Lay in the seat of the middle bearing and in its cover - liners without a groove on the inner surface, and in the remaining seats and corresponding covers - liners with a groove (Since 1986, the lower main bearing shells have been installed without a groove on the inner surface).
Note. Lubricate engine cylinders, as well as pistons and seals, bearing shells and thrust half rings of the crankshaft before installation with engine oil.
Lay the crankshaft in the main bearings and insert two thrust half rings into the sockets of the rear support (pic. 2-12), selected by strength in accordance with the instructions of the chapter «Crankshaft and flywheel». Install the main bearing caps according to the marks (pic. 2-13).
Warnings:
Install the main bearing caps in the original block. For this, the cylinder block and the covers belonging to it are marked with the same reference number (see fig. 2-13 and 2-24).
Install the thrust half rings with recesses to the thrust surfaces of the crankshaft, and place a steel-aluminum half ring on the front side of the rear support, and a cermet ring on the rear side (yellow color).
Put on the flange of the crankshaft the gasket of the gland holder, and in the sockets of the holder (pic. 2-14) insert the clutch housing front cover bolts. Put the holder with the stuffing box on the mandrel 41.7853.4011, and by moving it from the mandrel to the crankshaft flange, attach it to the cylinder block.
Install the front cover 6 along the two centering bushes (rice. 2-10) clutch housing.
Install the flywheel on the crankshaft so that the mark (cone-shaped hole) near the rim was against the axis of the crankpin of the fourth cylinder, lock the flywheel with lock A.60330/R and bolt it to the crankshaft flange.
Using the bushing from the set 02.7854.9500, insert the pistons with connecting rods into the cylinders (pic. 2-15). Set 02.7854.9500 contains a bushing for standard size pistons and bushings for oversized pistons (by 0.4 and 0.8 mm). Therefore, it is necessary to select a bushing suitable for the size of the piston to be installed.
Warning. The finger hole on the piston is offset by 2 mm, so when installing the pistons in the cylinders, the mark «P» on the pistons must face the front of the engine.
Install the bearings in the connecting rods and connecting rod caps. Connect the connecting rods to the crankshaft journals, install the covers and tighten the connecting rod bolts.
Install the sprocket on the crankshaft. Install the oil pump drive shaft and secure with the thrust flange.
Fit the two centering bushings on the block to the cylinder head with gasket, exhaust manifold and intake manifold. Tighten in sequence (pic. 2-16) fastening bolts in two steps:
- pre-torques 33.32-41.16 Nm (3.4-4.2 kgf·m) bolts 1-10;
- final torque 95.94 - 118.38 Nm (9.79-12.1 kgf·m) bolts 1-10 and torque 31.36-39.1 Nm (3.2 - 3.99 kgf·m) bolt 11.
Rotate the flywheel so that the mark on the crankshaft sprocket aligns with the mark on the cylinder block (pic. 2-17).
Install the sprocket on the camshaft assembled with the bearing housing and rotate the shaft so that the mark on the sprocket is against the mark on the bearing housing (see fig. 2 19) Remove the sprocket and, without changing the position of the shaft, install the bearing housing on the cylinder head and secure by tightening the nuts in a certain sequence (pic. 2-18).
Install the chain guide on the cylinder head.
Install the camshaft drive chain:
- put the chain on the camshaft sprocket and insert it into the drive cavity, installing the sprocket so that the mark on it matches the mark on the bearing housing (pic. 2-19) Do not overtighten the sprocket bolt;
- install the sprocket on the oil pump drive shaft * also without finally tightening the fastening bolt;
- install the chain tensioner shoe and tensioner without tightening the cap nut so that the tensioner spring can press the shoe; wrap the chain restrictor pin in the cylinder block;
- turn the crankshaft two turns in the direction of rotation, which will provide the desired chain tension; check the alignment of the marks on the sprockets with the marks on the cylinder block (pic. 2-17) and on the bearing housing (pic. 2-19);
- if the marks match, then locking the flywheel with lock A.60330/R (see fig. 2-10), finally tighten the sprocket bolts, chain tensioner cap nut, and fold back the sprocket bolt lock washers. if the marks do not match, then repeat the chain installation operation.
Adjust the clearance between the camshaft cams and the valve actuating levers.
Install the camshaft cover (pic. 2-20) with a gasket and an oil seal on the cylinder block, without finally tightening the fastening bolts and nuts. Using mandrel 41.7853.4010, center the position of the cover relative to the end of the crankshaft and finally tighten the nuts and bolts of its fastening.
Install the crankshaft pulley and tighten the ratchet.
Install the oil filter by hand screwing it to the riffle on the cylinder block. Install the crankcase ventilation oil divider, breather cap, and secure the oil separator drain tube retainer.
Install the oil pump and oil sump with gasket.
Install the coolant pump, alternator bracket and alternator. Put the belt on the pulleys and adjust its tension.
Install the heater radiator inlet pipe and outlet pipe on the cylinder head. Attach to the coolant pump! and to the exhaust manifold the outlet pipe of the heater radiator.
Install control gauges.
Install the oil pump drive gear and ignition distributor. Install the ignition distributor and adjust the ignition timing. Wrap the spark plugs, install the key 67.7812.9515 on them and tighten with a torque wrench. Install the fuel pump in accordance with the instructions in chapter «Supply system».
Install the carburetor and attach the hoses to it.
Install the cylinder head cover with gasket and fuel line bracket.
Install the air filter by attaching the hoses to the air filter housing, install the filter housing with gasket to the carburetor, then install the base plate and secure the housing with nuts. Install the filter element and secure the filter cover. Pour oil into the filler neck on the cylinder head cover.