Reassembly
Crankshaft Assembly, Reassembly
Special tools: 5006, 5021, 5025, 5033, 5098, 5115, 5199, 5267, 7158221, 998 5424, 998 8500
Assemble piston and con rod
Arrow on piston crown must point towards front of engine.
Numerical designation on con rod must face towards right-hand side of block (oil filter side).
Ensure that con rods and pistons are assembled in matched pairs.
NOTE: Fit gudgeon pin circlip, ensuring that circlip is fully seated in groove.
Install piston rings
Use piston ring pliers 998 5424.
Turn rings so that gaps are positioned approx. 120° apart.
Place bearing shells in con rod big end and bearing cap
Wipe bearing seats clean.
Place shells in position in con rod and bearing cap.
Oil cylinder bore, piston and bearing shells.
Fit piston in bore
Use piston ring compressor 115 8281.
When fitting piston, turn crankshaft so that corresponding crankshaft throw is pointing straight down- wards.
Insert piston in bore.
Push down piston (using implement such as hammer handle).
NOTE: Arrow on piston crown must point towards front
Install bearing cap
Ensure that bearing shell remains in position.
Check markings. Markings on con rod must agree with those on bearing cap.
Oil bolts.
Tighten bolts in two stages:
1. 20 Nm (15 ft.lb)
2. Tighten through further 90°
Install oil sump
Clean inside of sump as required.
Use new sump gasket. Ensure that tab on gasket is pointing towards engine mounting.
Tighten sump in position.
Tighten bolts to 11 Nm (8 ft.lb).
Install reinforcing bracket
Tighten bracket in stages.
Secure bracket first to flywheel housing and then to cylinder block.
Install bump stop on front crossmember.
Install left-hand engine mounting
Tighten two lower bolts in cylinder block.
Lower engine
Guide engine mountings into position.
Remove lifting gear (5006, 2 x 5033, 5115, 5267).
Tighten left-hand engine mounting
Install bottom nut.
Reattach wiring harness bracket and cable clip on transmission casing.
Install:
- new cylinder head gasket
- new water pump 0-ring
Place cylinder head in position
Carefully lower head over guides, taking care to avoid damage to gasket.
Tighten cylinder head bolts
Use protractor 5098.
Oil bolts.
Insert and tighten bolts in three stages in order illustrated.
1. 20 ± 2 Nm (15 ± 1.5 ft.lb)
2. 40 ± 5 Nm (29.5 ± 3.5 ft.lb)
3. Tighten through further 115° (±10°)
Install exhaust manifold
Use new gasket.
Install manifold.
Attach lifting lug between No.2 and 3 exhaust branches.
Connect front exhaust pipe to bracket.
Secure right-hand engine mounting to front cross- member.
Install heat shield.
Reconnect:
- temperature sensor connectors
- heater hose under No.3 and 4 intake branches
- upper coolant hose to thermostat housing.
NOTE: Note marking on upper hose. Clearance between hose and alternator belt must be at least 25 mm (1 in).
Fill engine with coolant
Inspect for leaks.
Install intake manifold
Use new gasket.
Screw in bottom bolts a few turns.
Place manifold and lifting lugs in position. Tighten manifold from center outwards.
Reattach support under intake manifold
Install cable clip.
Secure support to engine mounting.
Install air mass meter complete with air inlet hose and connections.
Apply liquid sealing compound
Apply compound to joint between camshaft carrier and cylinder head, and to bearing cap joint faces (1, 5 and 6).
Apply compound with a short-haired roller.
NOTE: Remove excess compound from oilways prior to reassembly.
Install camshaft carrier
Fit new 0-rings in grooves around spark plug wells.
Position carrier on cylinder head and install nuts 1,2, 4 and 5 in central bolted joint.
Plug openings around spark plug wells with paper.
Oil
Oil bearings and sliding surfaces on camshaft carrier, bearing caps, camshafts and tappets.
Insert tappets
Tappets must be replaced in original order.
Turn engine to TDC in No.1 cylinder
Check that TDC markings on vibration damper are aligned with zero marking on transmission cover.
