Order of execution
1. Heat piston 7 (see fig. Crankshaft and parts of the connecting rod and piston group), lowering it for 2–3 min into water heated to a temperature of 50–80°C.
2. Quickly insert the connecting rod 10 into the hot piston 7 and press in the pin 4. Insert the retaining rings 8. Make sure that the arrow on the piston head and the lugs on the connecting rod and the connecting rod cover are directed in the same direction.
3. Before installing new piston rings, measure the gap in the lock of each ring, inserting them into the cylinders, as described above. If the clearance is less than the nominal (for compression 0.3–0.45 mm, for oil scraper 0.25–0.5 mm), grind off the ends of the rings with a file. Piston rings engraved with the word «TOR», rings must be installed with this word to the piston head. Place the piston ring locks evenly at an angle of 120°from each other.
4. Install the connecting rod bearing shells 2 into the connecting rods 10 and the covers 11 so that the protrusion of the insert fits into the recess of the connecting rod or cover.
5. Lubricate the cylinders and pistons with engine oil and insert the pistons into the cylinders with the arrow on the piston head pointing forward towards the camshaft drive belt.
6. Lubricate the bearings and journals of the crankshaft with engine oil and install the cover 11 on the connecting rod 10 so that the cylinder number on the lower head of the connecting rod and the number on the cover are on the same side. Insert connecting rod bolts, tighten nuts and torque-tighten in two stages: 1st stage - 30 Nm (3.0 kgf·m); 2nd stage - tighten further a quarter of a turn (90°).
7. Rotate the crankshaft to make sure it turns freely.
8. Install the remaining pistons with connecting rods in the same way.
9. Use a feeler gauge to check the side clearance between the bottom head of the connecting rod and the web of the crankshaft. It should be equal to 0.37 mm.
10. Install the oil pump, cylinder head and camshaft drive belt.
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