Crankshaft and main bearings (Freelander 1)

Dismantling

1. Remove the cylinder head.

ENGINE - MODIFICATION K, volume 1.8, Piston group, Cylinder head gasket.

2. Take out a back epiploon of a cranked shaft.

ENGINE - MODIFICATION K, volume 1.8, Piston group, Replacing the crankshaft rear oil seal.

3. Remove the drive gear from the crankshaft.

4. Remove and discard the oil filter.

MAINTENANCE, MAINTENANCE, Engine oil and oil filter - K1.8.

5. Remove the oil pump.

ENGINE - MODIFICATION K, volume 1.8, Piston group, Oil pump overhaul.

6. Turn away 2 bolts of fastening of an arm of the pump of the hydraulic booster to the block of cylinders and remove an arm.

7. Remove the dipstick.

8. Turn out a bolt of fastening of the case of the thermostat with and a casing of an oil probe to the block of cylinders.

9. Turn away 2 bolts of fastening of a casing of an oil probe to the block of cylinders.

10. Remove the dipstick cover and discard the gasket.

11. Remove the transmission pan.

ENGINE - MODIFICATION K, volume 1.8, Piston group, Pallet.

12. Turn out bolts from fastenings of sleeves of cylinders LRT-12-144 and remove fastenings.

CAUTION: Store the cylinder head bolts in the order in which they were on the assembled engine. Do not rotate the crankshaft after removing the cylinder liner fasteners.

13. Turn away 2 bolts of fastening of an oil receiver to an oil distribution cover.

14. Remove the oil receiver with a strainer.

15. Remove the O-ring from the oil receiver and discard it.

16. Turn away 2 nuts of fastening of an oil-distributing cover to integral cover of radical bearings and remove a cover.

17. Install fasteners LRT-12-144 cylinder liners with nylon nuts included in the fastening kit. The base of the cylinder liners must not protrude above the cylinder surface. Screw in the cylinder head bolts until the cylinder liner mounts are securely held.

ATTENTION: The bolts used must be screwed into the same sockets in which they were on the assembled engine.

18. Temporarily install the timing belt drive gear and the front crankshaft pulley, screw in the front pulley bolt with washer.

19. Mark connecting rod caps for reassembly.

20. Rotate the crankshaft clockwise to set the pistons of cylinders 2 and 3 to bottom dead center.

21. Remove 4 fitting bolts (bolt that simultaneously acts as a pin) and remove the covers from the connecting rods of the 2nd and 3rd cylinders. Lay out the bolts and covers in the order they were installed.

22. Move the connecting rods away from the connecting rod journals and carefully slide the pistons up. Remove the liners from the connecting rods and connecting rod caps and dispose of them.

23. Rotate the crankshaft clockwise to set the pistons of cylinders 1 and 4 to bottom dead center.

24. Remove 4 fitting bolts (bolt that simultaneously acts as a pin) and remove the covers from the connecting rods of the 1st and 4th cylinders.

CAUTION: Lay out the fitting bolts and covers in the order they were installed on the engine.

25. Move the connecting rods away from the connecting rod journals and carefully slide the pistons up. Remove the liners from the connecting rods and connecting rod caps and dispose of them.

26. Remove the bolt from the crankshaft, remove the pulley and drive gear from it.

27. Turn out bolts from fastenings of sleeves of cylinders LRT-12-144 and remove fastenings.

CAUTION: Store the cylinder head bolts in the order in which they were on the assembled engine. Do not rotate the crankshaft after removing the cylinder liner fasteners.

28. In the sequence shown in the figure, unscrew the 10 bolts securing the integral main bearing cover to the cylinder block and remove the cover.

NOTE: The 2 bolts 'A' shown in the illustration are installed below the rear support flange. Also note the position of the bolt 'B' on the front of the bearing cap.

29. Remove the crankshaft from the cylinder block.

30. Take out 2 persistent half rings from the 3rd root bed.

31. Take out radical loose leaves from the block of cylinders and from a cover of bearings.

Installation

1. Use a solvent to clean the mating surfaces of the cylinder block and main bearing caps.

CAUTION: Do not use a metal scraper to clean the mating surfaces.

2. Wipe the bed liners in the cylinder block.

3. Wipe the bed liners in the main bearing cap.

4. Wipe the beds of the connecting rod bearings in the connecting rods and in the connecting rod caps.

5. Clean the drive pins and their holes.

6. Wipe the main and connecting rod journals of the crankshaft.

7. Wipe a nest of a back epiploon of a cranked shaft.

8. Rewrite the letter code of the main bearings from the bearing cap.

9. Rewrite the digital code of the main bearings from the front counterweight of the crankshaft.

10. Measure the diameter of the crankshaft main journals.

TECHNICAL CHARACTERISTICS, Engine - gasoline K1.8.

11. Pick up the main bearings for installation on the engine.

TECHNICAL CHARACTERISTICS, Engine - gasoline K1.8.

12. Colored markings on the edge of the liner indicate the thickness of the liner: GREEN = thin liner, BLUE = medium thickness liner, RED = thick liner.

ATTENTION: If the bearings of two different color markings are to be installed on the same neck, then the thicker bushing is installed in the main bearing cap. When installing the old crankshaft, the liners must be selected according to the table. Do not install thinner inserts.

13. Write down the crankpin size code letter found on the rear counterweight. Code designations are read from left to right, the first group refers to the 1st neck.