Install exhaust side camshaft
Place camshaft in camshaft carrier with guide pin for pulley facing upwards.
Press down camshaft with press tool 5021 (using rear bearing cap as guide).
Install bearing caps in original order.
Apply liquid sealing compound to joint face between camshaft carrier and front bearing cap (No.6).
Install bearing cap nuts in stages.
Remove press tool 5021 and replace center bearing cap (8).
Install intake side camshaft
Place camshaft in camshaft carrier with guide pin for pulley facing upwards.
NOTE: Turn distributor shaft to align driver with markings on the housing.
Fit housing and rotor spindle with new 0-rings.
Press down camshaft with press tool 5021 (using rear bearing cap as guide).
Install bearing caps in original order.
Apply liquid sealing compound to joint faces between camshaft carrier and front and rear bearing caps (Nos. 1 and 5).
Install bearing cap nuts in stages.
Remove press tool 5021 and replace center bearing cap (8).
Install camshaft carrier center nut.
Tighten bearing cap nuts and center nut
Tighten to 20 Nm (15 ft.lb).
Remount distributor
Replace high-tension lead between distributor cap and ignition coil.
Remove paper in camshaft carrier openings.
NOTE: Replace ignition lead clip beside left-hand bolt.
Apply sealer at front and rear camshaft bearing caps
Use silicone sealer.
Apply bead of sealer to angle between cap and joint face.
Install new gaskets and replace valve cover
Inspect rubber seal behind camshaft on exhaust side. Position spark plug well gasket with arrow pointing to No.1 cylinder and markings facing upwards.
Shape outer gasket to fit camshaft bearing caps. Place gasket in position and replace valve cover.
NOTE: Remember to connect earth lead to distributor.
Install:
- ignition leads (in correct firing order)
- ignition lead cover plate
Fill engine with oil
Use new oil filter.
Capacity, including filter 4.0 l (4.2 US qt)
Insert dipstick and check oil level.
Fit camshaft front oil seals
Use assembly tool 5025.
Grease seals.
Press seals home.
NOTE: Camshafts must not be rotated while fitting seals.
Install transmission mounting plate
Adjust position of plate to avoid contact with camshafts.
Insert bolts between camshafts and under right-hand idler.
Install idlers
Tighten to 25 Nm (18.5 ft.lb).
Install camshaft drive pulleys
Use counterhold 5199.
Insert center bolts and tighten to 50 Nm (37 ft.lb.). Check that pulley markings are aligned with markings on transmission mounting plate.
NOTE: Camshafts must not be allowed to rotate when replacing the center bolts.
Install timing belt
Position belt so that double-line marking coincides with top marking on belt guide plate (at top of crankshaft).
Place belt on camshaft pulleys, ensuring that single- line markings coincide with pulley markings.
Place belt in position over right-hand and then over left-hand idler.
Check markings
Check that all markings coincide and that the engine is turned to TDC in No.1 cylinder.
Slacken tensioner locknut
Turn crankshaft clockwise
Crankshaft pulleys should rotate one turn until markings again coincide with those on the transmission mounting plate.
NOTE: Engine must not be rotated counterclockwise while belt is being tensioned.
Turn crankshaft further clockwise
Continue to turn crankshaft until pulley markings are 1 1/2 teeth past markings on housing.
NOTE: Rotate crankshaft smoothly.
Tighten tensioner locknut
Install:
- lower transmission cover (2)
- radiator fan and pulley
- alternator drive belt
- battery earth lead
Check operation
Run engine until thermostat opens.
Stop engine.
CAUTION: Remember that transmission cover (1) is not replaced at this point.
Check belt tension
Use gauge 998 8500.
Rotate crankshaft to bring engine to TDC position in No.1 cylinder.
Position gauge between exhaust camshaft pulley and idler.
Read gauge.
Belt tension must be within 5.1 ± 0.2 unit range (5.5 ± 0.2 units for new belt).
Tighten tensioner locknut
Tighten to 50 Nm (37 ft.lb).
Install protective cap over locknut.
Install upper transmission cover (1).
Check operation
Test run engine.
Inspect for oil and coolant leaks.
Install splashguard under engine.