Use a dial indicator to measure the axial clearance while moving the balance shafts back and forth.
Axial clearance of balance shafts:
- nominal - 0.070 -0.135 mm
- maximum allowable - 0.15 mm
If the axial clearance is greater than the maximum allowable, replace the balance shaft thrust washer.
2. Loosen the mounting bolts, remove the oil separator plate (A), the balance mechanism housing cover (B) and remove the left balance shaft (D) and the right balance shaft (C).
Note: Do not damage the bearing surface of the balance shafts.
3. Check the balance shafts.
a) Measure the inner diameter of the balance shaft bearing.
Nominal diameter:
- left balance shaft - 20,000 - 20,020 mm
- right balance shaft - 24.000 - 24.020 mm
Maximum diameter:
- left balance shaft - 20.03 mm
- right balance shaft - 24.03 mm
b) Measure the diameter of journals No.1 of the balance shafts.
Nominal diameter:
- left balance shaft - 19.938 - 19.950 mm
- right balance shaft - 23.938 - 23.950 mm
Minimum diameter:
- left balance shaft - 19.92 mm
- right balance shaft - 23.92 mm
c) Clean the journals No.2 of the balance shafts and the inner surface of the bearing.
d) Place a plastic gauge on each balance shaft journal.
d) Install the balance mechanism housing cover and tighten the mounting bolts.
Note: Do not rotate the balance shafts during inspection.
Tightening torque: 27 Nm
e) Remove the balance mechanism housing cover and measure the width of the flattened plastic gauge, determining the value of the radial oil clearance.
- Nominal clearance - 0.060 -0.120 mm
- Maximum gap - 0.15 mm
4. Engage the balance shaft gears so that the mark on the right balance shaft gear is in the middle between the two marks on the left balance shaft gear and install the balance shafts into the balance mechanism housing.
5. Apply a layer of engine oil to the threads of the balancer housing cover mounting bolts, install the cover and tighten the mounting bolts.
Assembly
Note:
- Thoroughly clean all parts to be assembled.
- Before assembly, lubricate all parts that form rotating or sliding units with fresh engine oil.
- Replace all gaskets, O-rings and seals with new ones.
1. Install the main and connecting rod bearing shells.
2. Install the upper thrust half rings into the bed of main bearing block No.4 with the lubrication grooves facing outward.
3. Place the crankshaft into the cylinder block, holding it so that connecting rod journals No.2 and No.3 are at the top.
4. (K20A) Apply a layer of sealant to the crankshaft main bearing cap as shown in the figure.
5. Install the main bearing caps and thrust washers.
A. Install the main bearing caps.
- a) Install two thrust half rings on bearing cover No.4, orienting the oil grooves outward.
- b) Install the main bearing cap.
- c) Using a plastic-faced hammer, tap the bearing caps until they fit snugly.
D15B, D17A.
K20A.
- d) Apply a thin layer of engine oil to the threads and under the heads of the main bearing cap bolts.
B. Tighten the main bearing cap bolts.
- Tighten the main bearing cap bolts.
Tightening torque:
D15B — 45 Nm
D17A:
- 1 step - 25 Nm
- step 2 - 51 Nm
K20A:
- 1 step - 29 Nm
- step 2 - 60°
If the specified torque is not achieved when tightening any bolt, replace the bolt.
6. (K20A) Tighten the main bearing cap bolts (8 mm) in the sequence shown in the figure.
Tightening torque: 22 Nm
7. Make sure the crankshaft rotates smoothly.
8. Using a dial indicator, measure the crankshaft axial clearance while moving the crankshaft with a screwdriver (see above).
9. Install the piston and connecting rod assembly.
a) Install the piston sets into the cylinders according to their numbers, orienting the marks (B) on the pistons towards the front of the engine. Install rubber insulators (A) on the connecting rod bolt threads.
D15B, D17A.
K20A.
b) Using light taps, drive the piston into the cylinder.
10. Install the connecting rod lower head caps.
- a) Install the connecting rod lower head caps onto the connecting rods.
- b) Check that the numbering of the connecting rod bearing caps and connecting rods matches.
- c) Apply engine oil to the threads of the mounting bolts.
- d) Tighten the nuts (bolts) securing the connecting rod lower head caps evenly and alternately.
Tightening torque:
D15B, D17A — 32 Nm
K20A (models with rocker blocks of types 1 and 2):
- 1 step - 20 Nm
- step 2 - 90°
K20A (models with type 3 rocker block):
- 1 step - 29 Nm
- step 2 - 90°
If any bolt is not tightened to the specified torque, replace it.
11. Using a dial indicator, measure the end play as the connecting rod moves back and forth (see above).