Install a new oil seal into the cylinder block. Use a hammer handle to firmly insert the oil seal into the groove (see fig. 74)To ensure the required overlap, cut the gland above the split surface (see fig. 75). The protrusion height of the gland ends depends on the color of the gland material. For a graphite-gray gland, the protrusion is 1.0 mm, for a yellow-brown one - 0.5 mm.
Fig. 74. Installing the seal using a hammer handle.
Fig. 75. Overlap after cutting the gland.
Carefully install the crankshaft into the cylinder block. If the pistons were in the cylinder block, then insert the lower heads of the connecting rods onto the crankshaft journals.
Place the liners in the main bearing caps and lubricate their surface.
Install the covers into the cylinder block using a hammer with a rubber or plastic striker and press them into place. The covers can only be installed in one position. Check the marking on the cover. Fig. 76 shows the location of the markings on the main bearing cover.
Fig. 76. The bearing cover designation is stamped on the side of the cover. Cover No.1.
Tighten the main bearing cap bolts evenly to a torque of 80 Nm.
Turn the crankshaft to eliminate the jam. If the resistance to rotation is increased, eliminate it by lightly hitting the bearing caps with a plastic hammer.
Check the crankshaft axial clearance again as described when removing the crankshaft. If the clearance is increased, install bearing shells with larger flanges.
Install the intermediate sprocket shaft and upper sprocket into the bearings with the oil groove located at the bottom, install the intermediate sprocket and chain guide.
When replacing the crankshaft sprocket or intermediate sprocket, check their relative position. To do this, measure the distance from the end surface of the cylinder block to the end surface of the crankshaft sprocket and intermediate sprocket. The difference in measurements should not exceed 0.1 mm. If the value is greater, place an adjusting ring under the crankshaft sprocket.
Install the pistons and connecting rods as described in section 3.4.5.
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Install the camshaft drive.
Install the flywheel or drive discs (section 3.6.4).
Install the clutch in accordance with the marks on the flywheel and clutch housing, having first centered the driven clutch disc (section 9.2).
Install the oil pump (see section 4.1.1).
Install the oil pan (section 4.2).
Perform the remaining work in reverse order.