1. Clear a deposit on the edges of beds of the block of cylinders. Clean deposits from oil grooves in the beds of the cylinder block.
2. Establish loose leaves of radical bearings in bed of the block of cylinders according to the labels made at dismantling. Please note that the middle liner 1 is without a groove. When installing the main bearing shells, their locking antennae must enter the grooves of the beds. Lubricate the main bearing shells with engine oil.
Attention! After installing the main bearing shells in bed, their ends protrude slightly, therefore, for the correct orientation of the liners, when final tightening the bearing cap bolts, make sure that the protrusion of both ends is the same.
3. Install the crankshaft in the cylinder block.
4. Grease persistent half rings with engine oil. Pay attention to the grooves of the half rings: these sides of the half rings must be installed against the cheeks of the crankshaft.
5. Install the steel-aluminum half ring (white color) from the front side of the middle bed (camshaft drive side)...
6.... ceramic-metal half ring (yellow color) on the other side of the bed.
7. Turn the steel-aluminum and cermet half rings so that their ends are flush with the ends of the bed.
8. Insert loose leaves into covers of radical bearings according to the labels made at dismantling. In this case, the locking antennae of the liners should enter the grooves of the main bearing caps. Lubricate the main bearing shells with engine oil.
9. Establish covers of radical bearings according to labels. Marked on main bearing caps (notches) according to the cylinder number. The exception is the fifth main bearing cap, which has two marks, just like the second one. The second main bearing cap has two threaded holes for the oil receiver mounting bolts. In this case, the numbers of the cylinders are counted from the camshaft drive side, and the main bearing caps are set with marks 1 towards the generator bracket 2.
10. Grease with engine oil a carving and end faces of heads of bolts of fastening of covers.
11. Wrap bolts of fastening of covers of radical bearings and tighten them the demanded moment (see Annex 1) in the following order: first tighten the bolts of the third cover 1, then the second 2 and the fourth 3, then the first 4 and the fifth 5. After tightening the bolts, turn the crankshaft 2-3 turns - it should rotate easily, without jamming.
12. For ease of installation, lubricate the oil pump gasket with a thin layer of grease and «glue» her to the block. Remove excess grease.
13. Install the oil pump and tighten the bolts of its fastening (see «Removal and installation of the oil pump»).
14. For easy installation, lightly grease the rear oil seal retainer gasket and «glue» her to the block. Remove excess grease.
15. Establish the holder of a back epiploon and wrap bolts of its fastening.
16. Insert the connecting rod into the piston in accordance with the marks previously made so that the part number 1 on the connecting rod is facing away from the lug 2 on the piston boss.
17. To press the piston pin, it is better to use a special tool. In its absence, you can choose a suitable mandrel.
18. Heat the connecting rod head in an oven to 240°C for 15 minutes. Clamp the connecting rod in a vise, install the piston on it so that the holes for the pin match, and insert the fixture with the finger into the holes of the piston and connecting rod until it stops. To properly install the pin, the piston must be pressed with the boss against the upper head of the connecting rod in the direction of pressing.
19. After the connecting rod has cooled, lubricate the piston pin through the hole in the piston bosses.
20. Install retaining rings on both sides of the piston pin. At the same time, pay attention to the fact that the rings must be clearly installed in the piston grooves.
21. Install the oil scraper ring expander on the piston.
22. Install piston rings. It is recommended to do this with a special puller. If not, install the piston rings on the piston, carefully spreading the piston ring locks.
23. Piston ring installation order: install the oil scraper ring first (The oil scraper lock must be on the opposite side of the expander spring lock), then the lower compression ring, lastly the upper compression ring.
24. Pay attention to the fact that the inscription may be embossed on the piston rings «VAZ», «TOP» or «TOR». Piston rings should be installed with this inscription facing up (to the bottom of the piston). If there is no inscription, the oil scraper and upper compression rings can be installed in any position.
25. The lower compression ring differs from the upper compression ring not only in thickness, but also in the presence of a groove and must be installed with this groove down.
26. Turn the piston rings in the piston grooves to make sure they turn easily. If any piston ring is not turning or sticking, it must be replaced.
27. Turn the piston rings on the piston so that their locks are located at an angle of 120°to each other.
28. Thoroughly wipe the connecting rod journals of the crankshaft with a clean cloth.
29. Thoroughly wipe the cylinder mirrors with a clean cloth and lubricate them with engine oil.
30. Insert the connecting rod bushing into the connecting rod in accordance with the marks made earlier so that the ear of the bearing fits into the groove in the connecting rod. Then lubricate the connecting rod bearing and piston with engine oil.
31. Put a special mandrel on the piston to compress the piston rings and carefully lower the connecting rod into the cylinder. It is recommended to pre-turn the crankshaft so that its connecting rod journal, on which the connecting rod and piston group is mounted, is installed at BDC. The arrow on the piston crown must point towards the front of the engine (towards the camshaft drive).
32. Firmly press the mandrel against the block and use the hammer handle to push the piston into the cylinder. If the mandrel does not fit snugly against the cylinder block, piston rings can be broken.
33. Establish the lower head of a rod on a neck of a cranked shaft.
34. Insert the liner into the connecting rod cover in accordance with the previously made marks so that the liner antenna enters the groove in the cover. Then lubricate the bearing with engine oil.
35. Install the connecting rod cap. The cylinder numbers on the cap and the bottom end of the connecting rod must be on the same side.
36. Wrap nuts of fastening of a cover of a rod and tighten the demanded moment (see Annex 1). Install the rest of the pistons in the same way.
37. Install the oil receiver and tighten the three bolts of its fastening.
38. Apply anaerobic threadlocker to the flywheel mounting bolts. Install the flywheel, lock plate and tighten the flywheel mounting bolts (see «Removal, troubleshooting and installation of the flywheel»).
39. For ease of installation, apply a thin layer of grease to the surface of the block and «glue» oil pan gasket to it.
40. Install the oil sump and tighten the bolts of its fastening (see Annex 1). Next, assemble the engine in reverse order. Installation of a head of the block of cylinders is described in subsection «Replacing the cylinder head gasket», camshaft drive belt - in subsection «Timing belt replacement (camshaft drive) and tension roller».