| 1. Before assembly, clean all parts of the engine. |
| 2. Before assembling the parts, apply a thin coat of clean engine oil to all sliding surfaces. |
| 3. Replace the main and connecting rod bearings, even if they have minor damage or wear. When installing, use only new gaskets. |
| 4. Install the snap ring in the groove of the piston. |
 | 5. Install the piston into the connecting rod and insert the piston pin through piston and connecting rod until it locks already installed locking ring. Check that the relative position of the piston rod and was the same as before the disassembly. |
 | 6. Set the second snap ring of the piston pin in the groove on the other side of the piston. |
| 7. Keep the piston vertically and check for freedom of movement of the connecting rod. |
 | 8. Install the three parts oil scraper ring on the piston:
- Lubricate with clean engine oil extender oil ring and the upper and lower part of the ring;
- Set the extender oil scraper ring on the piston so that the ends of the expander facing up;
- Install the lower part of the oil scraper ring on the piston. The ring may be installed either side up;
- Install the upper part of the oil scraper ring on the piston. The ring may be installed either side up; |
 | 9. Check that the expander oil ring separates the top and bottom of the oil ring rotates freely on the piston. |
| 10. pliers for a release of piston rings establish on the piston 2nd compression ring. |
 | 11. pliers for a release of piston rings establish on the piston 1st compression ring. |
 | 12. Place the piston rings as shown. |
| 13. Clean the indigenous and crank pins of grease and lubrication holes blow compressed air. |
| 14. Install main bearing shells on the engine block. |
 | 15. Establish persistent half rings of a cranked shaft. |
| 16. Install the crankshaft main bearing shells in the cylinder block. |
| 17. Install the remaining main bearing shells in main bearing caps of the crankshaft. |
| 18. Arrange pieces of plastic measuring rod Plastigage on the necks of the crankshaft bearing. |
| 19. In accordance with the marking install main bearing caps. |
 | 20. In certain sequence tighten bolts of covers of radical bearings of the crankshaft in the following order:
TED: a. tighten the bolts tightening torque 39.2 N ??? m;
b. in the reverse order tightening the bolts to loosen;
from. tighten the bolts tightening torque 19.6 N ??? m;
d. tighten screws at an angle of 90 ?�;
e. tighten bolts on a corner 60 ?�;
BFD: tighten the bolts tightening torque 54-59 N ??? m. |
A warning  Do not turn the crankshaft when measuring the gap crankshaft bearing.
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| 21. Remove the bolts and remove the crankshaft bearing caps of the crankshaft. The measuring template measure width of deformed plastic core Plastigage and define backlash size. |
 | 22. If the backlash exceeds the limit, pereshlifuyte crankshaft journal and use repair loose leaves of the increased size. The gap in the crankshaft bearing:
TED: 0,024-0,042 mm
BFD: 0,018-0,036 |
| 23. Remove the crankshaft to the cylinder and remove the deformed plastic core Plastigage with the crankshaft journals and main bearing shells. |
| 24. Apply a thin coat of engine oil to the main bearing shells in the cylinder block and install the crankshaft inserts. |
| 25. Apply a thin coat of engine oil to the crankshaft main journals and loose leaves in covers of radical bearings. |
| 26. In accordance with the marking install main bearing caps of the crankshaft. |
 | 27. In certain sequence tighten bolts of covers of radical bearings of the crankshaft in the following order:
TED: a. tighten the bolts tightening torque 39.2 N ??? m;
b. in the reverse order tightening the bolts to loosen;
from. tighten the bolts tightening torque 19.6 N ??? m;
d. tighten screws at an angle of 90 ?�;
e. tighten bolts on a corner 60 ?�;
BFD: tighten the bolts tightening torque 54-59 N ??? m. |
| 28. Turn a cranked shaft and check that it rotates easily and smoothly. |
| 29. Establish a measuring tip of a dial indicator on the front end of the crankshaft. |
| 30. Move the crankshaft axis to stop and set the scale of dial gauge to zero. |
| | 31. Move the crankshaft axis to the other side to stop and read the values of axial clearance on the scale indicator. Crankshaft end play: 0,080-0,282 mm. |
 | 32. If the axial play exceeds the allowable value, replace persistent half rings of a cranked shaft. |
| 33. Install connecting rod bearings into the connecting rod. |
 | 34. To protect the crankshaft journals from damage, put on bolts of covers of rods pieces of rubber or plastic tubing. |
| 35. Check the location of the piston rings on the piston. |
| 36. Set the piston with the piston rings on the first cylinder, and the mark F in the piston should be directed to the front of the cylinder block. |
| 37. Rotate the crankshaft in a position to crank pins of the 1st cylinder is at bottom dead center. |
 | 38. The special adaptation compress piston rings on the piston. |
39. hammer handle press the piston into the cylinder so that the bottom head of a rod was established on the crankshaft.
