1. Clear a deposit on the edges of beds of the block of cylinders. Clean deposits from oil grooves in beds.
2. Establish loose leaves of radical bearings in bed of the block of cylinders according to the labels made at dismantling. When installing the liners, their locking antennae must enter the grooves of the beds.
3. Lubricate the liners with engine oil.
Attention! After installing the liners in the bed, their ends protrude slightly, so 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.
4. Install the crankshaft in the cylinder block.
5. 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.
6. Install the steel-aluminum half ring (white color) from the front side of the middle bed (camshaft drive side)...
7.... cermet (yellow color) on the other side of the bed.
8. Turn the half rings so that their ends are flush with the ends of the bed.
9. Insert loose leaves in 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 covers.
10. Lubricate the liners with engine oil.
11. Install the covers according to the marks. Lids are labeled (notches) according to the cylinder number. The exception is the fifth cover, on which two marks are applied, as well as on the second one. On the second cover there are two threaded holes 1 for the oil receiver mounting bolts. In this case, the numbers of the cylinders are counted from the side of the camshaft drive, and the covers are installed with marks 2 in the opposite direction from the oil filter fitting 3.
Attention! Use a soft-faced hammer made of brass, lead, or polyurethane to install the crankshaft main bearing caps. It is forbidden to install the covers by tightening the fasteners, as this will damage the seating surfaces of the covers and the cylinder block.
12. Grease with engine oil a carving and end faces of heads of bolts of fastening of covers.
13. Wrap the bolts and tighten them to the required torque (see annex 1) in the following order: first tighten the bolts of the third cover, then the second and fourth, then the first and fifth. After tightening the bolts, turn the crankshaft 2-3 turns - it should rotate easily, without jamming.
14. For ease of installation, lubricate the oil pump gasket with a thin layer of grease and «glue» her to the block. Remove excess grease.
15. Install the oil pump and tighten the bolts of its fastening (see «Removal and installation of the oil pump»).
16. For ease of installation, lightly grease the rear oil seal retainer gasket and «glue» her to the block. Remove excess grease.
17. Establish the holder of a back epiploon and wrap bolts of its fastening.
18. Insert the connecting rod into the piston in accordance with the marks made earlier so that the number of the uterus on the connecting rod is facing towards the front of the piston (an arrow is directed in this direction, knocked out on top of the piston bottom).
19. Lubricate the piston pin with engine oil and insert the pin into the piston and connecting rod.
20. Install retaining rings on both sides of the pin. At the same time, pay attention to the fact that the rings must be clearly installed in the piston grooves.
Warning! A ring that is not clearly fixed in the piston groove will pop out of it when the engine is running and cause accidental damage.
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 it is not there, install the rings on the piston, carefully spreading the locks of the rings.
23. The order of installation of the rings: the oil scraper ring is installed first (the ring lock must be on the opposite side of the expansion spring lock), then the lower compression ring, the last - the upper compression.
24. Pay attention to the fact that the inscription can be embossed on the rings «GOE» or «TOP». Rings should be installed with this inscription up (to the bottom of the piston).
25. Turn the rings in the piston grooves to make sure they turn easily. If any ring does not turn or sticks, it must be replaced.
26. Turn the rings on the piston so that their locks are located at an angle of 120°to each other.
27. Thoroughly wipe the connecting rod journals of the crankshaft with a clean cloth.
28. Thoroughly wipe the cylinder mirrors with a clean cloth and lubricate them with engine oil.
29. Insert the liner into the connecting rod in accordance with the previously made labels so that the tab of the liner enters the groove in the connecting rod. Then lubricate the liner and piston with engine oil.
30. Put on the piston a special mandrel for compressing 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).
31. 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.
32. Establish the lower head of a rod on a neck of a cranked shaft.
33. Insert the liner into the connecting rod cover in accordance with the marks made earlier so that the liner antenna enters the groove in the cover. Then lubricate the bearing with engine oil.
34. Install the connecting rod cap. The connecting rod markings on the cap and bottom head of the connecting rod must be on the same side.
35. Wrap bolts of fastening of a cover and tighten the demanded moment (see annex 1). Install the rest of the pistons in the same way.
36. Install the oil receiver and tighten the three bolts of its fastening.
37. Apply anaerobic threadlocker to the flywheel mounting bolts. Install the flywheel, lock plate and tighten the flywheel mounting bolts (see «Removal, installation and troubleshooting of the flywheel»).
38. For ease of installation, apply a light coat of grease to the surface of the block and «glue» oil pan gasket to it.
39. Install the oil sump and tighten the bolts of its fastening (see annex 1). Next, assemble the engine in reverse order. Installation of the block head is described in subsection «Replacing the cylinder head gasket», camshaft drive belt - in subsection «Replacing the timing belt and tensioner pulley».