1.6 liter engine assembly

Identification symbols and labels for the correct position of the piston and connecting rod

High pressure fuel pump drive

1. Install the crankshaft thrust races into the seats in the middle main bearing, guiding the oil grooves of the races out of the main bearing.

2. Insert the main bearing shells.

3. Lubricate the main and connecting rod journals of the shaft and the main bearing shells with oil.

4. Install the crankshaft on the main bearing shells in the engine block.

5. Install main bearing caps (arrows on the covers directed towards the drive of the gas distribution system) along with inserts.

6. Lubricate the threads of the new main bearing cap bolts with oil.

7. Tighten the main bearing cap bolts to the correct torque.

Attention! Use only new bolts to fasten the main and connecting rod caps.

8. If the piston rings were removed, then install them on the pistons with the inscription "TOP" towards the bottom of the piston.

9. Arrange the locks of the rings at an angle of 120°.

10. Lubricate the smooth surface of the cylinders, the side surfaces of the pistons and the piston rings with oil.

11. Install the half shells in the connecting rod bases.

12. Install the piston-connecting rod assemblies in the cylinders, paying attention to the installation marks:

• connecting rod and cap are marked with the number of the cylinder in which they are installed (cylinder No. 1 from the drive side of the gas distribution system);
• arrow on the bottom of the piston and the letter "F" on the side surface of the neck of the connecting rod should be directed towards the drive system;
• connecting rods are divided into four selection groups, differing in the distance between the axes of the holes of the head and base; this allows you to limit to a minimum the difference in protrusion of the piston above the upper plane of the cylinder block (and thus the difference in compression ratio in the individual cylinders);
• the selection group of the distance between the axes of the connecting rods is indicated by letters "A", "IN", "WITH" And "D", embossed on the connecting rod caps (letter "A" belongs to the shortest connecting rods);
• connecting rods are divided into two selection groups depending on their mass: "light" (easy) And "heavy" (heavy); all connecting rods in an engine must belong to the same mass group.

13. Insert half shells into connecting rod caps.


14. Lubricate the connecting rod bearings and shaft journals with oil.

15. Install the connecting rod caps, paying attention to their designation.

16. Install new connecting rod cap bolts and coat threads with oil.

17. Tighten the connecting rod cap bolts to the correct torque.

18. Install the front cover with oil pump. Lubricate the pump with oil and rotate it. Before installing the cover, insert the O-ring into the cover.

19. Install the rear crankshaft cover with a new gasket that reaches the bottom of the engine block.

20. Tighten the rear cover bolts.

21. Using special tool 21.148 and the mounting bolt, install the crankshaft pulley, the front plate of the cylinder block with a new gasket.

22. Lubricate the front crankshaft journal and the pulley O-ring with oil.

23. Install the oil pump receiver with a new seal.



24. Lubricate the points indicated by the arrows with a thin layer of sealing paste and install the oil pan with a new gasket.

25. First insert the four mounting bolts at the corners of the oil pan, tighten them by hand, then insert and tighten the rest of the oil pan mounting bolts by hand.


26. Tighten the bolts, except for the bolts at the corners of the pallet, to the correct torque.

27. Tighten the bolts at the corners of the oil pan to the correct torque.

28. Screw on the oil filter.

29. Install the high pressure fuel pump with a new seal on the gear housing and tighten the bolts and nuts.

30. Install the gear on the crankshaft, making sure that the keyway with the key in the neck is exactly opposite the groove in the gear

31. Lubricate the bearing seat in the intermediate gear with oil, install the gear with the bearing bush without the washer. The narrow part of the gear should point backwards.

32. When assembling the drive of the high pressure fuel pump, the marks on the gears must match.

33. Install the high pressure fuel pump gear.

34. Install the pump drive cover, after inserting the radial sealing rings.

35. Install the coolant pump with a new seal.

36. Install the crankshaft pulley.

37. Install the cylinder head.

38. Install vacuum pump with new O-ring. To do this, rotate the engine until the camshaft eccentric has the shortest stroke. Then install the bottom bolt, vacuum pump and top bolt in sequence. Tighten both bolts evenly and install the oil return hose.

39. Screw on the thermostat housing with a new seal. The colored label should be directed upwards.

40. Install glow plugs and current bar.

41. Install heat shield.

42. Screw the fuel filter to the cylinder head, connect the fuel lines to the pump.

43. Install a new fuel filter.


44. Set the high pressure fuel pump to the start of the fuel supply.

45. Install generator.

46. Install the flywheel on the crankshaft.

47. Install the clutch on the flywheel, after centering the clutch disc with the mandrel relative to the flywheel.

48. Install starter.

49. Install the exhaust manifold.