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| 40. Install connecting rod bearings into the connecting rod cap. |
| 41. Arrange pieces of plastic measuring rod Plastigage on necks connecting rod bearings of the crankshaft. |
 | 42. In accordance with the marking establish covers of rods and fix their nuts. Tightening torques:
TED: 47-50 N ??? m
BFD: 64-69 N ??? m
|
| 43. Remove the nuts and remove the rod. |
 | 44. The measuring template measure width of deformed plastic core Plastigage and define backlash size. Remove deformed plastic core Plastigage with the crankshaft journals and connecting rod bearing inserts. Nominal clearance of connecting rod bearings:
TED: 0,20-0,05 mm
BFD: 0,028-0,068 mm
Maximum permissible backlash: 0,10 mm |
| 45. If the backlash exceeds the limit, pereshlifuyte crankshaft journal and use repair loose leaves of the increased size. |
| 46. Apply a thin coat of engine oil to the crank pin of the crankshaft and connecting rod bearings into the connecting rod cap. |
| 47. Replace the cover and tighten the connecting rod nuts. Tightening torques:
TED: 47-50 N ??? m
BFD: 64-69 N ??? m |
 | 48. The probe inserted between the connecting rod and the crankshaft, connecting rod, measure the backlash. Nominal backlash rod: 0,110-0,262 mm
Maximum permissible backlash: 0,30 mm |
| 49. If the connecting rod side clearance exceeds the limit, replace the connecting rod and the connecting rod cap. |
| 50. Apply a thin coat of clean engine oil to the outer surface of the lip and rear oil seal ring of the crankshaft. |
| 51. Manually install the O-ring in the back cover of the cylinder. |
 | 52. Special adaptation push the O-ring in the back cover so that the end of the ring is flush with the lid or spoke of it no more than 0.5 mm. |
| 53. Apply a layer of silicone sealant thickness of 2 mm on an interfaced surface of the back cover. |
| 54. Replace the back cover and fix bolts. The inhaling moments: 7,8-10,8 N ??? m |
 | 55. Remove sealant squeezed when installing the rear cover on an interfaced surface of the oil pan. |
| 56. Apply a thin coat of clean engine oil to the lip of the front oil seal ring of the crankshaft and oil pump jack. |
| 57. Manually set the front crankshaft sealing ring. |
 | 58. Special adaptation push the sealing ring in the oil pump housing so that the end of the ring performed at 0.5-1.0 mm from the oil pump. |
| 59. Install new O-ring. |
 | 60. Apply a layer of silicone sealant with a diameter of 1-2 mm on an interfaced surface of the oil pump body, as shown in the figure. |
| 61. Install the oil pump and tighten 6 bolts. Tightening torque: 19-26 N ??? m |
| 62. Remove sealant squeezed during the installation of the oil pump to the oil pan mating surface. |
| 63. Clean the mating surface of the water pump. |
 | 64. Install the water pump with a new lining and fix bolts. Tightening torque: 19-26 N ??? m |
| 65. Replace the oil pressure sensor. The inhaling moments: 11,7-17,6 N ??? m |
| 66. Apply a thin layer of fresh engine oil sealing ring of the new oil filter. |
 | 67. Replace the oil filter to a contact of the O-ring of the oil filter to the engine block, then tighten the filter 1-1 / 6 turn. |
 | 68. Install maslozabornik strainer and a new lining and fix bolts. Tightening torques: 7.8-11.8 N ??? m |
| 69. Clear interfaced surfaces of the oil pan and the engine block. |
 | 70. Apply a continuous layer of silicone sealant to the mating surface of the oil pan |
 | 71. Install the oil pan and tighten the bolts. The inhaling moments: 7,8-10,8 N ??? m
|
| 72. Clean the threads of the flywheel mounting bolts and bolt holes from the remnants of the old sealant. If the sealant can not be removed from the thread bolts, replace them. |
