Tightening torques | |
Connecting rod cap bolts | 20 Nm + 45°±6° |
Oil pump mounting bolts | 25 Nm |
Removing
Place the car on a two post lift.
Remove the engine undertray.
Drain the engine oil.
Remove the oil filter.
Remove the lower jet link.
Fasten the radiator to the car with a safety strap (or belts).
Remove the front suspension subframe.
Remove the right front wheel drive shaft support bearing.
Disconnect the oil level sensor connector (if installed) (2).
Remove the top brace (3) catalytic converter.
Attention! Failure to follow the instructions for the following operation may result in damage to the oil receiver of the oil pump.
Turn away bolts of fastening of the pallet crankcase of the engine.
Install a hydraulic jack to support the engine oil pan.
Remove the engine sump bolts.
Remove the engine oil pan by holding it with a hydraulic jack.
Tilt the engine sump forward to access the oil pump mounting bolts.
Partially loosen the engine oil pan bolts by 3-5 mm.
Disconnect the oil pump to remove the engine oil pan.
Remove:
- engine oil pan,
- engine oil pan gasket,
- oil pump.
Removing the connecting rod bearing shells of cylinder No. 2
Wipe the lower connecting rod heads with a surface cleaner.
Mark the position of the connecting rod cap relative to the connecting rod with an indelible pencil.
Set the crankshaft to TDC.
Remove:
- connecting rod bolts,
- rod cover,
- lower connecting rod bearing.
Note: When reusing conrod bearing shells, mark the position of the lower conrod bearing shell relative to the con rod cap.
Wipe the mating surfaces of the connecting rod caps with a surface cleaner.
Install the connecting rod of the tool to the connecting rod.
Slide the connecting rod up to release it from the connecting rod journals.
Rotate the crankshaft 90°clockwise (from the timing drive).
Attention! Failure to follow this procedure may result in damage to the piston cooling nozzles.
Pull the piston/connecting rod assembly using the connecting rod of the tool, being careful not to let the piston touch the piston head cooling jets.
Remove the upper connecting rod bearing.
Note: When reusing connecting rod bearing shells, mark the position of the upper connecting rod bearing shell relative to the connecting rod.
Wipe the mating surfaces of the bearings on the connecting rod housing with a surface cleaner.
Installation
Installing the connecting rod bearing shells for cylinder No. 2
Parts that must be replaced: connecting rod cap bolts.
Note:
- Be sure to replace the 20mm wide conrod bearing shells with the 18mm wide conrod bearing shells.
- If the set of conrod bearing shells only consists of 18 mm wide conrod bearing shells, use only the tool head marked «K9KSUP».
Install the fixture head with the mark «K9K JNF» on the threaded socket of the tool.
Install the connecting rod bearing lower shell to the tool.
Note: The mating surfaces of the bearing shell and connecting rod must be dry and free from grease.
Install the connecting rod bearing lower shell onto the connecting rod cap using a tool.
Install the lower connecting rod bearing so that the edges do not protrude beyond the connecting rod cap.
Lubricate the surface of the connecting rod bearing (from the cheeks of the crankshaft) fresh engine oil.
Remove the marked head «K9KINF» and install the head marked «K9K SUP».
Install the connecting rod bearing upper shell onto the tool.
Install the upper connecting rod bearing to the connecting rod using a tool.
Install the upper connecting rod bearing so that the edges do not protrude beyond the connecting rod housing.
Lubricate the surface of the connecting rod bearing (from the cheeks of the crankshaft) fresh engine oil.
Slide the piston assembly with the connecting rod into place.
Rotate the crankshaft 90°counterclockwise.
Lubricate the connecting rod journal with fresh engine oil.
Pull the piston and connecting rod assembly to install the connecting rod onto the crankshaft.
Note: Before installing the connecting rod cap, make sure that there is no dirt (shavings, fleecy residues of rags, etc.) on the surfaces of the connecting rod or cap.
Install:
- connecting rod cap in accordance with the mark made during removal,
- new connecting rod bolts.
Tighten to the specified torque and tighten the connecting rod cap bolts to the specified angle (20 Nm + 45°±6°).
Removal / installation of liners of connecting rod bearings of cylinders No. 3, 1 and 4
Follow the same steps for removing the connecting rod bearing shells of the cylinders as on cylinder No. 2.
Note: To remove and install the connecting rod bearing shells for cylinders No. 1 and 4, install the pistons at BDC before performing the same removal and installation of the connecting rod bearing shells as for cylinder No. 2.
Parts that must be replaced:
- Oil filter.
- Drain plug gasket on the engine crankcase.
Attention!
- Do not scrape the mating surfaces of the aluminum parts as any damage to the mating surface may result in fuel leaks.
- To ensure sealing, mating surfaces must be clean, dry and free of oil (don't touch them with your fingers).
Using a wooden spatula or a matting wheel, clean the mating surfaces of the cylinder block and the engine oil pan.
Install the oil pump.
Screw in without tightening the oil pump mounting bolts, maintaining a gap of 3-5 mm.
Install the engine oil pan gasket.
Attention! Applying too much sealant can cause it to be squeezed out when parts are tightened. The ingress of sealant into the coolant can damage some components and assemblies (engine, radiator, etc.).
Apply silicone sealant:
- four beads with a diameter of 5 mm at a point (A),
- two drops with a diameter of 5 mm at a point (IN).
Reinstall the engine sump while holding it with a hydraulic jack.
Tilt the engine sump forward to access the oil pump mounting bolts.
Torque tighten the oil pump mounting bolts (25 Nm) with a PROS-TEEL torque wrench, part number 77 11 226 888 from 13 mm bolt.
Note: Make sure the engine oil pan gasket is actually in place before tightening the engine oil pan bolts.
Install the engine sump bolts.
Torque tighten the engine sump bolts in the order shown.
Install the upper catalytic converter strut.
Connect the oil level sensor connector.
Install the thrust bearing on the right front wheel drive shaft.
Install the front suspension subframe.
Remove the safety strap (or belts) from the radiator.
Install the lower tie rod.
Disconnect the crankshaft position sensor connector (4), to prevent the engine from starting.
Install the oil filter.
Fill the engine with oil.
Start the engine and wait until the oil pressure warning light goes out.
Connect the wiring harness to the crankshaft position sensor.
Install the engine undertray.
Clear stored faults using the diagnostic tool.