- Wipe the bearing beds and insert the bearings with the protrusions into the slots of the beds. Lubricate the bearings well, but make sure that the oil does not leak out.
- Install the thrust half rings at the middle main bearing. The lubrication grooves face the crankshaft flange, i.e. outward, as can be clearly seen in Figure 105.
Fig. 105. Install the thrust half rings into the cylinder block with the lubrication grooves facing outward. The half rings are installed similarly in relation to the main bearing caps, but are pulled out beyond the projection.
- Carefully insert the crankshaft into the bearing shells. If the connecting rods are still in the cylinder block, insert the connecting rod bearings onto the connecting rod journals.
- Insert the lower bearing shells into the crankshaft bearing cap (protrusions into cutouts) and lubricate the surfaces well.
- Put the caps on and tap the rubbers with a new or plastic hammer. The arrows on all caps should point forward.
- Tighten the cover bolts from the center outwards in several passes to a tightening torque of 60 Nm. After tightening the bolts, turn the crankshaft several times to determine if it is jammed. For this purpose, the crankshaft pulley with the key is temporarily put on.
- Check the axial play again as described in Chapter 2.7.2 (see also fig. 104). If the play was large from the very beginning, replace the thrust half ring.
- Install the pistons and connecting rods as described in Chapter 2.6.4.
- Install both seals (chapter 2.7.4).
- Screw on the rear intermediate engine plate.
- Install the crankshaft timing gear with key and fit the timing belt guide disc.
- Install the flywheel. On a 2.0L engine, apply a drop or two of locking compound to the threads. On a 1.0L engine, this is not required, but it will not hurt to do so. Hold the crankshaft by inserting a wooden wedge between the crank cheek and the crankcase wall, and tighten the bolts to the specified torque. If an automatic transmission is installed, install the driven disk in the same manner chapter 2.7.5 further instructions are given regarding the flywheel.
- Install the clutch on the flywheel observing the markings. The driven disk must be well centered (Chapter 8.2). Tighten the bolts evenly crosswise to a tightening torque of 15-22 Nm.
- Install the oil pump (see chapter 3.2)
- Install the oil pan (see chapter 3.1).
- All other work should be carried out in reverse order.
- Finally, install the cylinder head and valve timing mechanism as described in the relevant chapters.