General information
1. To ensure maximum durability with minimum care, the engine must not only be assembled correctly, but we must also take care of cleanliness during assembly. All oil paths must be installed in the appropriate places. During assembly, carefully lubricate with engine oil all bearings and other working surfaces, such as seal lips and journal surfaces on which they operate.
2. Before starting assembly, it is necessary to replace all bolts and studs with damaged threads.
3. You will need to prepare: a torque wrench, a hand oiler, a clean rag, a set of hexagonal socket and multi-tongue socket socket cap screws, and a set of gaskets and seals, as well as a new oil filter
4. The work place must be clean and well lit.
5. All parts should be thoroughly washed, dried and laid out on clean paper.
6. First, we mount individual units, such as, for example, the head, oil pump, pistons with connecting rods, water pump, if disassembled. Then we assemble the engine from these units. The sequence of these actions is as follows:
a) Insert the main bearing shells into the frames and mount the crankshaft.
b) Insert the pistons with connecting rods and screw them to the crankshaft.
c) Press the back cover with the seal.
d) We put on the covering plate and press the flywheel, as well as the clutch.
d) We put on the front cover of the crankshaft in case these are 1.1 and 1.3 l engines, together with the oil pump we press the tube of the vessel.
e) Mount the injection pump bracket (1.6D engines).
g) Install and tighten the oil pump (engines 1.6 and 1.8).
c) We put on and clamp the timing gear on the crankshaft.
i) Put on and clamp the oil pan.
c) We put on the water pump.
l) Put the timing belt on the crankshaft gear.
m) Put on the lower distribution cover.
n) We put the pulleys on the crankshaft and on the water pump.
o) Clamp the bracket with the oil filter.
p) We install the pistons in a position where none of them is at TDC. Then we install the gasket under the head and fasten the head completely, remembering the order of tightening the bolts.
p) Install the timing belt tensioner (not available in models where the tensioner is a water pump).
c) Install the injection pump, pressing it against the carrier plate and bracket.
t) We set the distribution, put the distribution belt on the camshaft gear and tighten it.
u) Put on the upper distribution cover.
f) Put on the gasket and clamp the valve cover.
7. Finally, we put on the remaining engine equipment and tighten the gearbox.
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