1. Using engine oil, install the upper thrust washers on each side of main bearing #2 with the oil grooves facing the crankshaft.
2. Install the bearing shells in their places. Lubricate the working surface of the shell with clean engine oil. To correctly install the lower shell, align the protrusion on the shell with the groove on the cover (arrow).
3. Install the crankshaft in the cylinder block so that the main journals of the 2nd and 3rd cylinders are at TDC. Check the axial clearance of the crankshaft.
4. Lubricate the lower bearing shells in the main bearing caps with clean engine oil and check that the tabs on the shells are in the grooves in the cap.
5. Install main bearing caps 2 through 5 and screw them in place without tightening.
6. Apply a thin layer of sealant to the mating surface of the cylinder block with the first bearing cap.
7. Install the seal on both sides into the groove of bearing cap No.1.
8. When installing the cover, two 0.25 mm thick metal strips must be used to protect the seal from displacement.
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9. Lubricate both sides of the metal strips with engine oil and secure them to the seal. Install the bearing cap #1, insert the bolts into it and tighten them by hand, then pull out the metal strips with pliers.
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10. Tighten the bearing cap bolts gradually and consistently to the specified torque. Using a sharp knife, trim the ends of the seal so that they protrude above the cylinder block surface by approximately 1 mm.
11. On 1.6 and 1.8 litre petrol engines, install the front and rear bearing caps and tighten the bolts to the specified torque.
12. Install a new seal ring onto the rear of the crankshaft.
13. Install the pistons with connecting rods.
14. Install the woodruff key and oil pump drive sprocket with gasket. Install the oil pump drive chain onto the sprocket.
15. Check that the mating surfaces of the front cover and cylinder block are clean and dry.
16. Apply a thin layer of sealant to the mating surfaces of the front seal cover and bolt it in place. Install a new front seal ring onto the crankshaft. Check the chain position on the crankshaft sprocket, install the oil pump and pan.
17. If the cylinder head was removed, install it.