) clean and dry the bearing seats in the rods and covers;

16) set the rods and caps bearing inserts;

17) set on the thread connecting rod bolts protective cap technology;

18) Apply engine oil to the cylinder walls, pistons and bearing shells;

19) set the pistons in the cylinders;

20) during the installation of each piston to rotate the crankshaft so that the crank pin, inserts the corresponding piston is in the lowest position;

21) check that the classes of the pistons. Insert one by one piston in the cylinder, using a device for compression of piston rings;

22) Remove the protective caps and set the connecting rod bearing caps;

23) check that the marking rods and connecting rod bearing caps;

24) tighten the connecting rod bolts in two steps (to use new connecting rod bolts. Before installation, lubricate the bolts with oil):

- Tighten the bolts to 20 Nm;

- Tighten by 90 ?�;

25) Make sure that the connecting rods can be easily moved in the transverse direction;

26) set maslozabornik oil pump with a tube;

27) Place the gasket on the tube maslozabornika;

28) connect the tube. Tighten to a torque of 17 Nm;

29) Install new oil seal channels;

30) Install the oil pan. With a roller with short bristles applied to housing uncured polymerisable mastic (RLM 1161 059-9);

31), insert the four screws and install the housing flush with the rear surface of the block. Tolerance ?� 0,025 mm. To check, use a vernier caliper and the probe;

32) tighten the bolts until 17 Nm, starting from the front and moving backwards;

33) Install new oil filter;

34) set the attachments, assemblies and parts in the reverse order;

35) Establish a flywheel / drive plate using a gear retainer 999 5112 and 999 5593 special bolts;

36) set the flywheel using three special bolts and tighten them until the moment 45 Nm;

37) Install the remaining standard bolts (new) and tighten them until the moment 45 Nm;

38) replace the three special bolts on the new standard and tighten them until the moment 45 Nm;

39) all flywheel bolts tighten by 65 ?�;

40) set the engine on the car.