Details of the crank mechanism
A - 4-cylinder engine; B - 6-cylinder engine; 1 - crankshaft; 2 - liners of main bearings; 3 - thrust half rings for adjusting the axial stroke of the crankshaft; 4 - key; 5 - crankshaft sprocket; 6 - crankshaft pulley; 7 - pulley hub; 8 - flange; 9 - a bolt of fastening of a cover of a rod; 10 - centering bearing of the input shaft of the gearbox; 11 - flywheel crown; 12 - flywheel of a car engine with a manual gearbox; 13 - flywheel of the engine of cars with automatic transmission; 14 - insert of the lower head of the connecting rod; 15 - connecting rod; 16 - bushing of the upper head of the connecting rod; 17 - piston pin; 18 - retaining ring; 19 - piston; 20 - oil scraper ring; 21 - lower compression ring; 22 - top compression ring
Marking of connecting rod caps and main bearings
Installing the middle main bearing cap with thrust washers
Installation of pistons in cylinders. The arrow on the piston crown must point towards the camshaft drive.
X - marking of classes of diameter of cylinders and pistons
Tightening the connecting rod cap bolts with a tightening angle tester
Installation of a back epiploon of a cranked shaft
A - at the factory
B - under repair
Installing the tool for pressing the front crankshaft oil seal
Installing flywheel retainer 102 589 01 40 00 on removed engine
Removing the emphasis of the intermediate shaft of the engine M 102
Installing the bearing of the input shaft of the gearbox on the crankshaft of the M 102 engine
1 - flywheel; 2 - crankshaft; 3 - bearing; 4 - thrust spacer
1. Check the size and condition of the crankshaft.
2. Check up a condition of loose leaves of radical bearings. If they are reused, mark them according to the cylinder numbering.
3. Check the extension and diameter of the draw rod of the connecting rod cap bolts and replace them if necessary.
4. Check up pairing of covers with rods. Slide the connecting rod cap onto the bolt in a horizontal position until it rests on the connecting rod and check that the cap does not move. Otherwise, replace the connecting rod.
5. Check the outer diameter of the piston, the condition of the pistons and piston rings. Check up a condition of a piston finger and apertures under a finger in the piston. On engines of release since 1984 check up a backlash between a rod and the piston.
6. Check up a condition of bolts of fastening of a flywheel.
7. Lubricate the main bearing shells with engine oil and install them in the bearing caps. Place the crankshaft in the main bearings. Install the main bearing caps.
8. Tighten bolts of fastening of covers of radical bearings.
9. Check up an axial free wheeling of a cranked shaft. If it is more than normal, replace the thrust half rings in the seats of the middle main bearing.
10. Assemble the pistons with the connecting rods, lubricate the working surfaces of the liners with engine oil and install them in the connecting rods and connecting rod caps. The mark on the connecting rod cap should point towards the intake manifold, and the arrow on the piston crown should point towards the camshaft drive.
11. Position the piston ring locks at a 120°angle. However, they should not be along the axis of the crankshaft and perpendicular to it. In this case, the Teflon guide sleeve of the oil scraper ring spring must be on top of the ring lock.
12. Using a piston ring compressor, insert the pistons with connecting rods into the cylinders. Install the connecting rod caps and tighten their bolts.
13. Check up protrusion of pistons in ВМТ over the plane of the block of cylinders.
14. Establish the holder of a back epiploon on a flange of a cranked shaft.
15. Put the oil seal on tool 102 589 00 43 00 and press it into the holder (Spare parts are supplied with an oil seal with a lip shifted 3 mm towards the engine in order to avoid sliding of the working edge of the new oil seal on the sliding surface of the old oil seal.
16. Install the crankshaft gear by directing its recess to the mounting band.
17. Install the oil pump drive spacer.
18. Establish an intermediate shaft with a persistent half ring.
19. Wrap a lock bolt.
20. Install the ignition distributor.
21. Install the tensioner pusher shoe.
22. Put on a chain of a drive of a camshaft.
23. Install the lower chain guide.
24. Establish the holder of a forward epiploon of a cranked shaft.
25. Install the camshaft drive cover with a new gasket (pay attention to the different length of the bolts of its fastening).
26. Wrap bolts of fastening of an oil receiver to the 2nd radical bearing.
27. Using drift 102 589 000 14 00, press in a new crankshaft front oil seal.
28. Insert the key into the crankshaft slot.
29. Install the crankshaft pulley hub.
30. Install the crankcase.
31. Block the latch flywheel and tighten the pulley bolt with three washers.
32. Install the pulley on the hub.
33. Turn the crankshaft until the piston of the 1st cylinder reaches TDC.
34. Install the cylinder head.
35. Install the camshaft drive chain tensioner.
36. Install an oil filter, ignition distributor, generator, power steering pump, starter, intake and exhaust manifolds on the engine.