Fitting the pistons with connecting rods
Lubricate the upper parts of the cylinders and the connecting rod journals of the crankshaft with engine oil.
Fit the pistons complete with connecting rods using a piston ring compressor into the cylinder liner, observing the matching of pistons and cylinders.
The marks on the pistons must face towards the flywheel.
Fit the connecting rods onto the connecting rod journals of the crankshaft.
Fit the connecting rod caps (see Fig. 13).
Tighten the nuts of the connecting rod cap studs to a torque of 20 N·m + (45°±5°).
Fit the oil pump drive sprocket, the oil pump drive chain and the oil pump (see Fig. 14).
Tighten the oil pump retaining bolts to the required torque.
The tightness of the front cover of the engine cylinder block can be ensured either by fitting a gasket or by fitting the cover with Loctite 518 sealant. The mating surfaces of the cylinder block and the front cover of the engine block must be clean, dry and free from oil traces; do not touch them with your hands.
Loctite 518 is applied in a 1 mm wide bead; the application location is shown in Fig. 15.
Fit the front cover of the engine cylinder block.
Tighten the front cover retaining bolts of the cylinder block in the sequence shown in Fig. 16.
The mating surfaces of the cylinder block and the water pump must be clean, dry and free from oil traces; do not touch them with your hands.
Fit the water pump. Instead of a gasket, use Loctite 518 sealant (1 mm wide bead); the application location is shown in Fig. 17.
Note. Apply one or two drops of Loctite Frenetanch to the water pump retaining bolts (1) and (4) (see Fig. 18).
Tighten the M6 bolts and the M8 bolt in the sequence shown in Fig. 18.
Apply four beads of Rhodorseal 5661 about 5 mm wide to the joints of the front and rear covers and to the mating surfaces of the cylinder block. For the location of the application points see 1, Fig. 19; for the rear cover the sealant is applied in the same way.
Apply two drops of Rhodorseal 5661 about 7 mm in diameter to the mating surface of the front cover and the cylinder block (2).
When fitting the engine oil sump, make sure that the tabs (1) of the oil baffle are fitted in the slots (2) (see Fig. 20). The cylinder block and the engine oil sump must be aligned on the flywheel side so as not to damage the clutch housing when connecting the engine to the gearbox.
Fit the oil baffle.
Fit the oil sump with a new gasket.
Tighten the oil sump retaining bolts in the sequence shown in Fig. 21:
- first pass: 8 N·m;
- second pass: 14 N·m.
Fit the oil level sensor and tighten it to the required torque. The tightening torques are given at the beginning of the article.
Fit the knock sensor and tighten it to the required torque.
Fit the oil pressure sensor and tighten it to the required torque.
Press in the rear crankshaft oil seal with the Mot1129-01 driver (see Fig. 22).
Press in the front crankshaft oil seal with the Mot1385 driver (see Fig. 23).
Replace the flywheel retaining bolts. Reuse of the old bolts is not permitted.
Clean the crankshaft mating flange and the threaded holes for the retaining bolts.
Check the technical condition of the flywheel.
Degrease the flywheel support surface and the mating surface on the crankshaft flange.
Fit the spacer sleeve (А, Fig. 24), mounting position — chamfer towards the flywheel.
Coat the threaded surfaces of the bolts with Loctite Frenetanch.
Screw in the retaining bolts by hand until they touch the flywheel, then lock the flywheel with the Mot582-01 or Mot1677 locking tool (see Fig. 25).
Tighten the flywheel retaining bolts to a torque of 55 N·m.
Fit the clutch driven disc and the clutch housing with the pressure plate as an assembly.
Centre the driven disc with the Emb1518 driver (see Fig. 26); the driver is suitable for centring the discs of VAZ cars.
Tighten the clutch housing retaining bolts.
Remove the flywheel locking tool.
