Install the cylinder block on the engine assembly stand
We assemble and prepare the piston group
Preparing the crankshaft for assembly.
Engine assembly 470.63
First you need to lay the crankshaft.
To do this, unscrew the side bolts for fastening the yokes (main bearing caps) (Fig. 1).
We unscrew the lower bolts for fastening the yokes (main bearing caps) (Fig. 2).
We take out the yoke and put them in order (Fig. 3).
We wipe the seats of the main bearings.
We lay the upper root bearings with a groove in the middle (Fig. 4).
Lubricate with engine oil and install the pushers in the sockets of the block (Fig. 5).
Lubricate the upper main bearings with a thin layer of engine oil (Fig. 6).
We put the crankshaft in the cylinder block.
The crankshaft must be laid so that the counterweight of the first cylinder looks down relative to the engine sump (then it sits better in place) (Fig. 7).
We insert the lower main bearings into the yokes (main bearing caps), lubricate the bearings and install the yokes so that the bearing locks match (Fig. 8).
We bait the lower bolts of the yokes.
Into the grooves of the rear main bearing we insert steel-aluminum half rings so that the grooved side is adjacent to the thrust ends of the shaft, and the mustache enters the groove on the rear main bearing cover.
We pre-tighten the bolts of the main bearings with a torque of 94.2 ÷ 117.7 Nm (9.6 ÷ 12 kgf.m).
We start tightening from the middle main bearing (Fig. 10), in the order 3-4-5-2-1.
Finally tighten the bolts of the main bearing caps to a torque of 206÷230.5 Nm (21÷23.5).
We screw in and tighten the M12 coupling bolts of the block, providing a tightening torque of 80.4 ÷ 90.2 Nm (8.2 ÷ 9.2 kgf.m).
When tightening with a torque wrench, the resistance should increase smoothly, without jerking. Count the moment when the key moves.
At the end of tightening, the crankshaft should turn freely from the force of the hand applied to the dowel pins of the flywheel, the axial clearance in the thrust bearing should be at least 0.05 mm.
For the convenience of installing the piston group, turn the block on the stand to a vertical position.
We start the installation from the eighth cylinder.
Insert the upper connecting rod bearing, lubricate it with a thin layer of engine oil (Fig. 11), and lubricate the cylinder with a thin layer of engine oil.
Using a tool for installing the piston group, we insert the connecting rod with the piston into the cylinder block, ensuring a different arrangement of the locks of the rings so that the locks do not coincide on the same axis with the piston pin.
With the wooden side of the hammer, carefully knock out the piston, making sure that the bolts and the connecting rod bearing are in the correct position.
Insert the bushing into the connecting rod cover, lubricate the connecting rod and install it so that the locks of the bearings match (Fig. 13). We bait the connecting rod cap nuts.
The tightening torque of the bolts of the connecting rod caps with M12 threads to an elongation of 0.25÷0.27 mm.
Reinforced bolts with M13 thread - 117.7÷127.4 Nm (12÷13 kgf.m).
After that, insert the connecting rod with the piston into the fourth cylinder.
Rotate the crankshaft and insert the piston with the connecting rod into cylinders 7 and 3.
In the same way, insert the remaining pistons with connecting rods and tighten with a torque wrench (Fig. 14), the moment indicated above.
Turn the crankshaft several times.