1. Rear oil seal; 2. Rear oil seal holder; 3. Knock sensor; 4. Cylinder block; 5. Oil dipstick guide; 6. Top compression ring; 7. Second compression ring; 8. Oil scraper ring; 9. Piston; 10. Piston pin; 11. Connecting rod; 12. Connecting rod bearing; 13. Thrust bearing; 14. Main bearing; 15. Crankshaft; 16. Key; 17. Connecting rod bearing cap; 18. Connecting rod nut; 19. Main bearing cap bolt; 20. Main bearing cap; 21. Back plate; 22. Flywheel (models with manual gearbox); 23. Amplifying disc (models with automatic transmission); 24. Drive disc (models with automatic transmission); 25. O-ring; 26. Crank angle sensor (POS)
Disassembly
1. Remove the engine and transmission assembly from the vehicle and separate the transmission from the engine. See above section «Removal and installation».
2. Install the engine on the stand (special tool) in the following way:
Note: Let's use an engine stand as an example (suitable special tool) with mounting of the cylinder block on the rear side (from the gearbox side).
- A. Remove the cover and clutch disc. See chapter Clutch.
- b. Remove flywheel.
Fix the crankshaft with the ring gear holder (special tool), loosen the mounting bolts crosswise and remove.
Attention: Make sure the signal disk (1) not damaged or deformed.
Note: The figure shows the drive disc.
- With. Remove back plate
- d. Raise the engine with a winch and place it on a stand.
For information on installing lifting eyes on the engine, see section above «Removal and installation».
3. Drain the engine oil and coolant from the engine.
4. Remove the following components and related parts:
- air cleaner housing assembly; see section «Air cleaner and air duct»;
- the top of the intake manifold; see section «upper intake manifold»;
- fuel injectors and fuel tube assembly; see section «Fuel injectors and fuel pipe»;
- ignition coils; see section «Ignition coil»;
- valve cover; see section «Valve lid»;
- oil pan and coarse oil filter; see section «Oil pan and coarse oil filter»;
- front cover and timing chain; see section «Valve train chain»;
- camshaft; see section «camshaft»;
- cylinder head assembly; see section «cylinder head»;
- oil filter; see chapter Lubrication system and engine cooling system;
- low oil pressure warning light switch; see chapter Lubrication system and engine cooling system.
5 Remove the knock sensor.
Attention: Handle the sensor carefully, avoiding shock.
6. If necessary, remove the oil dipstick guide.
Attention: Once removed, the guide cannot be reinstalled. Take it out only when absolutely necessary.
7 Remove the rear oil seal retainer.
Remove by inserting a screwdriver between the main bearing cap and the rear oil seal retainer.
8 Remove the rear oil seal from the holder. Remove the seal using a screwdriver.
Caution: Be careful not to damage the rear oil seal holder.
9. Remove connecting rods and piston assemblies as follows:
Before removing the connecting rods, check the side clearance of the connecting rod. See section «Connecting rod side clearance».
- A. Bring the crankpin of the connecting rod to be removed to BDC
- b. Remove the big end cap.
- With. Push the connecting rod and piston assembly towards the cylinder head with a hammer handle
10. Remove the bearings from the connecting rod and connecting rod bearing cap.
Attention: When removing, make notes on the position of their installation and put them in order without mixing them.
11. Remove piston rings from pistons.
Use a piston ring expander (1).
Attention: Do not damage the piston when removing the piston rings. Do not spread the piston rings too wide - they may break.
Check the piston ring backlash before removing the piston rings. See section below «Piston ring side clearance».
12. Remove the piston from the connecting rod.
Press out the piston pin using a stand and a press.
Note: The piston pin has a press fit in the connecting rod.
Attention: Be careful not to damage the piston and connecting rod.
13. Remove the main bearing caps.
- A. Loosen and turn out the bolts in several passes in the reverse order shown in the figure.
Before loosening the main bearing cap bolts, measure the crankshaft end play. See section «Axial play of the crankshaft».
- b. Remove the main bearing caps by lightly tapping with a plastic mallet.
14. Remove the crankshaft.
15. Remove the main and thrust bearings from the cylinder block and remove the main bearing caps.
Attention: When removing, make notes on the position of their installation and put them in order without mixing them.
Assembly
1. Blow out the coolant passages, oil passages, cylinders and crankcase with compressed air and remove foreign particles from them.
2. If the plug was turned out (1), shown in the figure, apply sealant to the threads of the plug.
Use branded sealant or equivalent
Do not reuse the washer. Replace it with a new one.
Tighten to the required torque: 58.8-68.6 Nm (6.0-6.9 kg m)
3. Install the main and thrust bearings as follows:
- A. Remove foreign particles, dust, dirt and oil from the contact surfaces under the bearings in the cylinder block and from the main bearing caps.
- b. Install thrust bearings (1) on both sides of the neck №3 (2) in the cylinder block.
Install thrust bearings with oil groove (3) towards the crank arm (outside)
- With. Install the main bearings (1) , observing the installation direction.
