Disconnect the wire from the negative terminal of the battery, and then the wires and vacuum hose from the ignition distributor. After unscrewing the fastening nuts, remove the ignition distributor with the high-voltage wire bracket. Remove the fuel pump, and then the auxiliary drive housing.
Remove the front timing belt cover, set the gearshift lever to neutral and turn the crankshaft clockwise to a position where the mark on the camshaft pulley is opposite the timing mark on the rear timing belt cover (see figure 6), and the mark on the flywheel was opposite the middle division of the scale (see figure 52).
Loosen the axle mounting nut 7 (see figure 25) tension roller and turn it to a position where the belt tension is minimal. Remove the belt from the camshaft pulley. Holding the camshaft pulley from turning with device 67.7811.9509, unscrew its mounting bolt and remove the pulley. Instead of the named device, you can use some kind of lever with grips for the pulley holes.
Remove the cylinder head cover and camshaft bearing housings by unscrewing the mounting nuts. Remove the camshaft from the cylinder head beds and remove the seal from it.
Before installing the camshaft, check that the camshaft bearing housing mounting bushings are in place (in figure 38 bushings are shown mounted on studs). Clean the mating surfaces of the cylinder head and bearing housings from any remaining old gasket, dirt and oil.
Lubricate the bearing journals and cams of the camshaft with engine oil and place it in the cylinder head supports in such a position that the cams of the first cylinder are directed upward.
On the cylinder head surfaces mating with the bearing housings, in the area of the extreme camshaft supports, apply SUPER THREE BOND No.50 sealant or a similar domestically produced sealant KLT-75T. It should be borne in mind that the engine may not be started earlier than 1 hour after applying the sealant.
The bearing housings are installed and the nuts that secure them are tightened in two steps:
- 1st step - pre-tighten the nuts in the sequence indicated on figure 18, b, until the bearing housing surfaces are flush with the cylinder head, making sure that the housing mounting bushings fit freely into their sockets;
- 2nd step - finally tighten the nuts to a torque of 2.2 kgf·m in the same sequence.
Immediately after tightening the bearing housing fastening nuts, carefully remove any remaining sealant squeezed out of the gaps during tightening in the areas mating with the cylinder head cover gasket and the auxiliary unit housing: unremoved polymerized sealant residues in the indicated areas will lead to oil leakage through the seals.
Using mandrel 67.7853.9580, press in a new camshaft oil seal, after lubricating it with engine oil. A pipe with an outer diameter of 28 mm and an inner diameter of 22 mm and a conical guide can also be used as a mandrel. Insert a segment key into the socket on the front end of the camshaft and install the toothed pulley. Holding the camshaft pulley from turning with device 67.7811.9509, secure it with a bolt and washer.
When installing the pulley, make sure that the mark on the pulley is approximately opposite the installation mark on the rear protective cover of the toothed belt. The permissible misalignment is no more than two pulley teeth, otherwise the valves of the 4th cylinder will rest against the piston. For this reason, it is also not allowed to turn and rotate the camshaft and crankshaft before installing the belt.
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Adjust the position of the camshaft pulley until the mark on the pulley is precisely aligned with the mark on the rear protective cover and put the belt on the pulley. Slightly tighten the belt with the tension roller, turning the roller axis counterclockwise.
Turn the crankshaft two revolutions clockwise and check that the timing marks on the camshaft pulley and the rear protective cover match, and also whether the mark on the flywheel is opposite the middle division of the scale (see figure 52).
If the marks do not match, then loosen the belt with a tension roller, remove it from the camshaft pulley, adjust the pulley position, put the belt back on the pulley and slightly tighten it with a tension roller. Again check the coincidence of the installation marks by turning the crankshaft two revolutions.
If the timing marks match, adjust the belt tension as indicated in section. "Engine adjustments", and install the front toothed belt cover. Adjust the valve drive clearances and install the cylinder head cover.
Install the auxiliary unit housing and the fuel pump (see the description of the operation in the "Fuel Pump" section). Install the ignition distributor so that the middle division of the scale on its housing is opposite the mark on the auxiliary unit housing. At the same time, secure the high-voltage wire bracket. Connect the wires and vacuum hose to the ignition distributor.
Connect the air and throttle valve drive cables to the carburetor and adjust the drive (see "Engine adjustments"). Install the air filter and connect the crankcase ventilation and warm air intake hoses in place.
Connect the wire to the negative terminal of the battery, check and adjust the ignition timing (see ibid).