Remove the oil pump, rear crankshaft oil seal cover, all pistons and the front timing belt cover.
Attention!
- The main bearing caps are bored together with the block and cannot be replaced or re-positioned.
- Bearing caps 1–5 have markings on the outlet side, bearing caps 6 and 7 have no markings. Bearing cap 6 is a thrust bearing.
- Place the removed crankshaft on a support that prevents the surface from coming into contact with the toothed wheel of the crankshaft speed sensor.
Loosen the bolts (25, 10 pcs., see Fig. 6.2), and remove the stiffening insert (23) of the cylinder block crankcase.
Check the axial clearance of the crankshaft (Fig. 6.55). If the axial clearance exceeds the permissible value (0.080–0.234 mm), then it is necessary to check the crankshaft and the thrust bearing shells. Worn parts are subject to replacement.
Unscrew the bolts securing the main bearing caps from the edges to the middle, remove them (1–7, Fig. 6.56) and arrange them according to the numbering in the "cash register" for the parts to be removed. The numbering of the bearing caps starts from the side of the torsional vibration damper.
Remove the crankshaft and carefully place it on a stand. Remove the main bearing shells and replace them.
If necessary, unscrew the bolts and remove the crankshaft speed sensor gear. When installing the gear, replace the bolts with new ones and tighten them:
- M5 (10.9) with a torque of 13 Nm (1.3 kgf·m);
- M5 (8.8) with a torque of 5.5 N·m (0.55 kgf·m).
Remove traces of dirt and oil from blind holes by blowing them out with compressed air. Lubricate the main bearing shells with engine oil and place them in the crankcase body and bearing caps.
Place the crankshaft in the engine crankcase. Install bearing caps 1 – 7 (bearing 1 on the timing drive side) so that the bearing shell guide splines are on the same side. Bearing caps 1–5 are marked (Fig. 6.57) on the outlet side. Bearing caps 6 and 7 are not marked. Bearing cap 6 is a thrust bearing. Center the bearing caps precisely.
Replace the main bearing cap mounting bolts with new ones, without washing off their coating. New mounting bolts (old edition) wash in kerosene and lubricate with engine oil. Tighten the main bearing cap bolts in the following order:
- tighten all main bearing cap mounting bolts from the middle to the edges with a torque of 22 N·m (2.2 kgf·m);
- unscrew the main bearing cap mounting bolts No.6;
- tap the rear and front ends of the crankshaft with a plastic-faced hammer to locate the thrust bearing;
- tighten the main bearing cap mounting bolts No.6 to a torque of 22 N·m (2.2 kgf·m);
- tighten all the main bearing cap mounting bolts from the middle to the edges at an angle of 90°, for which use the "11.2.110" or "00.9.120" tools.
Check axial clearance (see fig. 6.55) crankshaft, the nominal value of which should be within 0.080–0.234 mm.
Replace the connecting rod bearing shells and the front bearing of the manual transmission primary shaft, if provided. Assemble the engine.