Install main bearings with lubrication groove and hole (2) into the cylinder block, and bearings without them - into the main bearing caps (5).
Before installing the main bearings, apply fresh engine oil to the bearing surfaces (from within). Do not apply oil on the reverse side, but wipe it thoroughly.
When installing, align the lug of the stopper (3) grooved main bearing (4).
Make sure the oil holes in the cylinder block line up with the holes in the corresponding bearing.
4. Install the crankshaft in the cylinder block.
Turn the crankshaft by hand and make sure it turns freely.
5. Install the main bearing caps.
Mark them in front (1) towards the front of the engine.
Note: The cylinder block and main bearing caps are made in one piece. They can only be replaced as a set.
6. Tighten the main bearing cap bolts in several passes in the order indicated by the numbers in the figure.
- A. Apply fresh engine oil to the threads and seating surfaces of the main bearing cap bolts.
- b. Tighten the bolts with a torque of 24.5-30.3 N.m (2.5-3.0 kg m)
- With. Tighten 90-100°clockwise (norm: 95°) (corner tightening).
Attention: Check the tightening angle with a protractor wrench (special tool). Avoid judging by eye without the use of tools.
After tightening the main bearing cap bolts, turn the crankshaft by hand and check that it rotates freely.
Check crankshaft end play. See section «Axial play of the crankshaft».
7. Install the connecting rods into the pistons as follows:
- A. Assemble the piston and connecting rod so that the front mark (1) on the piston crown and cylinder number (2) on the connecting rod were located, as shown in the figure.
- b. Press in the piston pin using a stand (special tool).
Note: The piston pin has a press fit in the connecting rod. After installation, make sure the piston moves freely.
8. Install the piston rings with an expander, as shown in the figure.
Attention: When installing the piston rings, do not damage the piston. Do not spread the piston rings too wide - they may break.
Position the piston ring locks relative to the piston front mark (1), as it shown on the picture.
Install the top and second compression rings with the markings facing up.
9. Install bearings in connecting rods and caps.
When installing connecting rod bearings, apply fresh engine oil to the bearing surfaces (domestic). Do not apply oil on the reverse side, but wipe it thoroughly.
When installing, align the lug of the stopper (1) on a connecting rod bearing with a notch (2) on the rod.
10. Install the connecting rods and piston assemblies to the crankshaft.
Bring the crankpin of the connecting rod to be installed to BDC.
Apply a sufficient amount of engine oil to the cylinder walls, piston and crankpin.
Check the number of the cylinder to which the connecting rod corresponds.
Using a piston ring compressor (special tool) (1) Insert the piston with the class marking on the piston head towards the front of the engine.
Attention: When inserting the large connecting rod head, do not damage the cylinder walls and the connecting rod journal.
11. Install the connecting rod bearing cap.
Before installation, check if the marking of the cylinder number matches (1), embossed on the connecting rod markings on the cover.
12. Tighten the connecting rod nuts as follows:
- A. Apply fresh engine oil to the threads and seating surfaces of the connecting rod nuts and bolts.
- b. Tighten with a torque of 13.7-15.7 N.m (1.4-1.6 kg m)
- With. Tighten 45-50°clockwise (norm: 45°) (corner tightening)
Warning: Use a protractor wrench (special tool). Avoid judging by eye without the use of tools.
After tightening the nuts, make sure the crankshaft rotates freely.
Check the side clearance of the connecting rod. See section «Connecting rod side clearance».
13. Press in the rear oil seal.
Check that the area around the rear oil seal is not damaged and use a drift to drive the oil seal in.
Press in until the end of the rear oil seal is flush with the lip of the holder.
14. Install the rear oil seal holder.
Apply sealant evenly to the areas shown in the illustration.
Use branded sealant or equivalent.
Install so that it is aligned with the locating pin on the side of the cylinder block.
15. Install the dipstick guide (1).
Press in the oil dipstick guide (1) into the cylinder block with the control surface as shown in the figure.
Apply sealant to the press-in areas.
Caution: Replace the dipstick with a new one.
16. Install the knock sensor.
Install the sensor with the connector facing the front of the engine.
Attention:
- Handle the sensor with care. If you hit or dropped the knock sensor, replace it with a new one.
- Make sure that there are no foreign particles on the contact surface of the cylinder block and the rear surface of the knock sensor.
- Use recommended bolts.
- Do not tighten the bolts while holding the connector.
- Make sure the knock sensor does not interfere with other parts.
17. After this operation, the components removed in step 4 are assembled in the reverse order of disassembly.
18. Hang the engine with a winch, unscrew the bolts and separate from the stand.
19. Install the back plate.
20. Install flywheel (1).
Install with signal disc (4) toward the rear of the engine.
Install by aligning the hole (6) for dowel pin with dowel pin (5) from the back of the crankshaft.
Attention: Make sure the signal disk (4) not damaged or deformed.
Fix the crankshaft with the ring gear holder (special tool) and tighten the bolts crosswise.
21. Install the remaining components in the reverse order of removal.