1. Remove the crankshaft from the cylinder block.
Clean the rear of the bearing shell and its mounting location in the cylinder block and main bearing caps. Install the bearing shells in their places (on all engines except the 1.7L diesel engine, the central main bearings (A) have thrust half rings (B)).
2. Lubricate the working surface of the bearing with clean engine oil and install the crankshaft into the engine cylinder block.
3. Measure the crankshaft axial clearance.
4. Lubricate the lower shells in the main bearing caps with clean engine oil and check that the tabs on the shells are in the grooves in the cap. Install the first through fourth main bearing caps and screw them in loosely.
5. Make sure the rear bearing cover is clean and dry, then apply a bead of sealant to the grooves on each side of the cover and install the cover on 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 mounting bolts in several steps (on the left - to the required torque, 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 rear crankshaft cover. Wipe off any excess sealant.
9. Check that the crankshaft rotates smoothly and without sticking.
10. Install the pistons with connecting rods.
11. Install a new left crankshaft oil seal, flywheel, oil pump, cylinder head, timing belt pulleys and timing belt.
Petrol engines 1.8 and 2.0 l
12. Install the crankshaft (see point 1).
13. Check that the bearing caps and main bearing block are clean and dry, then install the main block on the cylinder block. Tighten the main block mounting bolts in a diagonal sequence from the center to the edge to the specified torque.
14. Install the partition into the base of the cylinder block and secure with bolts, tightening them to the required torque.
15. Install new left crankshaft oil seal, flywheel, oil pump, cylinder head, timing belt pulleys and timing belt.
Diesel engine 1.7 l
16. Remove the crankshaft from the engine block.
17. Clean the rear of the bearing shell and its installation location in the cylinder block and main bearing caps.
18. Install the inserts in their places, while the protrusion on the insert should be aligned with the groove on the cover.
19. Using a small amount of grease, 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 crankshaft axial clearance.
22. Check that the lower shells are correctly installed in the bearing caps and install the caps on the cylinder block. The arrows on the bearing caps must point towards the toothed belt drive.
23. Lubricate the cover mounting bolts with engine oil and tighten the bolts evenly and gradually to the specified torque in a diagonal sequence from the center to the edge.
24. Check that the crankshaft rotates easily and evenly.
25. Make sure the mating surfaces of the crankshaft rear cover and cylinder block are clean and dry. Using a screwdriver blade as a lever, remove the sealing ring from the cover.
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26. Apply a thin layer of sealant to the mating surface of the crankshaft rear cover and install the cover on the engine.
27. Install the pistons and connecting rods. Install a new rear crankshaft seal ring, then install the flywheel, oil pump housing, cylinder head, timing belt pulley and new timing belt.
Diesel engine 2.0 l
28. Remove the crankshaft from the cylinder block.
29. Clean the rear of the bearing and its installation location in the cylinder block and main bearing caps. Install the bearings in their places.
30. Lubricate the working surface of the bearing with clean engine oil and install the crankshaft into the engine cylinder block.
31. Measure the crankshaft axial clearance.
32. Lubricate the lower shells in the main bearing caps with clean engine oil and check that the tabs on the shells are in the grooves in the cap. Install the first through fourth main bearing caps and screw them in loosely.
33. Make sure the rear bearing cover is clean and dry, then apply a bead of sealant to the grooves on each side of the cover and install the cover on 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 mounting bolts in several steps.
36. After tightening the main bearing cap bolts, press the sealant into the groove of the rear crankshaft cover (filling the groove with sealant must be done until the sealant appears from the hole shown 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 on the engine with the tube on the main block facing the timing chain. Then install the bolts and tighten the bolts to the specified torque 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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