| 73. Install the adapter plate on the block of cylinders and fix bolts. Tightening torques:
TED: 18,6-30,4 N ??? m
BFD: 7,8-11,0 N ??? m |
| 74. Install the flywheel or the drive plate to the crankshaft. |
| 75. Put on a carving of bolts reusable thin layer of sealant. |
| 76. The special tool, lock the flywheel from turning. |
 | 77. In certain sequence, in two or three stages tighten bolts of fastening of a flywheel. Tightening torques: 97-103 N ??? m |
| 78. Install the clutch disc and clutch cover with pressure plate. |
 | 79. Install the mandrel, centering clutch disc and a few steps in a certain sequence tighten bolts of fastening of a casing of coupling with a press disk. Tightening torques:
TED: 22-32 N ??? m
BFD: 18-26 N ??? m |
| 80. Remove the tool that blocks the flywheel from turning and the mandrel, centering clutch disc. |
| 81. Install the valve stem and valve stem seal set. |
 | 82. Special adaptation press-fit valve stem cap. |
A warning Valve stem seals inlet and exhaust valves are different. Valve stem seals exhaust valves have 4 teeth.
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| 83. Remove tool for fitting valve stem seals. |
| 84. Install the lower spring seat in the cylinder head. |
| 85. If available, set the protection of the hydraulic valve clearance compensator. |
 | 86. Set the valve spring so that the coils with fine pitch (B) were sent to the cylinder head. |
 | 87. Install the upper spring seat and the special adaptation, compress a spring. |
| 88. Place the biscuits and remove special tool for spring. |
| 89. Plastic hammer several times, hit the end of the valve stem to crackers established in its place. |
| 90. If present, remove the protection of the hydraulic valve clearance compensator. |
| 91. Similarly establish other valves. |
| 92. Install the gasket and the cylinder head to the engine block. |
| 93. Install the mounting bolts of the cylinder head. |
 | 94. In certain sequence tighten bolts of the cylinder head in the following order:
TED: a. tighten the bolts tightening torque 49 N ??? m;
b. in the reverse order tightening the bolts to loosen;
from. tighten the bolts torque 39,2N ??? m;
d. tighten screws at an angle of 90 ?�;
e. tighten bolts on a corner 90 ?�;
BFD: tighten the bolts tightening torque 76-81 N ??? m. |
| 95. Set hydraulic valve clearance compensators. |
| 96. Install the new intake manifold gasket. |
| 97. Install the intake manifold and fix bolts. The inhaling moments: 17,6-25,5 N ??? m |
 | 98. Establish an arm of an inlet collector and fix bolts. Tightening torques:
TED: (A) 15,7-22,5 N ??? m
(V) 36,3-53,9 N ??? m
BFD: 31,4-46,1 N ??? m |
| 99. Set the generator and fasten the mounting bolts and adjusting bolt. |
| 100. Install the alternator drive belt and adjust its tension. Deflection of a belt drive of the generator:
New belt: 8-9 mm
The belt which was in the use: 9-10 mm |
| 101. Tighten all screws generator demanded moment. Tightening torques:
Mounting bolts: 37-52 N ??? m
Adjusting bolt: 19-26 N ??? m |
| 102. Set the front and rear lifting eyes of the engine. |
| 103. The lifting mechanisms remove the engine from the stand. |
 | 104. Install exhaust manifold and coolant bypass pipe and fix their bolts. Tightening torques: (A) 38,2-46,1 N ??? m |
| 105. Install engine support ?��3 and bracket and secure them with screws. Tightening torques: 73,5-102,9 N ??? m |
| 106. Install engine support ?��2 and fix bolts. The inhaling moments: 37,2-51,9 N ??? m |
 | 107. Install the gearbox and tighten 8 bolts. Tightening torques:
4 upper screws (1, 2, 3, 4), 89-116 N ??? m
4 bottom screws (5, 6, 7, 8) 37-52 N ??? m |
108. Install the starter and fix bolts. Tightening torque: 37-52 N ??? m |
| 109. Fill the engine with engine oil. |
