Contents: Removal ⬇ Installation ⬇
Removal
1. Remove the power unit from the engine compartment (see the relevant chapter).
2. Disconnect the manual transmission from the engine.
3. Remove the timing case (see the relevant chapter).
4. Lock the flywheel with shoe 1 KM-652, unscrew the mounting bolts and remove the flywheel from the crankshaft (see illustration).
5. Remove the torsional vibration damping unit 2 from the crankshaft sprocket (see illustration), (see the relevant chapter).
6. Number the main bearing caps 1 and connecting rod bearing caps 2, and also mark the recesses 3 for supplying oil (see illustration).
7. Unscrew the connecting rod bearing cap mounting bolts and remove them.
8. Unscrew the main bearing cap mounting bolts and remove them.
9. Remove the crankshaft from the cylinder block together with the vibration damper chain.
10. Remove the chain from the crankshaft sprocket.
11. Clean the sealing surfaces and remove any remaining old sealant.
12. Inspect all parts for damage and wear and replace them if necessary.
13. Check the condition of the crankshaft (see the relevant chapter).
Installation
14. Lubricate the new crankshaft bearing shells with engine oil and place them in the cylinder block or in the covers (see illustration).
15. Install the torsional vibration damping unit on the crankshaft sprocket and place the shaft in the cylinder block.
If necessary, correct the position of the crankshaft in the cylinder block by lightly hitting the journal cheeks with a rubber hammer.
16. Apply a small amount of black sealant into the groove on the rear thrust surface (see illustration).
17. Install, using the marks made before removal, the main bearing caps 1, screw in the mounting bolts and tighten them with a force of 90 Nm, then tighten them further by 60° in one pass, and then by 15° in the second (see illustration).
18. Pump black sealant into the holes under the rear bearing cover (see arrows in illustration 10.17).
19. Lubricate the connecting rod bearing shells with engine oil and install them on the journals and in the caps, then install the caps 2 in their original places and secure with new bolts. Also install new thrust half rings 3 (see illustration 10.17). The tightening torque of the connecting rod bearing cap bolts is 35 Nm with subsequent additional turns of 45° and 15°.
20. Apply a thin layer of white sealant to the working surface of the crankshaft oil seal and pack it in using a 2 KM-934-2 mandrel with a 3 KM-454-A handle (see illustration).
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21. Secure the flywheel to the crankshaft by screwing in and tightening the new mounting bolts. The tightening torque of the flywheel bolts is 45 Nm, followed by additional turns of 30° and 15°. To prevent the crankshaft from turning when tightening the bolts, lock the flywheel with a 4 KM-652 thrust shoe (see illustration).
22. Install the torsional vibration damping unit (see the relevant chapter).
23. Install the timing gear housing (see the relevant chapter).
24. Cars with manual transmission. Connect the engine and gearbox.
25. Install the power unit into the engine compartment (see the relevant chapter).
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