2. Place the cylinder block on a flat, clean bench surface with the crankcase facing up. Wipe the beddings of the liners with a lint-free cloth - they should be spotlessly clean.
3. Wipe the back of the earbuds clean and dry, leaving no lint from the cloth. Lay the liners in the bed, with the lug of the lock in the recess in the bed, correctly arranging the holes (pic. 13.3). Do not use a hammer or other excessive force to install the liners. It is extremely important to keep the working surface of the liners undamaged and clean.
4. Install thrust washers on both sides of the third leg. Brush them lightly with oil to keep them in place. Install them with the tabs in the recesses of the block, oil grooves out (pic. 13.4).
5. Wipe the crankshaft journals again with a clean rag. The oil passages must be free of dirt that will damage the new liners on the first start.
6. Carefully place the crankshaft into the crankcase, being careful not to dislodge the liners.
Checking clearance in bearings
7. When installing the crankshaft, clearance must be left in its bearings to ensure oil circulation. This gap cannot be measured with a flat feeler gauge; for this, "Plastigauge" - a thin rod of soft plastic, which fits between the necks and liners when tightening the cap fasteners. Changing the width of the plastic rod serves to estimate the gap.
8. Small (slightly shorter than neck width) place a piece of plastic on the neck parallel to the axis of the shaft (pic. 13.8).
9. Wipe the surfaces of the new lower bushings and place them in the main bearing covers, aligning the locks with the notches in the covers (pic. 13.9).
10. Wipe the front surfaces of the earbuds and coat them with a thin layer of silicone grease to keep the flattened plastic from sticking. Install the covers in their places, using the manufacturer's markings for this. The locks of the liners should be on one side.
11. Starting from the center cover, tighten the fixing bolts half a turn to the prescribed torque specifications for the first stage. Do not rotate the crankshaft while doing this to dislodge the plastic. Gradually unscrew the bolts securing the covers and remove them, shifting the plastic.
12. Bring the spatula supplied with the "Plastigauge" - calculate the gap on it. Compare your results with the data given in Specifications. If the gap is out of range, this may be due to dirt trapped under the liner. Try cleaning the components and repeat the measurement. If the results are still unacceptable, measure the neck diameters and check the bearing sizes. If the piece of plastic is wider on one side than on the other, the neck may be tapered and needs to be resurfaced.
13. If satisfactory results are obtained, carefully remove the remaining plastic from the liners and necks. Use a soft scraper for this - metal can damage the surface.
Final crankshaft installation
14. Carefully remove the crankshaft from the block again. Wipe the bearing surfaces.
15. Lubricate the liners with clean engine oil.
16. Lay the crankshaft in the block with the connecting rod of the first cylinder up, so as to prepare for the installation of the first cylinder.
17. Be convinced of correct laying of loose leaves in covers of support, grease them with pure engine oil. Install the support half rings on both sides of the cover of the third support, with the protrusions in the recesses in the cover, with the oil channels out (pic. 13.17, a, b).
18. Install the support covers on the block, observing the order and orientation of the covers: cover No. 1 should be on the side of the timing belt, the locks of the liners should be installed on one side (pic. 13.18, a, b). Insert the cap screws and tighten them at this stage "by hand".
19. Starting from the middle support, tighten the cover bolts to the prescribed torque, tighten to the angles prescribed specifications (pic. 13.19, a, b).
20. Check the rotation of the crankshaft - it should be easy, without jamming. If force is required to rotate, find out the cause before proceeding with further assembly.
21. Check the crankshaft end play as described in paragraph 8. If the thrust surfaces have been checked and new thrust washers fitted, the clearance should be within "tolerances".
22. Install pistons with connecting rods, or attach them to the shaft as described in paragraph 15.
23. As described in chapters 2A or 2B, do the following:
- A) Install the front and rear oil seal housings with new oil seals.
- 6) Install the oil pump and receiver, baffle plate and sump.
- V) Install flywheel and clutch or faceplate (what is provided).
- G) Install the crankshaft sprocket and timing belt.
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