You will need: a torque wrench, a hammer, a device for installing pistons in cylinders, wrenches "10", "13", "14", "17", "19", "21", "22", "36" (or gas), socket heads "12" and "13" (or a special key for cylinder head bolts), a screwdriver, a mounting blade.
Put the piston on the connecting rod, making sure that the hole for the pin matches the hole in the upper head of the connecting rod.
Use your hand to push the pin lubricated with engine oil into the piston and connecting rod holes.
Insert the retaining rings into the piston boss grooves and additionally lubricate the pin with engine oil through the holes in the piston bosses.
Install the piston rings in the reverse order of removal.
Do not loosen them when installing rings larger than necessary, so as not to deform or break them.
Install the lower compression ring with the groove (shown by the arrow) down in the second groove.
If the ring is marked "Top" or "TOP", then install the ring with the mark up (towards the piston bottom).
Orient the rings.
Install the rings on the remaining pistons.
Orient the rings as follows:
- - the lock of the upper compression ring should be at an angle of 30–45° to the axis of the piston pin;
- - the lock of the lower compression ring – at an angle of approximately 180° to the axis of the lock of the upper compression ring;
- - the lock of the oil scraper ring – 90° to the axis of the lock of the upper piston ring.
Place the upper main bearing shells (with grooves).
Install the liners so that the liner's mounting tab aligns with the notch on the bed.
Place the wider liners (without a groove) in the bed and the middle bearing cap.
Lubricate the liners with engine oil.
Install the crankshaft in the cylinder block.
Place the lower ones (without a groove) in the main bearing caps. liners.
Lubricate the crankshaft main journals with engine oil.
Lubricate the liners in the crankshaft main bearing caps with engine oil.
Install the caps (except the rear one) of the main bearings and lubricate the thrust half rings with engine oil.
Install the caps in the same block in accordance with the marks, orienting them in the same direction as before disassembly.
Install the rear (metal-ceramic, yellow) and front (steel-aluminum) thrust half rings of the rear support of the crankshaft.
Install the thrust half rings with the notches facing the bearing surfaces of the crankshaft
Install the rear main bearing cap and cap bolts, tighten them with a torque wrench.
Check the crankshaft axial clearance with a flat feeler gauge, moving the crankshaft with a mounting blade until it stops.
The axial clearance should be 0.06–0.26 mm.
The maximum allowable clearance is 0.35 mm.
If the clearance is larger, replace the thrust half rings with others that are larger by 0.127 mm.
Check the correct assembly by turning the crankshaft by hand a few turns. The shaft should rotate freely and smoothly.
Insert the connecting rod bolts (if they were removed) and the bearing shells into the connecting rods, aligning the mounting tab of the bearing shell with the recess on the connecting rod.
Lubricate the cylinder bores, pistons, piston rings and connecting rod bearings with engine oil.
Install the ring compression device on the piston and, by tightening the screw, compress the rings.
Install the piston in the cylinder in accordance with the cylinder number marking on the connecting rod, press (for example, with a hammer handle) on the piston and slide it from the mandrel into the cylinder.
Install the pistons in the remaining cylinders in the same way.
When installing the pistons in the cylinders, the arrow on the piston should face the front of the engine
Install the connecting rod bearings in the connecting rod caps, aligning the mounting tab on the bearing with the recess on the cap.
Lubricate the connecting rod bearings in the connecting rod caps with engine oil and connecting rod journals of the crankshaft.
Install the connecting rod cap by connecting the connecting rod to the crankshaft journal and aligning the marks on the connecting rod and cap.
Tighten the connecting rod bolt nuts without tightening them completely.
Install the remaining connecting rod caps in the same way.
Tighten the connecting rod bolt nuts with a torque wrench.
Install the crankshaft rear oil seal holder shaft, replacing the gasket.
Center the holder relative to the shaft flange with a special mandrel (if there is none, center the holder along the working edge of the oil seal) and tighten the six holder mounting bolts, aligning the plane of the holder with the plane of the block connector without distortions.
Install the flywheel (after installing the front cover of the clutch housing) so that the mark (cone-shaped hole) near the rim is opposite the axis of the connecting rod journal of the fourth cylinder, and secure the flywheel by tightening its mounting bolts.
Install the parts and assemblies in the sequence listed below: crankshaft sprocket, oil separator, oil pump drive gear, oil pump drive shaft, oil pump (replacing the gasket), oil sump (replacing the gasket and not finally tightening the mounting bolts), cylinder head (replacing the gasket).
Tighten the head mounting bolts in four steps in a specific sequence (see "Replacing the cylinder head gasket Niva Chevrolet").
Install the sprocket on the camshaft assembled with the bearing housing, and turn the shaft so that the mark on the sprocket is opposite the mark on the bearing housing.
Remove the sprocket and, without changing the position of the shaft, install the bearing housing on the cylinder head.
Secure the housing by tightening the nuts in a certain sequence (see "Replacing the camshaft Niva Chevrolet").
Install the chain tensioner shoe.
Turn the crankshaft so that the mark on the crankshaft sprocket aligns with the mark on the cylinder block.
Put the chain on the sprocket without changing the position of the crankshaft.
Put the chain on the sprocket of the oil pump drive shaft and, having pulled the drive branch, install the sprocket on the shaft without tightening the bolt of its fastening completely.
Attach a wire to the chain and lift the chain up in the drive cavity (or hook it from above and lift it up).
Put the chain on the camshaft sprocket, tighten the drive branch and install the sprocket on the shaft, ensuring that it is aligned mark on the sprocket and the lug on the bearing housing and do not completely tighten the bolt of its fastening.
Install the chain tensioner (if it was removed when disassembling the cylinder head).
Turn the crankshaft two turns in the direction of rotation to ensure the required chain tension.
Check that the marks on the sprockets coincide with the marks on the cylinder block and on the bearing housing.
If the marks do not coincide, repeat the installation of the chain.
If the marks coincide, finally tighten the sprocket bolts and bend the edges of the sprocket bolt lock washers.
Install the cylinder head cover, replacing the gasket.
Install the camshaft drive chain cover with the front crankshaft oil seal, replacing the gasket.
Center the holder relative to the shaft flange using a special mandrel (if there is no mandrel, center the holder along the working edge of the oil seal, temporarily installing the pulleys on the crankshaft tailstock) and tighten the cover mounting bolts and nuts.
Tighten the bolts that simultaneously secure the power steering pump bracket after installing the pump.
Finally tighten the oil pan mounting bolts. Install the crankshaft pulleys.
Install the remaining parts and assemblies in the reverse order of removal.
Run the engine in the following sequence:
- - Make sure the throttle drive is adjusted correctly, fill with oil and coolant, check the tightness of all connections.
- - Start the engine and let it run without load according to the following cycle.
Crankshaft speed min -1 - running time, minutes:
- 820-900 - 2 min;
- 1000 - 3 min;
- 1500 - 4 min;
- 2000 - 5 min
Do not run the engine to maximum modes.
During operation, check the tightness of the engine and its systems, oil pressure, ignition setting, idle speed, pay attention to the presence of extraneous noises.
If extraneous noises or other malfunctions are detected, stop the engine and eliminate their cause.
After starting to operate the car, observe the modes provided for the break-in period of a new car.
