Note. At installation it is necessary to use new nuts/bolts of lower heads of connecting rods.
1. Keep in mind that the following procedure is based on the premise that the crankshaft and main bearing caps are installed (see paragraph 18).
2. Clean the backs of the bearing shells and the bearing mounting areas in the connecting rod and bearing cap. Install the bearing shells into place, making sure that the tab on each shell fits into the groove in the connecting rod and cap (pic. 19.2). Do not touch the running surface of the bearing shells with your fingers. If new bearings are installed, use kerosene to remove all traces of protective grease from them. Wipe the bearings and connecting rods dry with a lint-free cloth.
Pic. 19.2. Installing the bearing shell in the connecting rod; make sure that the protrusion (marked with an arrow) entered the recess in the connecting rod
3. Lubricate the cylinders, pistons and piston rings, and then insert each piston and connecting rod assembly into the appropriate cylinder.
4. Begin assembly with cylinder #1. Make sure the piston ring locks are still positioned as described in paragraph 17, and then compress the rings using a piston ring compressor. Insert the piston and connecting rod assembly into the top area of cylinder #1 so that the piston is correctly positioned as follows:
- A) On 1.8L and 1.9L engines, make sure that the cloverleaf groove on the piston crown faces the front of the cylinder block (towards the oil filter).
- b) On 2.0L engines, make sure that the valve recess on the piston crown faces the rear of the cylinder block.
5. Using a piece of wood or a hammer handle, lightly tap the piston crown and «drive» piston into cylinder/sleeve. The bottom of the piston should be flush with the top end of the cylinder (pic. 19.5).
Pic. 19.5. Inserting the piston into the cylinder with a hammer handle
6. Check if the earbuds have moved out of the correct position. Lubricate the crankpin and both bearings liberally. Carefully, so as not to stain the cylinder bore, move the piston assembly with the connecting rod down until it sits on the connecting rod journal. Install the connecting rod bearing cap, install new nuts and tighten them first by hand only. Keep in mind that surfaces with identification markings must be matched (this means that the lugs of the bearing shells must be adjacent to each other).
7. Tighten the bearing cap nuts evenly and progressively to the specified torque per step 1. Once the bearing cap nuts have been tightened per step 1, then use a socket and extension to tighten to the specified angle per step 2. To ensure accuracy at this step tightening, it is recommended to use a goniometer.
8. After tightening the bearing cap nuts, rotate the crankshaft. Make sure it rotates freely. In the case of installing new elements, some stiffness is acceptable, but there should be no binding or sticking.
9. Similarly establish three other pistons in gathering with rods.
10. Install the cylinder head and oil pump as described in chapter 2B or 2B or in paragraph 5 this chapter (whichever is applicable).