Replacing connecting rod bearings (Freelander 1)

Dismantling

1. Disconnect the negative battery terminal.

2. Remove the cylinder head.

ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Cylinder head gasket.

3. Remove the engine sump.

ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Sealing of oil pan.

4. Temporarily remove the cylinder liner fasteners LRT-12-144. Do not rotate the crankshaft after removing the cylinder liner fasteners.

CAUTION: The cylinder head mounting bolts must be laid out in the order in which they were installed on the engine.

5. Unscrew the 2 bolts securing the oil receiver to the oil distribution cover.

6. Remove the oil receiver with the mesh filter.

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



8. Unscrew the 2 nuts securing the oil distribution cover to the integral main bearing cover and remove the cover.





9. Install the LRT-12-144 cylinder liner fasteners using the nylon nuts included in the fastener kit. The base of the cylinder liner fasteners should not protrude above the cylinder bore.

10. Secure the cylinder liner mounts with the cylinder head mounting bolts, screwing the bolts back into place (where they were before disassembly).

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

12. Rotating the crankshaft clockwise, set the pistons of cylinders 2 and 3 to the bottom dead center.

13. Mark the connecting rod lower head caps.

14. Unscrew the 4 fitting bolts (the bolt that also functions as a pin) and remove the caps from the connecting rods of the 2nd and 3rd cylinders. Lay out the bolts and caps in the order in which they were installed.

15. Move the connecting rods away from the crankpins and carefully push the pistons upward. Remove the bearing shells from the connecting rods and caps and discard them.

16. Rotating the crankshaft clockwise, set the pistons of cylinders 1 and 4 to the bottom dead center.



17. Mark the connecting rod lower head caps.

18. Unscrew the 4 fitting bolts (the bolt that also functions as a pin) and remove the caps from the connecting rods of the 1st and 4th cylinders. Lay out the bolts and main caps in the order in which they were installed on the engine.

19. Move the connecting rods away from the crankpins and carefully push the pistons upward. Remove the bearing shells from the connecting rods and caps and discard them.

Installation

1. Using a micrometer, measure the crankpin diameters, measuring in four directions on each crankpin.



2. Write down the letter code of the crankpin size group located on the rear counterweight. The code designations are read from left to right, the first group refers to the 1st journal.

TECHNICAL SPECIFICATIONS, Engine - petrol K1.8.

3. 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. Select the corresponding liners.

TECHNICAL SPECIFICATIONS, Engine - petrol K1.8.

4. The color marks on the edge of the bearing indicate their thickness: YELLOW = thin bearing, BLUE = medium-thick bearing, RED = thick bearing. If bearings of two different color markings are to be installed on one journal, the thicker bearing is installed in the connecting rod cap.

5. Wipe the connecting rod journals and the surface of the beds in the lower head of the connecting rods.

6. Select the appropriate inserts.

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

8. Install the connecting rod bearings into the connecting rod and into the caps.

9. Carefully slide the connecting rod onto the journal, install the connecting rod cap, paying attention to the fact that the installation grooves in the cap and in the connecting rod body should be on different sides, and slightly tighten the connecting rod bolts.

10. Tighten the connecting rod cap mounting bolts:

• Stage 1: 20 Nm.
• Step 2: 45° turn.

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

11. Using a feeler gauge, measure the axial clearance of the lower connecting rod head on the crank pin. The clearance value should be from 0.10 to 0.25 mm.

12. Wipe the oil distributor cover, oil receiver and mating surfaces.

13. Blow out the oil passages in the oil distribution cover and in the oil receiver.

CAUTION: If the threads are damaged, a new oil distributor cap must be installed. Do not use thread repair inserts (such as Helicoil).

14. Temporarily remove the cylinder liner fasteners LRT-12-144.

CAUTION: Do not rotate the crankshaft after removing the cylinder liner fasteners. The cylinder head bolts used to tighten the liner fasteners should be laid out in the order in which they were installed on the engine.

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

ATTENTION: Assembly of prepared parts must be carried out immediately to prevent contamination of surfaces with applied sealant.

16. Install the oil distributor cover onto the integral main bearing cover, fit the nuts and tighten them to 9 Nm.

17. Install the LRT-12-144 fasteners onto the cylinder liners and tighten the bolts slightly.

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

18. Lubricate the new O-ring with clean engine oil and place it on the oil pickup tube.

19. Install the oil pickup pipe, screw in the bolts and tighten them to a torque of 12 Nm.

20. Loosen the crankshaft pulley mounting bolt, remove the pulley and bolt with washer.



21. Install the oil pan.

ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Sealing of oil pan.

22. Install the cylinder head.

ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Cylinder head gasket.

23. Connect the negative battery terminal.