Note: New big end nuts/bolts must be used during installation.
1. Please note 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, ensuring that the tab on each shell fits into the groove in the connecting rod and cap (figure 19.2). Do not touch the working surface of the bearing shells with your fingers. If new bearings are being installed, remove all traces of protective grease from them using kerosene. Wipe the bearings and connecting rods dry with a lint-free cloth.
Figure 19.2. Installing the bearing shell into the connecting rod; make sure the ledge (marked with an arrow) entered the recess in the connecting rod
3. Lubricate the cylinders, pistons and piston rings, and then insert each piston assembly with the connecting rod into the corresponding cylinder.
4. Begin assembly with cylinder #1. Make sure the piston ring joints are still positioned as described in paragraph 17, and then compress the rings using a piston ring compressor. Insert the piston assembly with the connecting rod into the upper area of cylinder No. 1 so that the piston is correctly positioned as described below:
- a) On 1.8L and 1.9L engines, ensure that the cloverleaf-shaped recess on the piston crown faces the front of the cylinder block (towards the oil filter).
- b) On 2.0L engines, ensure that the valve recess on the piston crown faces the rear of the cylinder block.
5. Using a wooden block or the handle of a hammer, lightly tap the piston crown and drive it into the cylinder/liner. The piston crown should be flush with the top of the cylinder (figure 19.5).
Figure 19.5. Inserting the piston into the cylinder using a hammer handle
6. Check that the liners have not shifted from the correct position. Generously lubricate the crankpin and both bearings. Carefully, so as not to dirty the cylinder bore, move the piston assembly with the connecting rod down until it seats on the crankpin. Install the big-end bearing cap, screw on the new nuts and tighten them by hand only at first. Please note that surfaces with identification markings must be consistent (this means that the mounting projections of the bearing shells must be adjacent to each other).
7. Tighten the bearing cap nuts evenly and gradually to the specified torque as per stage 1. Once the bearing cap nuts have been tightened as per stage 1, then use a socket head and extension to tighten them to the specified angle as per stage 2. To ensure accuracy at this stage of tightening, it is recommended to use a protractor.
8. After tightening the bearing cap nuts, turn the crankshaft. Make sure it rotates freely. When installing new components, some stiffness is acceptable, but there should be no binding or seizing.
9. Install the other three pistons and connecting rods in the same manner.
10. Install the cylinder head and oil pump as described in chapter 2B or 2B or in paragraph 5 this chapter (whichever is applicable).