After we have prepared the nodes and parts for assembling the cylinder block, we proceed to the assembly.

The assembly of the connecting rod with the piston is discussed in the article - "Piston Assembly". Block and crankshaft fault detection was discussed in the article - "Block and crankshaft preparation".

Installation of piston cooling nozzles

New injectors must be carefully pressed into the holes in the cylinder block, this operation is complicated by the fact that the injectors are small and access to the mounting holes is difficult, so we recommend using tools.

Fit the plate (2) of tool Mot. 1494 to the cylinder block without tightening the two mounting bolts (1) (see Fig. 1 and 2).

Сборка блока цилиндров двигателя К4МСборка блока цилиндров двигателя К4М

When installing the injectors of cylinders 1 and 3, the left hole of the support (1), Figure 1, is used.

When installing injectors for cylinders 2 and 4 - right-hand hole (Figure 2). Everything else is carried out in the same way.

Install the jig (3) into the plate (2). To center the plate, the end of the conductor must go into the hole for the nozzle.

- Tighten the two mounting bolts (1).

- Remove the jig (3).

Сборка блока цилиндров двигателя К4М

- Install the mandrel (1) instead of the jig (see Fig. 3). Insert the nozzle into the mandrel.

Сборка блока цилиндров двигателя К4М

Note. Pay attention to the direction of installation of the nozzle, the nozzle tip must be directed towards the center of the cylinder (see arrow, fig. 4).

- Hit the mandrel several times with a hammer until the collar (see 2, Fig. 3) touches the mandrel with the support.

Сборка блока цилиндров двигателя К4М

Check if the piston crown cooling nozzles are oriented correctly.

Mark "A" corresponds to the injectors of cylinders 2 and 4, and mark "B" corresponds to the injectors of cylinders 1 and 3 (see Fig. 5).

Crankshaft bearing shells

Reuse of the crankshaft bearing shells is not recommended.

When working, hard wear particles are interspersed into the soft layer of the liners, such liners subsequently accelerate the wear of the crankshaft journals.

Selection of root bearings

Сборка блока цилиндров двигателя К4М

The engine is equipped with bushings (see Fig. 6) without orienting elements (without a guide "whisker").

The inserts are fitted using tool Mot. 1493-01.

Dimensions of main bearing shells

Group

by diameter

holes

in the block

Dimensional groups by the diameter

of the main necks and the thickness of the liners, mm

A или D

B или  E

C или  F

1

yellow label

C1=1,949­—1,955

blue mark

C1=1,946­—1,952

Black label

C1=1,943­—1,949

2

red mark

C4=1,953­—1,959

yellow label

C1=1,949­—1,955

blue mark

C2=1,946­—1,952

Installation

Сборка блока цилиндров двигателя К4М

- Install grooved liners in all beds of the cylinder block (see Fig. 7).

- Install the grooved bushings in the main bearing caps 2 and 4, and the non-grooved bushings in the main bearing caps 1, 3 and 5.

Сборка блока цилиндров двигателя К4М

At the factory, a guide is used to install the main bearing shells (see fig. 8). The insert is placed in the device and fed inward until the front edge of the insert stops in the protrusion of the device.

Checking main bearing clearance

When checking the clearance, never turn the crankshaft.

- Remove oil residues from the main journals and cylinder block bearings.

- Install the crankshaft and the crankshaft thrust washers on the 3rd support (with the grooves towards the crankshaft cheeks).

Сборка блока цилиндров двигателя К4М

- Cut a few pieces of calibrated plastic wire from the coil (see 1, fig. 9).

- Lay the wire along the crankshaft main journal axis (outside the area of the bearing lubrication holes).

Сборка блока цилиндров двигателя К4М

- Reinstall the crankshaft main bearing caps (see Fig. 10).

- Tighten the crankshaft main bearing cap bolts as shown in the order shown. In this case, the plastic wire will be crushed - it will take up the entire gap between the liner and the crankshaft journal.

- Remove the main bearing caps and lift the crankshaft out of bed.

- By the width of the flattened calibrated wire, using a standard template, determine the gap between the inserts and the main journals (2) (see Fig. 10).

- Check the gap, which should be 0.027-0.054 mm.

- Clean the crankshaft and main bearing shells from the calibrated wire residues.

Checking the axial clearance of the crankshaft

- Lubricate the crankshaft main bearing shells with engine oil. Only the surface directed towards the shaft journal is lubricated.

- Install the crankshaft.

- Check the presence of thrust half rings on the 3rd support (the half rings grooves should be directed towards the crankshaft cheeks).

The seating surfaces of the cylinder block support and main bearing cap # 1 must be clean, dry and free from oil. Excess sealant will be squeezed out when the parts are tightened.

Drops of solidified sealant entering the oil or coolant can clog some components and assemblies (engine, radiator, etc.).

Сборка блока цилиндров двигателя К4М

- Apply RHODORSEAL 5661 in strips 1 mm wide (see arrow, fig. 11).

- Install the crankshaft main bearing caps by installing cover # 1 on the flywheel side (see Fig. 10).

- Tighten the crankshaft main bearing cap bolts in the specified order.

- Check the axial movement of the crankshaft, which should be:

- new half rings, mm. 0.045-0.252;

- old half rings, mm. 0.045-0.852.

- Check the ease of rotation of the crankshaft.

Installing connecting rod bearing shells

Сборка блока цилиндров двигателя К4М

The engine is equipped with smooth bushings without guide barbs (see 4, Fig. 12). The inserts are fitted using tool Mot. 1492.

-Select the mandrel (1) according to the motor model (see the labels (2) for the motor model).

- Place the mandrel into the groove in the body (3).

- Fit the connecting rod to tool Mot. 1492.

- Slide the upper end of the connecting rod onto the support pin and press the connecting rod in the direction of the arrow (a).

- Place the insert on the mandrel.

- Feed the mandrel with the insert into the lower end of the connecting rod (b).

- Remove the mandrel from the connecting rod head and repeat the operations with the rest of the connecting rods.

- Place the connecting rod cover on the body pins.

- Place the connecting rod bush on the mandrel (c).

- Feed the mandrel with the insert into the connecting rod cover (d).

- Remove the mandrel from the connecting rod cap and assemble the rest of the connecting rod caps in the same way.

The assembly of connecting rods with pistons and the installation of rings are discussed in the article - "ShPG assembly"

Tightening torques for fasteners

Node - Tightening torque, Nm

Crankshaft main bearing caps retaining bolts 20 + 62˚ ± 4˚

Connecting rod cap bolts 20 + 40˚ ± 6˚

Water pump cover retaining bolts 15

Water pump retaining bolts 17

Water pump pulley retaining bolts 20

Bolt of fastening of the idler roller 50

Oil damper and oil pump bolts 24

Oil pan retaining bolts 14

Oil level sensor 16-24

Oil filter nipple (without cooler) 10-20

Oil filter nipple (with cooler) 55-60

Knock sensor 20

Oil pressure switch 30

Oil filter 10-14

Coolant supply pipe retaining bolts 9

Flywheel retaining bolts 50-55

Dual Damping Flywheel Retaining Bolts 18-22, + 50˚ ± 6˚

M6 bolts for fastening the clutch cover 15 ± 10%

M7 bolts for fastening the clutch cover 20 ± 10%

M8 bolts for fastening the clutch cover 25 ± 10%

Continuation of the article on assembling the K4M cylinder block in the next article.