Removing the flywheel
1 key; 2 - flywheel; 3 – a bolt of fastening of a flywheel; 4 - washer; 5 - retainer A.60330 / R to keep the flywheel from turning; 6 - front cover of the clutch housing
Removing the tensioner and calming the chain
1 - camshaft drive circuit; 2 – a bolt of fastening of a shoe; 3 - tensioner shoe; 4 – a nut of fastening of a tensioner; 5 - tensioner body; 6 – a cap nut of a tensioner; 7 - bolts for fastening the damper; 8 – a bolt of fastening of an asterisk of the roller of a drive of the oil pump
1. Wash the engine in a car washer, put it on a stand for dismantling and drain the oil from the crankcase.
2. Remove the carburetor by disconnecting the hoses and throttle linkage from it.
3. Remove the fuel pump, ignition distributor, use the key 67.7812.9514 to turn out the spark plugs and the coolant temperature indicator sensor.
4. Remove the alternator drive belt and coolant pump, remove the alternator and alternator bracket.
5. Remove the coolant pump by disconnecting the coolant supply pipe from the heater from the pump and exhaust manifold.
6. Remove the coolant outlet pipe and the coolant outlet pipe to the heater from the cylinder head.
7. Using tool A.60312, unscrew and remove the oil filter with gasket.
8. Unscrew the oil pressure warning light sensor, remove the crankcase ventilation breather cap, crankcase and oil pump. Remove the oil separator drain tube retainer and remove the crankcase ventilation oil separator.
9. Remove the crankshaft pulley by securing the flywheel with retainer A.60330 / R (see fig. Removing the flywheel) and unscrewing the ratchet with the key A.50121.
10. Remove the cylinder head cover and camshaft chain cover. Loosen the camshaft sprocket and oil pump drive shaft bolts.
11. Loosen cap nut 6 (see fig. Removing the tensioner and calming the chain) chain tensioner, unscrew the nuts 4 securing it to the cylinder head, remove the tensioner and, unscrewing the bolt 2, remove the shoe 3 of the chain tensioner.
12. Unscrew the chain stop pin, remove the oil pump and camshaft drive sprockets and remove the chain.
13. Loosen the stud nuts 4. Having unscrewed the fastening nuts, remove the stud bearing housing 4 and, having removed the thrust flange 1, carefully remove the camshaft 2 so as not to damage the surface of the bearing housing 3 bearings.
14. Turn away bolts of fastening of a head of cylinders and remove it together with a final collector and the inlet pipeline.
15. Remove the thrust flange 1 of the oil pump drive roller and remove the roller 3 from the cylinder block (2 - flange bolt, 4 - key).
16. Using a universal puller A.40005/1/7 from the set A.40005, remove the sprocket from the crankshaft.
17. Unscrew the nuts of the connecting rod bolts, remove the connecting rod caps and carefully remove the pistons with connecting rods through the cylinders.
Attention! When disassembling the engine, mark the piston, connecting rod, main and connecting rod bearing shells in order to install them in their original place during assembly.
18. Install retainer 5 (see fig. Removing the flywheel), unscrew the bolts 3, remove the washer 4 and the flywheel from the crankshaft, remove the front cover of the clutch housing.
19. Using extractor A.40006, remove the gearbox input shaft bearing from its socket in the crankshaft.
20. Remove the crankshaft oil seal holder.
21. Turn away bolts of covers of radical bearings. Remove them together with the lower bearings, remove the crankshaft, upper bearings and thrust washers on the rear support.