Table of contents: Selection of bearing shells 🠇 Installation 🠇
Selection of bearing shells
1. The crankshaft should be submitted to an engine overhaul specialist for inspection and measurement. Our specialists can perform any regrinding/repair and select the appropriate main and connecting rod bearing shells.
Installation
Note: When installing the crankshaft, new main bearing cap/housing bolts must be used.
2. If applicable, install oil jets in the bearing area of the cylinder block.
1.4L engines
3. Using a small amount of grease, glue the upper thrust washers to each side of the top of the No. 2 main bearing. Make sure the oil grooves on each thrust washer are facing outward (away from the cylinder block).
4. Wipe clean the backs of the bearing shells and the bearing mounting areas in the cylinder block/crankcase and main bearing housing/bearing caps.
5. Install the bearing shells into their original locations, ensuring that the protrusion on each bearing shell fits into the groove in the cylinder block/crankcase and main bearing housing/bearing cap. Be careful not to touch the working surfaces of the bearing shells with your fingers. Please note that there is a groove on the upper and lower bearing shells #2 and #4 (figure 17.5).
Figure 17.5. Install grooved bearing shells for bearings No. 2 and 4 (1.4 l engines)
6. Generously lubricate each bearing shell in the cylinder block/crankcase with clean engine oil.
7. Install the woodruff key, then install the oil pump drive sprocket and place the drive chain on the sprocket (figure 17.7). Install the crankshaft in place so that connecting rod journals No. 2 and 3 are in the TDC position; the crankpins of cylinders #1 and #4 will be in the BDC position. This is the ready position for installing piston #1. Check the crankshaft end clearance as described in paragraph 13.
Figure 17.7. Install the oil pump drive chain and sprocket (1.4 l engines)
8. Thoroughly degrease the mating surfaces of the cylinder block/crankcase and main bearing housing. Apply a thin bead of sealant to the surface of the main bearing housing that mating with the cylinder block. Then smooth the sealant into a thin layer (figure 17.8).
Figure 17.8. Apply a thin layer of sealant to the mating surface of the cylinder block (1.4 l engines)
9. Make sure that the mounting pins are in their proper places. Then lubricate the lower bearing shells with clean engine oil. Install the main bearing housing onto the cylinder block, ensuring that the lower bearings remain in the correct position.
10. Install the main bearing housing mounting bolts and tighten them all by hand only. Working in a spiral pattern, starting from the center bolts and working outward, tighten the bolts evenly and gradually to the specified torque as per Stage 1 (figure 17.10). Once all the bolts have been tightened according to stage 2, working in the same sequence, use a socket head and extension to tighten the bolts to the specified angle according to stage 2. It is recommended to use a protractor at this stage of tightening to ensure accuracy. If you do not have a protractor, mark the relative positions of the bolt head and main bearing housing with white paint before tightening; the marking can then be used to check that the bolt is turned correctly during tightening.
Figure 17.10. Tighten the ten main bearing bolts to the specified torque (1.4 l engines)
11. Install all smaller main bearing housing bolts to the cylinder block base and tighten them to the specified torque. Make sure the crankshaft rotates freely.
12. Install the pistons and connecting rods on the crankshaft as described in paragraph 18.
13. After ensuring that the drive chain is correctly positioned on the sprocket, install the oil pump and oil pan as described in chapter 2A.
14. Install two new oil seals onto the crankshaft as described in chapter 2A.
15. Install the flywheel as described in chapter 2A.
16. Install the cylinder head (if it was removed), as described in chapter 2A. Also install the crankshaft timing belt and timing belt (see Chapter 2A).
1.6L engines
17. Using a small amount of grease, glue the upper thrust washers to each side of the top of the No. 2 main bearing. Make sure the oil grooves on each thrust washer are facing outward (away from the cylinder block) (figure 17.17).
Figure 17.17. Install thrust washers on both sides of main bearing No. 2 so that the oil grooves face outward (1.6 l engines)
18. Install the liners in their regular places as described in paragraph. points 4 and 5 (figure 17.18). If new bearings are being installed, remove all traces of protective grease from them using kerosene. Wipe the earbuds dry with a lint-free cloth. Generously lubricate each bearing shell in the cylinder block/crankcase and bearing cap with clean engine oil.
Figure 17.18. When installing the bearing shell, make sure that the protrusion (marked with an arrow) was located in the corresponding cutout (1.6 l engines)
19. Install the crankshaft in place so that connecting rod journals No. 2 and 3 are in the TDC position; the crankpins of cylinders #1 and #4 will be in the BDC position. This is the ready position for installing piston #1. Check the crankshaft end clearance as described in paragraph 13.
20. Lubricate the lower bearing shells in the main bearing caps with clean engine oil. Make sure that the mounting tabs on the inserts fit into the corresponding recesses in the covers.
21. Install the main bearing caps according to their original position, orienting them correctly (the protrusions on the bearing shells and the recesses in the block and covers must be located on the same side).
22. Lightly lubricate the threads and the back of the main bearing cap bolt heads with engine oil, then install the bolts. Working in a spiral sequence, starting from the center bolts and working outward, tighten the bolts evenly and gradually to the specified torque as per Stage 1. Once all the bolts have been tightened as per Stage 1, working in the same sequence, use a socket head and extension to tighten the bolts to the specified angle as per Stage 2. It is recommended to use a protractor at this stage of tightening to ensure accuracy. If you do not have a protractor, mark the relative positions of the bolt head and main bearing housing with white paint before tightening; the marking can then be used to check that the bolt is turned correctly during tightening.
23. Make sure the crankshaft can turn freely.
24. Install the pistons and connecting rods assemblies onto the crankshaft as described in paragraph 18.
25. Install the woodruff key into the groove on the crankshaft and install the oil pump drive sprocket. Install the drive chain onto the sprocket.
26. Clean and dry the mating surfaces of the right housing (on the timing belt side) cuffs and cylinder block. Mark the installation depth of the cuff, and then use a large flat-head screwdriver to remove the "old" cuff from the housing.
27. Apply a bead of suitable sealant to the mating surface of the seal body and ensure that the locating pins are present. Install the crankcase seal housing onto the end of the crankshaft and then move it to its normal position on the cylinder block. Tighten the housing mounting bolts securely.
28. Repeat steps according to step. p. 26 and 27 and install the left cuff housing (on the flywheel side).
29. Install new crankshaft oil seals as described in chapter 2A.
[Information posted on the website www.peugeotbook.ru]
30. After ensuring that the drive chain is correctly positioned on the sprocket, install the oil pump and oil pan as described in chapter 2A.
31. Install the flywheel as described in chapter 2A.
32. Install the cylinder head (if it was removed). Also install the crankshaft timing belt pulley and timing belt (see Chapter 2A).