Removal
Remove the engine from the car (see the relevant chapter).
Install the engine on the KM-412 stand with the appropriate adapters.
Place a container under the oil drain plug to collect any leaking oil. Remove the plug and drain the engine oil from the engine.
By moving the tensioner pulley downward, release the tension and remove the accessory drive belt.
Remove the timing belt of the gas distribution mechanism drive (see the relevant chapter).
Remove the flywheel.
Remove the crankcase (see the relevant chapter).
Warning: Be careful not to damage the mating surfaces of the crankcase and cylinder block.
Remove the oil pump, oil pickup pipe with mesh filter, rear cover of the cylinder block with rear crankshaft oil seal (see the relevant chapters).
Remove 8 bolts and oil gallery.
Remove the bolts and the connecting rod caps (see the relevant chapter).
Remove the bolts and covers from the cylinder block.
Remove the crankshaft from the cylinder block.
Clean the removed parts thoroughly.
Examination
Check the crankshaft main and connecting rod bearing journals for wear and tear. Check the crankshaft oil holes for clogging.
Install the crankshaft on the V-shaped prisms.
Install the dial indicator tip onto the crankshaft journal. Slowly rotate the crankshaft and measure its runout using a dial indicator.
If the crankshaft runout exceeds 0.04 mm, replace the crankshaft.
Installation
Lubricate the new main bearing shells with engine oil and install them into the cylinder block and main bearing caps.
Warning! Install the main bearing shells in the following sequence:
- A - upper and lower bearing shells of main journals 1 and 4 of the crankshaft.
- B - upper bearing shells of main journals 2 and 3 of the crankshaft.
- C - lower bearing shells of main journals 2 and 3 of the crankshaft.
Before installing the crankshaft, apply a thin layer of clean engine oil to all sliding surfaces. Install the crankshaft onto the main bearing shells in the cylinder block.
Lubricate the new thrust half rings with engine oil and install them on both sides of the crankshaft main journal.
Warning! The oil grooves on the thrust washers must be located on the crankshaft side.
Install the crankshaft main bearing caps in accordance with the markings and secure with bolts, tightening them to a torque of 39 N·m.
Warnings:
- Before screwing in the crankshaft main bearing cap bolts, lubricate the threads and bases of the bolt heads with engine oil.
- Start tightening the main bearing cap bolts from the front side of the cylinder block.
Turn the crankshaft and check that it rotates easily and smoothly.
Check the crankshaft axial clearance. Install the dial indicator tip onto the rear end of the crankshaft. Move the crankshaft along the axis until it stops and set the dial indicator scale to zero. Move the crankshaft along the axis in the other direction until it stops and read the axial play values on the indicator scale.
If the crankshaft axial clearance exceeds 0.30 mm, replace the thrust half rings.
Install the connecting rod caps onto the connecting rods and secure with new bolts, tightening them to a torque of 54 N·m.
Install the oil pump (see the relevant chapter).
Install the rear cylinder block cover with the rear crankshaft oil seal and secure with bolts, tightening them to a torque of 18 Nm.
[Source is on this resource: OPELBOOK.ru]
Install the oil gallery and secure with new bolts, tightening them in the specified sequence as follows:
- 1st pass: tighten the bolts to 29 Nm;
- 2nd pass: tighten the bolts to an angle of 55-65°;
Screw in the side bolts securing the crankshaft main bearing caps and tighten them in a specific sequence to a torque of 39 N·m.
Install the oil pick-up pipe with the mesh filter and secure with bolts, tightening them to a torque of 25 N·m.
Install the crankcase (see the relevant chapter).
Install the flywheel.
Install the timing belt of the gas distribution mechanism drive (see the relevant chapter).
Warning: Before installing the timing belt, check the valve timing.
Install the crankshaft pulley and accessory drive belt.
Remove the engine from the KM-412 stand.
Install the engine into the car (see the relevant chapter).
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