Preparation for disassembly
1. (Manual transmission) Remove cover and clutch disc.
2. (Manual transmission) Remove flywheel.
3. (Automatic transmission) Remove the drive disk.
4. Remove the rear end cap. Remove the two bolts, end cap and dust cover.
5. Install the engine on a stand for disassembly.
6. Remove the generator.
7. Remove the timing belt and pulleys.
8. Remove the cylinder head (see section "cylinder head").
9. Remove injection pump (see section "Fuel system").
10. Remove the water pump (see section "Cooling system").
11. Remove the oil pan and oil pump (see section "Lubrication system").
12. Remove the oil cooler (see section "Lubrication system").
Disassembly
1. Remove the four bolts, holder and gasket.
2. Check up an axial backlash of a rod. Using a dial indicator, measure the end play by moving the connecting rod back and forth.
- Rated axial clearance - 0.08-0.30 mm
- Maximum axial clearance - 0.35 mm
If the axial clearance exceeds the maximum allowable value, then replace the connecting rod. If necessary, replace the crankshaft.
3. Remove the covers of the lower heads of the connecting rods and check the clearance in the connecting rod journals.
A) Using a center punch or digital stamp, mark the alignment marks on the connecting rod and cap to ensure correct assembly.
b) Loosen the connecting rod cap nuts.
V) Use a plastic-headed hammer to tap on the bolts and remove the connecting rod caps.
Note: Leave the connecting rod bearings in place.
G) Cover the connecting rod bolts with small pieces of hose to protect the crankshaft from damage.
d) Clean the crankpin and bearing.
e) Check the connecting rod journal and bearing for chipping and cracks. If the connecting rod journal or bearing is damaged, replace the bearing shells. If necessary, grind or replace the crankshaft.
and) Place a piece of plastic gauge along the axis of the crankpin.
h) Install the connecting rod cap and tighten the nuts. The second pass is a 90°turn.
- Tightening torque - 54 Nm
Note: Do not turn the crankshaft.
And) Remove the connecting rod cap.
To) Measure the size of the gauge at the point of maximum width, determine the gap.
- Nominal neck size - 0.036 - 0.064 mm
Repair No. 1:
- Engine 2L - 0.023 - 0.073 mm
- Engine 3L - 0.033 - 0.079 mm
Max Gap: 0.10mm
If the clearance exceeds the maximum allowable value, grind or replace the crankshaft.
Note: If bearings of nominal size are installed, then the bearing can be replaced with a bearing having the same number, the marking of which is printed on the connecting rod cap. The standard bearing has one of three sizes marked "1", "2" And "3" respectively.
Wall thickness at the center point of a bearing shell of nominal size:
- Marking "1" - 1.478 - 1.482 mm
- Marking "2" - 1.482 - 1.486 mm
- Marking "3" - 1.486 - 1.490 mm
l) Completely remove the remaining caliber.
4. Remove the connecting rod and piston group.
A) Remove carbon deposits from the top of the cylinder.
b) Push the connecting rod and piston assembly and upper bearing shell through the top side of the cylinder block.
Note: keep bearings (liners), connecting rod and cap together. Arrange the piston and connecting rod assemblies in the removal order.
5. Check up an axial backlash of a cranked shaft. Using a dial indicator, measure the end play while moving the crankshaft back and forth with a screwdriver acting as a lever.
- Rated axial clearance: 0.04 - 0.25 mm
- Maximum axial clearance: 0.30mm
If the axial clearance exceeds the maximum allowable value, replace the thrust bearing.
Thickness of thrust half rings:
- Nominal - 2.430 - 2.480 mm
- Repair No. 1 - 2.493 - 2.543 mm
- Repair No. 2 - 2.555 - 2.605 mm
6. Remove main bearing caps and check clearance "main journal - bearing".
A) Remove the ten main bearing cap bolts.
b) Using the removed main bearing cap bolts, move the main bearing cap back and forth, then remove the main bearing caps, lower main bearing shells, and lower thrust washers (only in main bearing cap no. 3).
Note: Keep the lower main bearing shell and main bearing cap together.
Position the main bearing caps and lower thrust washers in the order in which they were removed.
V) Raise the crankshaft.
Note: Keep the upper main bearing shells and upper thrust washers with the cylinder block.
G) Clean the neck and shell of each main bearing.
d) Check the journal and bushing of each main bearing for chipping and cracks. If the journal or bushing is damaged, replace the bearing shells. If necessary, grind or replace the crankshaft.
e) Install the crankshaft to the cylinder block.
and) Place a plastic gauge on each neck.
h) Install the main bearing caps (see section "Cylinder block assembly").
- Tightening torque - 103 Nm
Note: Do not turn the crankshaft.
And) Remove the main bearing caps.
To) Measure the size of the gauge at the point of maximum width, determine the gap.
- Nominal size - 0.034 - 0.065 mm
- Repair size No. 1 and 2 - 0.033 - 0.079 mm
- Maximum clearance - 0.10 mm
If the clearance exceeds the maximum allowable value, then replace the bearing shells. If necessary, grind or replace the crankshaft.
Note: If bearings of nominal size are installed, then the bearing can be replaced with a bearing of the same number, the marking of which is located on the back on the lower right side of the cylinder block. Standard bearings are divided into three sizes marked "1", "2" And "3" respectively.
Wall thickness at the center point of a standard size bearing shell:
- Marking "1" - 1.979 - 1.983 mm
- Marking "2" - 1.983 - 1.987 mm
- Marking "3" - 1.987 - 1.991 mm
l) Completely remove the remaining caliber.
7. Remove the crankshaft.
A) Raise the crankshaft.
b) Remove the upper main bearing shells and upper thrust washers from the cylinder block.
Note: Position the main bearing caps, bearing shells and thrust washers in the order in which they were removed.
8. Remove check valves and oil nozzles (see section "Lubrication system").