Contents: Removal ↓ Installation ↓
Removal
Remove the camshaft in the following order:
- disconnect the wires from the battery;
- remove the air filter and close the carburetor neck with a technological plug;
- disconnect the carburetor throttle drive rods from the intermediate lever on the cylinder head cover and the air damper drive cable from the carburetor;
- remove the upper protective cover of the camshaft belt drive (on engine 2105);
- remove cover 1 (Fig. 21) of the cylinder head with gasket 2;
- set the gearshift lever to neutral and turn the crankshaft clockwise until the mark on the camshaft pulley (sprocket) aligns with the mark on the bearing housing;
- on engine 2105 remove spring 7 (see fig. 19) tension roller 4. Loosen bolts 3 securing bracket 6 of the tension roller, move it to the extreme left position and remove the belt from the camshaft pulley;
- holding pulley 7 from turning with device 67.7811.9509 (see fig. 21) camshaft, unscrew its mounting bolts and remove the pulley. Instead of the named device, you can use some kind of lever with grips for the pulley holes;
- unscrew the nuts securing the bearing housing to the cylinder head 8 and remove it together with the camshaft 5;
- then on the workbench unscrew the nuts securing the holder 6 of the seal, remove it and the thrust flange 4;
- remove the camshaft from the bearing housing 3.
On engines 2101, 2103, unscrew the camshaft sprocket mounting nut, loosen nut 5 (see fig. 63) chain tensioner, press the tensioner rod with a mounting blade and secure it with a cap nut.
- Remove the camshaft sprocket with the chain and move the chain to the side.
- Loosen the camshaft thrust flange mounting nuts.
- Loosen the bearing housing mounting nuts and remove it.
- Loosen the thrust flange nuts, remove it and take the camshaft out of the bearing housing.
Installation
Before installing the camshaft, check that the camshaft bearing housing mounting bushings are in place. They are placed on the outer bearing housing mounting studs and are shown by arrows in Fig. 21. Clean the mating surfaces of the cylinder head from dirt, oil and old sealant residues (on 2105 engines). Tighten the valve lever adjusting bolts so that the levers are lowered and do not interfere with the installation of the bearing housing with the camshaft. Lubricate the bearing journals and cams of the camshaft with engine oil and insert it into the bearing housing, simultaneously putting the thrust flange on the studs.
On 2105 engines, lubricate the new seal with engine oil and press it into the holder. Attach the holder with the seal to the bearing housing without tightening the fastening nuts. Install the bearing housing on the control plate and insert the centering mandrel 67.7853.9548 in the form of a pipe with an outer diameter of 40 into the holder+0,06+0,05 mm and an internal one of 1640.02 mm. Adjust the holder with the oil seal so that the non-parallelism of its lower plane A (Fig. 22) relative to the lower plane B of the bearing housing is no more than 0.15 mm. Then, tightening the nuts of the oil seal holder, remove the mandrel from it and attach the pulley to the camshaft, lubricating the pulley mounting bolt with a sealant such as KLT-75T.
Apply a sealant such as SUPER THREE BOHD No.50 or a similar domestically produced sealant KLT-75T to the cylinder head surface mating with the seal holder. It should be borne in mind that the engine may not be started earlier than 1 hour after applying the sealant.
Turn the pulley until the timing marks are aligned (see fig. 11) and install the bearing housing with the camshaft on the cylinder head. Check whether the installation sleeves have entered the holes in the bearing housing, and then tighten the bearing housing fastening nuts in the sequence shown in Fig. 23. Holding the pulley from turning with tool 67.7811.9509, tighten the pulley fastening bolt.
Place the belt on the camshaft pulley and install the tension roller bracket spring. Then smoothly rotate the crankshaft two turns clockwise, keeping the belt under constant tension and not loosening it when the shaft stops. Tighten the tension roller mounting bolts. After this, check that the marks on the pulley and the camshaft bearing housing match (see fig. 11), as well as marks on the crankshaft pulley with a long mark on the camshaft drive cover (see fig. 73). If the marks do not match, then reinstall the belt, and if they do match, then tighten the tension roller bracket mounting bolts.
On engines 2101, 2103, put the sprocket on the camshaft (without securing it) and turn it until the alignment marks on the sprocket and bearing housing are aligned (see fig. 11). Remove the sprocket and, without disturbing the position of the camshaft, install the bearing housing on the cylinder head. Check whether the installation sleeves enter the holes in the bearing housing, and then tighten the nuts in the sequence shown in Fig. 23.
Place the chain on the camshaft sprocket and install the sprocket on the camshaft. Loosen the chain tensioner cap nut by turning the crankshaft 2 turns in the direction of rotation and check that the timing marks match (see Fig. fig. 11 and fig. 73). If the marks match, tighten the tensioner cap nut, sprocket mounting bolt and bend back the sprocket bolt lock washer.
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Check and adjust the clearance between the levers and the camshaft cams. Install the cylinder head cover with the gasket. On 2105 engines, tighten the cover mounting nuts in the sequence shown on fig. 13, and then install the upper camshaft timing belt cover.
Attach the carburetor throttle drive rods to the intermediate lever on the cylinder head cover, and the air damper drive cable to the carburetor. Adjust the carburetor throttle and air damper drives (see section "Engine adjustments"). Install the air filter, connect the wires to the battery, check and, if necessary, adjust the ignition timing.