14. Write down the numbers of the size groups of the beds in the lower heads of the connecting rods. These are the numbers 5, 6 or 7, applied to the connecting rod caps. Choose the appropriate earbuds.

TECHNICAL CHARACTERISTICS, Engine - gasoline K1.8.

15. Colored markings on the edge of the liner indicate the thickness of the liner: YELLOW = thin liner, BLUE = medium thickness liner, RED = thick liner. If the inserts of two different color markings are to be installed on one neck, then a thicker insert is installed in the connecting rod cover.

16. Install the selected main bearings in the bed. Groove liners are installed in the cylinder block, flat liners are placed in the main bearing cap.

17. Wipe and install in new thrust half rings in the cylinder block, on the 3rd bed, oil grooves out.

18. Lubricate the main journals with clean engine oil.

19. Holding the crankshaft so that the connecting rod journals are in a horizontal plane, lay the crankshaft in bed.

20. Check that the mating surfaces of the cylinder block and main bearing caps are clean and dry.

21. Apply a continuous bead of STC 4600 sealant to the cylinder block along the contours shown in the figure and spread it in a thin layer using a roller trowel.

WARNING: Assembly of prepared parts must be done immediately to prevent contamination of surfaces with applied sealant.

22. Lubricate the main journals with engine oil. Fit the main bearing cap to the cylinder block, screw in the bolts, paying attention to the fact that the flange head bolt must be in position 10.

23. Tighten the bolts in the sequence shown in the figure:

Stage 1: 5 Nm
Stage 2: 30 Nm

24. Install fasteners LRT-12-144 cylinder liners with capron nuts included in the fastening kit. The base of the cylinder liners must not protrude above the cylinder surface. Screw in the cylinder head bolts until the cylinder liner mounts are securely held.

ATTENTION: The bolts used must be screwed into the same sockets in which they were on the assembled engine.

25. Install the indicator on the cylinder block, placing its leg on the end of the crankshaft toe.

26. Move the crankshaft back and install "zero" indicator.

27. Move the crankshaft forward and determine the axial movement of the crankshaft.

28. Compare the obtained value with the requirements of the specifications.

TECHNICAL CHARACTERISTICS, Engine - gasoline K1.8.

CAUTION: If axial movement (backlash) with new half rings installed exceeds the permissible value, then the crankshaft must be replaced.

29. Remove the indicator.

30. Temporarily install the timing belt drive gear and the front crankshaft pulley, screw in the front pulley bolt with washer.

31. Install the selected connecting rod bearings in the connecting rod and caps.

32. Lubricate the connecting rod journals and connecting rod bearings with clean engine oil.

33. Carefully slide the connecting rods onto the necks, install the connecting rod caps, paying attention to the fact that the mounting grooves in the cover and in the connecting rod body should be on opposite sides, tighten the connecting rod bolts with your fingers.

34. Tighten the fitting bolts of the connecting rod cover:

Stage 1: 20 Nm.
Stage 2: 45°turn.

NOTE: With the cylinder head removed and the main bolts tightened, crankshaft rotation will be difficult.

35. Using a feeler gauge, measure the axial movement of the bottom head of the connecting rod.

TECHNICAL CHARACTERISTICS, Engine - gasoline K1.8.

36. Moisten a lint-free cloth with solvent and wipe clean the sealing surfaces of the main bearing cap and oil distribution cap.

37. Temporarily remove the LRT-12-144 cylinder liners.

CAUTION: Do not rotate the crankshaft after removing the cylinder liner fasteners.

38. Apply a continuous bead of STC 4600 Sealant to the contours shown in the figure and spread it in a thin layer using a roller trowel.

WARNING: Assembly of prepared parts must be done immediately to prevent contamination of surfaces with applied sealant.

39. Install the oil distribution cover on the integral cover of the main bearings, fit the nuts and tighten them to a torque of 9 Nm.

ATTENTION: If the threaded part of the cylinder head bolts is damaged, then it is necessary to install a new oil distribution cover and a new oil receiver. Thread repair inserts are not allowed (type Helicoil).

40. Install the LRT-12-144 mounts on the cylinder liners and lightly tighten the cylinder head mounting bolts.

ATTENTION: The bolts used must be screwed into the same sockets in which they were on the assembled engine.

41. Turn away a bolt of fastening of a pulley of a cranked shaft, remove a pulley and a bolt with a washer.

42. Wipe the oil pickup tube and mating surfaces.

43. Lubricate a new O-ring with clean engine oil and fit onto the oil pickup tube.

44. Install the oil pick-up tube, screw in the bolts and tighten them to a torque of 10 Nm.

45. Replace the pallet.

ENGINE - MODIFICATION K, volume 1.8, Piston group, Pallet.

46. Wipe the dipstick tube and mating surfaces.

47. Put a new seal on the dipstick housing.

48. Screw in the bolts securing the probe casing to the cylinder block and tighten them to a torque of 10 Nm.

49. Screw in the bolt securing the probe casing and thermostat housing to the cylinder block and tighten it to 10 Nm.

50. Insert the dipstick.

51. Install the oil pump.

ENGINE - MODIFICATION K, volume 1.8, Piston group, Oil pump overhaul.

52. Install the power steering pump bracket on the cylinder block, screw in the bolts and tighten them to a torque of 45 Nm.

53. Screw on the new oil filter and tighten it by hand until it makes full contact with the sealing surface, then tighten the filter another half turn.

54. Install the timing gear.

55. Install the crankshaft rear oil seal.