Laying the crankshaft and the piston group in the cylinder block of the KamAZ engine

We install the cylinder block on the engine assembly stand.

We assemble and prepare the piston assembly.

We prepare the crankshaft for assembly.

Assembling the 470.63 engine

First the crankshaft must be laid in place.

1. We unscrew the side retaining bolts of the main bearing caps (Fig. 1).

2. We unscrew the lower retaining bolts of the main bearing caps (Fig. 2).

3. We remove the main bearing caps and lay them out in order (Fig. 3).
4. We wipe the seats of the main bearings.

5. We lay the upper main bearing shells with a groove in the middle (Fig. 4).

6. We lubricate with engine oil and fit the tappets into the block bores (Fig. 5).

7. We lubricate the upper main bearing shells with a thin layer of engine oil (Fig. 6).

8. We lay the crankshaft into the cylinder block. The crankshaft must be laid so that the counterweight of the first-cylinder crank faces downwards relative to the engine sump (then it seats better) (Fig. 7).

9. We insert the lower main bearing shells into the main bearing caps, lubricate the shells and fit the caps so that the shell tabs coincide (Fig. 8).
10. We engage the lower cap bolts.

11. Into the grooves of the rear main bearing we insert the steel-aluminium half-rings so that the side with the grooves bears against the thrust faces of the shaft and the tab enters the groove on the rear main bearing cap.
12. We preliminarily tighten the main bearing bolts to a torque of 94.2÷117.7 N·m (9.6÷12 kgf·m).

13. We start tightening from the middle main bearing (Fig. 10) in the order: 3-4-5-2-1.
14. We finally tighten the main bearing cap bolts to a torque of 206÷230.5 N·m (21÷23.5 kgf·m).
15. We screw in and tighten the М12 tie bolts of the block, ensuring a torque of 80.4÷90.2 N·m (8.2÷9.2 kgf·m).

Note: When tightening with a torque wrench, the resistance must increase smoothly, without jerks. Read the torque while the wrench is moving.

After tightening is complete, the crankshaft must turn freely under hand force applied to the flywheel dowels. The axial clearance in the thrust bearing must be at least 0.05 mm.

For convenient fitting of the piston assembly, we turn the block on the stand to the vertical position. We start fitting from the eighth cylinder.

16. We insert the upper connecting rod shell, lubricate it with a thin layer of engine oil (Fig. 11) and lubricate the cylinder with a thin layer of engine oil.

17. Using the piston assembly fitting tool, we insert the connecting rod with the piston into the cylinder block, ensuring a different arrangement of the ring gaps so that the gaps do not coincide on the same axis with the piston pin.
18. With the wooden side of the hammer we carefully tap the piston, watching the correct position of the bolts and the connecting rod shell.

19. We insert the shell into the connecting rod cap, lubricate the connecting rod and fit it so that the shell tabs coincide (Fig. 13).
20. We engage the connecting rod cap retaining nuts.

Connecting rod cap bolt tightening torque:

• with М12 thread — to an elongation of 0.25÷0.27 mm;
• heavy-duty bolts with М13 thread — 117.7÷127.4 N·m (12÷13 kgf·m).

21. After that we insert the connecting rod with the piston into the fourth cylinder.
22. We turn the crankshaft and insert the piston with the connecting rod into cylinders 7 and 3.

23. In the same way we insert the remaining pistons with connecting rods and tighten them with a torque wrench (Fig. 14) to the torque specified above.
24. We turn the crankshaft several times.