- Lubricate the cylinder bore.
- Sort all connecting rods by cylinder numbers. Label "VORN" on the connecting rod and on the bottom of the piston should be directed towards the engine pulleys.
Pic. 96. On the 1.6 liter engine there is a mark "VORN" (1) and the tide on the connecting rod (2) should be located on one side. On a 2.0L engine, the straight edge of the connecting rod should face forward
- Distribute the piston ring locks evenly every 120 around the circumference of the piston. Figures 97 and 98 show how the locks are offset in relation to the piston pins. The arrow is directed in the direction of travel. It is good to study both drawings, since putting on the side elements of the oil scraper rings is different on both types of engines.
Pic. 97. Location of piston ring locks around the circumference of the piston on a 1.6 liter engine. The arrow is pointing forward. Thermal gaps are located in the following places: 1. Upper side ring; 2. Label "VOPN"; 3. Compression ring No. 2; 4. Compression ring No. 1 and expansion spring lock; 5. Lower side ring.
Pic. 98. Location of ring locks around the circumference of the piston on a 2.0 liter engine. The arrow is facing forward. Thermal gaps are located in the following places: 1. Upper side ring; 2. Expansion spring; 3. Compression ring No. 2; 4. Label "Vorn"; 5. Upper compression ring; 6. Bottom side ring
- Apply piston ring tightening tape where the piston rings are installed and press the rings into the grooves. Check that they are properly seated.
- To avoid scratching the cylinder bores, place short pieces of rubber or plastic hose on the connecting rod studs. The nuts must be replaced, as once installed, the nuts become loose.
- Rotate the crankshaft until the two journals of the shaft are installed in the lower MT position.
- Push the connecting rod into the hole from above.
- To prevent the connecting rod from scratching the cylinder bore or the connecting rod journal, place the engine on its side. The connecting rod bearing shells must be located in the connecting rod with their protrusion in the cutout.
- When pulling out, check again that the mark is facing as shown in Figure 99.
Pic. 99. After the piston is inserted as shown on the left side of the picture (label "Vorn" on the front side), insert it together with the tape to tighten the piston rings into the cylinder.
- Push the piston until the piston rings are sequentially inserted into the cylinder and the connecting rod leg is seated on the shaft journal.
- Place the second liner into the bearing cap and lubricate it. Place the cap on the connecting rod studs and tap lightly. Pieces of rubber hose must first be removed. Make sure that the marks on the connecting rods and bearing caps are on the same side, since a mistake can be made at the last moment.
- Lubricate the surfaces of the nuts on the connecting rod bearing caps.
- Alternately tighten the new connecting rod nuts to 50 Nm.
- After installing the connecting rod, rotate the crankshaft several times to immediately detect any jamming.
- Rotate the crankshaft so that the other two axles are located at the bottom and install the remaining pistons and connecting rods in the same way.
- Check the position of all marks again and check that the pistons are installed correctly.
- Install, as shown in Figure 21, the dial indicator on the cylinder block and between the sides of the connecting rod and crankshaft, moving the connecting rod bearing on the shaft journal in both directions by hand. The axial play of the connecting rod bearing should not exceed 0.30 mm (engine 1.6 l.) or 0.35 mm (2.0 l engine).