Table of contents: Tools used to install piston…↓ Final installation of the connecting…↓
- Lay out the pistons and connecting rods in the correct order. The numbers on the connecting rods correspond to the cylinder number.
- Remember that the mark (arrow) on the piston head should face the front of the engine (camshaft drive).
- Wipe the cylinders with a clean, lint-free cloth.
- Apply lubricant to the piston rings and then install the ring compressor onto the first piston to be installed.
Note: The skirt should protrude approximately 6mm to guide the piston into the cylinder.
- If you don't have a hose clamp, you can use a hose clamp of a suitable size.
Tools used to install piston assemblies with rings into engine cylinders
Universal (adjustable) bushing - general view
The simplest device made from a metal strip (by clamp type)
Connecting rod bearings - installation on the crankshaft
- Before installing the pistons and connecting rods, the walls of the block grooves must be thoroughly cleaned and the crankshaft installed in place.
- Remove the cap from connecting rod number 1 (the covers should have factory marks or marks made during removal).
- Clean the back of the new upper bearing shell, then place it into place in the connecting rod. Make sure the key on the bearing fits into the recess in the connecting rod. Do not hammer the bearing shell or scratch the bearing surface. Do not lubricate the bearing yet.
- Clean the back of the second bearing and install it into the connecting rod cap. Make sure the liner key fits into the cover recess, but do not apply grease yet.
- Orient the piston so that the "front" mark (arrow) on its top is facing forward (towards the camshaft drive), carefully insert the piston with the connecting rod into the first cylinder.
- Gently press down on the top of the piston with a wooden block (you can use a hammer handle), while simultaneously guiding the end of the connecting rod into its place on the crankpin of the crankshaft. Work slowly and if you feel resistance, stop immediately. Find out the cause and eliminate it. Do not press hard on the piston under any circumstances, as this could damage the seating surfaces.
- Once the piston and connecting rod are installed, it is necessary to check the connecting rod bearing oil clearance before the connecting rod is finally screwed into place.
- Cut a piece of appropriately sized clearance gauge plastic slightly shorter than the width of the connecting rod bearing and place it on the number 1 crankpin, parallel to its axis.
- Clean the surface of the connecting rod bearing cap and install the connecting rod cap with the "front" mark facing forward (towards the camshaft drive).
- Apply a thin coat of oil to the threads and underside of the bolt heads, then install them.
- Tighten the bolts to a torque of 18.6-20.6 N·m, and then tighten to an angle of 90-95°.
Caution: Do not rotate the crankshaft while doing this.
- Unscrew the bolts and remove the connecting rod cover, being careful not to damage the plastic.
- Compare the width of the crushed plastic to the scale on the package to determine the gap. The standard value is 0.046+0.012 mm. The limit value is 0.07 mm.
Caution: After removing the connecting rod bearing cap, pay attention to the bearing shell (the amount of protrusion) (arrow). If there is no protrusion, replace the liners.
- If the clearance is not within specifications, the bearing shells may be the wrong size. But before you decide to replace the bearings, check to see if any dirt or oil has gotten between the bearings and the connecting rod or cap. Also check the journal diameter of the shaft. If the width of the gap measuring plastic is different at each end of the strip, the shaft journal may be tapered and will need to be reground.
- The size group of connecting rod bearing liners is selected by measuring the crankshaft journal and comparing it with the values specified in the "Crankshaft journal diameter" column of the table below.
Dimensional groups of connecting rod bearings
| Crankshaft journal diameter, mm | Size group number | Liner thickness, mm | Identification color of the insert |
| 51,968-51,974 | 0 | 1,500-1,503 | Black |
| 51,962-51,968 | 1 | 1,503-1,506 | Brown |
| 51,956-51,962 | 2 | 1,506-1,509 | Green |
Caution: When selecting the size group and installing new liners, be sure to measure the diameter of the hole in the lower head of the connecting rod. The standard value is 55.000-55.013 mm. If the diameter differs from the standard, the connecting rod must be replaced.
Crankshaft identification marks
1 - identification code; 2 — number (mark) of the main journal diameter group; 3 — number (mark) of the crank pin diameter group.
- If the required oil clearance cannot be achieved using standard size connecting rod bearing shells, oversize shells must be used.
- When using oversize connecting rod bearing shells, measure the inside diameter of the shells in the installed state and regrind the crankshaft connecting rod journal so that the oil clearance value corresponds to the standard values.
| Size, mm | Thickness, mm |
| Repair size 0.25 | 2,132-2,140 |
Attention: When regrinding the connecting rod journals and the crankshaft for oversize liners, it is necessary to maintain a flange (arrows) on all crankshaft journals of 1.5 mm in size.
Final installation of the connecting rod
- Carefully clean all traces of clearance gauge plastic from the journal and bearing surfaces, being careful not to scratch the bearing.
- Make sure the bearing surfaces are completely clean and apply a uniform layer of grease to both bearings. You will have to push the piston into the cylinder bore to gain access to the connecting rod bearing.
- Place the connecting rod on the journal, install the cap, apply a thin film of oil to the threads and the underside of the bolt heads, then install them and tighten to the specified torque.
- Repeat the described procedure for the remaining pistons and connecting rods.
Caution: Before final installation of the connecting rod, it is necessary to measure the diameter of the connecting rod bolts at a distance of 19 mm from its end. The standard value is 7.95±0.05 mm. The maximum value is 7.75 mm. If the bolt diameter is less than the maximum allowable value, it must be replaced.
- Check the piston group assembly.
- Once all pistons and connecting rods are installed, turn the crankshaft by hand a few times and check for binding.
- Check the play of the connecting rods.
- Compare the measured clearance with the technical data. If the clearance was within the norm before disassembly, and the old connecting rods and crankshaft were used, then it should remain within the norm. If new connecting rods or a new crankshaft were installed, the clearance may not be within the norm. In this case, it is necessary to remove the connecting rods and take them to a workshop for mechanical processing.