1. Remove the crankshaft from the cylinder block.
Clean the back of the bushing and its mounting location in the cylinder block and main bearing caps. Put the earbuds in place (on all engines except 1.7L diesel engine central main bearings (A) have persistent half rings (IN)).
2. Lubricate the bearing surface with clean engine oil and install the crankshaft into the engine block.
3. Measure the end play of the crankshaft.
4. Lubricate the lower bearing shells in the main bearing caps with clean engine oil and check that the tabs on the bearing shells are in the cap grooves. Install the main bearing caps one through four and screw them in without tightening.
5. Check that the rear bearing cover is clean and dry, then apply a layer of sealant to the grooves on each side of the cover and install the cover to the engine block.
6. Lubricate the crankshaft bearing cap bolts with clean engine oil, insert them into the caps and tighten by hand.
7. Gradually and in a diagonal sequence from the center to the edge, tighten the bearing cap bolts in several steps (on the left - by the required moment, on the right - by turning to the required angle).
8. After tightening the main bearing cap bolts, press the sealant into the groove of the crankshaft rear cover. Wipe off excess sealant.
9. Check that the crankshaft rotates smoothly and without binding.
10. Install pistons with connecting rods.
11. Install a new left crankshaft oil seal, flywheel, oil pump, cylinder head, timing belt pulleys and timing belt.
1.8 and 2.0 L petrol engines
12. Install the crankshaft (see paragraph 1).
13. Check that the bearing caps and main bearing block are clean and dry, then install the main block onto the cylinder block. Tighten the main unit mounting bolts in a diagonal sequence from the center to the edge to the required torque.
14. Install the bulkhead at the base of the cylinder block and secure with bolts, tightening them to the required torque.
15. Install new crankshaft left oil seal ring, flywheel, oil pump, cylinder head, timing belt pulleys and timing belt.
Diesel engine 1.7L
16. Remove the crankshaft from the engine block.
17. Clean the back of the bushing and its mounting location in the cylinder block and main bearing caps.
18. Install the earbuds into place, making sure that the tab on the earbud aligns with the groove on the cover.
19. Using a small amount of lubricant, secure the thrust washers to the second bearing cap and check that the oil grooves in each half ring face the crankshaft.
20. Lubricate the upper crankshaft bearing shells with clean engine oil and install the crankshaft.
21. Measure the end play of the crankshaft.
22. Check that the lower shells are properly seated in the bearing caps and install the caps on the cylinder block. The arrows on the bearing caps must point towards the timing belt.
23. Lubricate the cap bolts with engine oil and in a diagonal sequence from the center to the edge evenly and gradually tighten the bolts to the required torque.
24. Check that the crankshaft rotates easily and evenly.
25. Check that the mating surfaces of the crankshaft rear cover and cylinder block are clean and dry. Using the blade of a screwdriver as a lever, remove the O-ring from the cover.
26. Apply a thin layer of sealant to the mating surface of the rear crankshaft cover and install the cover to the engine.
27. Install pistons and connecting rods. Install a new crankshaft rear O-ring, then install the flywheel, oil pump housing, cylinder head, timing belt pulley and new timing belt.
Diesel engine 2.0L
28. Remove the crankshaft from the cylinder block.
29. Clean the back of the bushing and its mounting location in the cylinder block and main bearing caps. Install the earbuds in place.
30. Lubricate the bearing surface with clean engine oil and install the crankshaft into the engine block.
31. Measure the end play of the crankshaft.
32. Lubricate the lower bearing shells in the main bearing caps with clean engine oil and check that the tabs on the bearing shells are in the cap grooves. Install the main bearing caps one through four and screw them in without tightening.
33. Check that the rear bearing cover is clean and dry, then apply a layer of sealant to the grooves on each side of the cover and install the cover to the engine block.
34. Lubricate the crankshaft bearing cap bolts with clean engine oil, insert them into the caps and tighten by hand.
35. Gradually and in a diagonal sequence from the center to the edge, tighten the bearing cap bolts in several steps.
36. After tightening the bolts securing the main bearing caps, press the sealant into the groove of the rear crankshaft cover (filling the groove with sealant must be done until the sealant emerges from the hole indicated by the arrow). Wipe off excess sealant.
37. Check that the bearing caps and main bearing block are clean and dry. Install the main block to the engine with the tube on the main block pointing towards the timing chain. Then install the bolts and tighten the bolts in a diagonal sequence from the center to the edge.
38. Install a new left crankshaft oil seal, then install the flywheel, chains, sprockets and cylinder head.
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