Pick up the main bearing caps with liners and install them on the bed of the block. Tighten the roof mounting bolts to a torque of 6.5 kgf·m.
Note. When installing, the sags on the main bearing caps must be aligned with the protrusions on the lower bearings.
Use a set of feelers to measure the free axial movement of the crankshaft on the third bearing, which should be within 0.07-0.17 mm. If the gap exceeds the maximum allowable 0.25 mm, and the crankshaft main journals are not ground, install liners with nominal size shoulders on the third support. If the main journals are ground to the repair size, put liners with collars of the appropriate size on the third support.
Install three piston rings into the corresponding grooves in the pistons, placing their locks through 120°.
Orient the piston ring locks forward or backward in the direction of the vehicle. There is a mark on the lower compression and oil scraper rings «top» or «oben» («top»), which must face upwards when the ring is installed in the groove.
Check the diameter markings on the piston crowns.
Install the pistons, orienting the arrow on the piston head forward in the direction of the vehicle (towards the camshaft drive).
Assemble pistons with connecting rods. The connecting rods of the same engine must belong to the same mass group, which is marked on the connecting rod caps.
Lubricate the pistons and piston rings with engine oil, press the piston rings in the grooves with a suitable mounting sleeve and insert the pistons with connecting rods into the cylinders.
Install the liners in the connecting rods and connecting rod caps in accordance with the marks made during disassembly, if worn liners are used.
Install the connecting rods and covers on the crankshaft journals, while the sagging on the covers and the locking tabs on the liners should be directed towards the intermediate shaft.
Screw on the connecting rod nuts. then tighten them with a torque of 3.5 kgf·m.
Note. Replace the connecting rod bolts every time the engine is reassembled.
Note. When assembling the engine, always install new crankshaft oil seals. The use of used oil seals is not allowed.
Install the rear oil seal holder with a new cardboard gasket. Using tool 2003/1, press the oil seal into the holder until it stops.
Install the flywheel, ensuring that the surface under the clutch disc protrudes relative to the cylinder block within 30.50-32.10 mm.
If necessary, install a spacer between the flywheel and the crankshaft flange. Install the lock washer on the flywheel with the beveled edge toward the flywheel. Apply special glue to the fastening bolts.
Install the crankshaft front oil seal retainer with a new cardboard gasket. Press a new oil seal into the holder using drift 3083.
Insert the intermediate shaft into the cylinder block. Install the holder with the pressed-in oil seal and sealing gasket on the intermediate shaft.
Install the oil pump after checking its technical condition.
Install the oil pan with a new gasket.
Install the cylinder head.
Install the camshaft drive belt.
Install water pump.
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