Note. At installation it is necessary to use new nuts/bolts of lower heads of connecting rods.
1. Please note that the following procedure is based on the premise that the cylinder liners (aluminum block engines) are in their original positions in the cylinder block/crankcase, as described in paragraph 11, and the crankshaft and main bearing housing/caps are installed.
2. Clean the backs of the bearing shells and the bearing mounting areas in the connecting rod and bearing cap.
3. Install the bearing shells into place, making sure that the tab on each shell fits into the groove in the connecting rod and cap. Do not touch the running surface of the bearing shells with your fingers (pic. 18.3).
Pic. 18.3. Make sure that the protrusion on the bearing shell (marked with an arrow) has been correctly inserted into the cutout
4. Lubricate the cylinders, pistons, and piston rings, and then insert each piston and connecting rod assembly into the appropriate cylinder.
5. Begin assembly with cylinder #1. Make sure the piston ring locks are still positioned as described in paragraph 16, and then compress the rings using a piston ring compressor.
6. Insert the piston and connecting rod assembly into the top area of the No. 1 cylinder/sleeve with the arrow on the bottom of the piston facing the end of the engine where the timing belt is located.
7. Once the piston is correctly positioned, use a piece of wood or a hammer handle to 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/liner (pic. 18.7).
Pic. 18.7. Drive the piston into the cylinder using the hammer handle
8. Check if the earbuds have moved out of their correct position. Lubricate the crankpin and both bearings liberally. Carefully, so as not to stain the cylinder head/liner, 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 (pic. 18.8). 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).
Pic. 18.8. Install the connecting rod bearing cap, orienting it correctly, and install new nuts
9. Tighten the bearing cap nuts evenly and progressively to the specified torque.
10. As soon as nuts of fastening of covers of bearings will be tightened properly, turn a cranked shaft. Make sure it rotates freely. In the case of installing new elements, some stiffness is acceptable, but there should be no binding or sticking.
11. Install the cylinder head and oil pump as described in chapter 2A.