Note: Thoroughly clean all parts to be assembled.
Apply new engine oil to all sliding and rotating surfaces before installing parts.
Replace all gaskets, o-rings and oil seals with new items.
1. Install oil jets and check valves (see section "Lubrication system").
2. Install the main bearing shells.
A) Align the protrusion of the bearing with the recess in the block and in the main bearing cap.
b) The bored bearing shell must be installed in the cylinder block.
3. Install the top thrust washers in the recess of the 3rd (L-series) or 5th (KZ-series) main journal, and the grooves of the half rings should be oriented outward (from the neck).
4. Install the crankshaft to the cylinder block.
5. Install the main bearing caps and lower thrust washers.
A) Install cover 3rd (5th) main bearing with upper half rings installed in it, the grooves of which must be directed outward (from the neck).
b) Install the rest of the covers, taking into account their number and the direction of the arrows, which should be directed towards the toe of the crankshaft.
V) Apply a light coat of engine oil to the threads and under the heads of the main bearing cap bolts.
G) Install and evenly tighten the ten main bearing cap bolts in several passes, in the sequence shown, to 103 Nm (L-series) or in two steps 49 Nm + 90° (KZ-series)
d) Check up smoothness of rotation of a cranked shaft.
e) Check crankshaft end play (see above).
6. Install the connecting rod and piston group.
A) Cover the connecting rod bolts with short pieces of hose to protect the crankshaft from damage.
b) Using a piston ring crimper, insert the connecting rod and piston group into each cylinder, following the numbering.
The arrow on the piston must point towards the front of the engine.
7. Install the connecting rod caps.
A. Place the cap on the connecting rod.
A) Align the numbered connecting rod cap with the corresponding connecting rod.
b) Reinstall the connecting rod cap so that the front side markings face the front of the engine.
B. Install the connecting rod cap nuts. Note: The connecting rod cap nuts are tightened in two successive steps.
If any of the connecting rod bolts is broken or deformed, replace it.
A) Apply a light coat of engine oil to the threads and under the connecting rod cap nuts.
b) Install and alternately tighten the nuts of the connecting rod caps, doing this in several passes to a torque of 54 N·m (L-series) or 29 N·m (KZ-series).
If any of the connecting rod nuts does not meet torque requirements, replace the nut.
V) Mark the front side of the connecting rod cap nut with paint.
G) Tighten the connecting rod cap nuts 90°as shown.
Note: (only for L series engines) If new nuts are used, the pre-tightening torque is 34 Nm, then turn the nut 120°.
d) Check for a 90°misalignment of the mark with respect to the direction towards the front.
e) Check up smoothness of rotation of a cranked shaft.
and) Check the end play of the connecting rod.
8. Install rear oil seal retainer, install new gasket and four bolt retainer. Tightening torque 13 Nm.
Only for KZ engines
9. Balance shaft assembly
A) Clamp the shaft in a vice on the counterweight.
b) Install the thrust flange, align the shaft pin with the drive gear hole, put on the gear.
V) Tighten the pinion bolt to 32 Nm.
10. Insert both balance shafts into the block, tighten the thrust flange mounting bolts to 8 Nm