Disconnect the wire from the terminal «minus» battery, and then the wires and vacuum hose from the ignition distributor. Having unscrewed the fastening nuts, remove the ignition distributor with the high voltage wire bracket. Remove the fuel pump, and then the accessory drive housing.
Remove the front toothed belt guard, set the shift lever to neutral position and turn the crankshaft clockwise so that the mark on the camshaft pulley is against the alignment mark on the rear toothed belt cover (see fig. 6), and the mark on the flywheel was against the middle division of the scale (see fig. 52).
Loosen the axle nut 7 (see fig. 25) tension roller and turn it to a position in which the belt tension will be minimal. Remove the belt from the camshaft pulley. Holding the camshaft pulley from turning with tool 67.7811.9509, unscrew its fastening 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 fastening nuts. Remove the camshaft from the beds of the cylinder head and remove the oil seal from it.
Before installing the camshaft, check whether the locating sleeves of the camshaft bearing housings are in place (in fig. 38 bushings shown fitted over studs). They clean the mating surfaces of the cylinder head and bearing housings from the remnants of the old gasket, dirt and oil.
Lubricate the bearing journals and camshaft cams with engine oil and place it in the cylinder head bearings in such a position that the cams of the first cylinder are directed upwards.
SUPER THREE BOND no. 50 or a similar sealant of domestic production KLT-75T. It must be borne in mind that it is allowed to start the engine no earlier than 1 hour after applying the sealant.
Install the bearing housings and tighten the nuts of their fastening in two steps:
- 1st reception - pre-tighten the nuts in the sequence indicated on rice. 18b, until the surfaces of the bearing housings touch the cylinder head, making sure that the mounting sleeves of the housings freely enter their sockets;
- 2nd reception - finally tighten the nuts with a torque of 2.2 kgf-m in the same sequence.
Immediately after tightening the nuts of the bearing housings, carefully remove the sealant residue squeezed out of the gaps during tightening in the areas mating with the cylinder head cover gasket and with the auxiliary unit housing: non-removed polymerized sealant residues in these places will lead to oil leakage through the seals.
Using mandrel 67.7853.9580, a new camshaft oil seal is pressed in, having previously lubricated it with engine oil. As a mandrel, you can also use a pipe with an outer diameter of 28 mm and an inner diameter of 22 mm and a conical guide. Insert a segment key into the socket at the front end of the camshaft and install the toothed pulley. Holding the camshaft pulley from turning with fixture 67.7811.9509, fix it with a bolt with a washer.
When installing the pulley, make sure that the mark on the pulley is approximately opposite the alignment mark on the rear toothed belt guard. The permissible mismatch 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 camshafts and crankshafts before installing the belt.
The position of the camshaft pulley is corrected until the mark on the pulley is exactly aligned with the mark on the rear protective cover and the belt is put on the pulley. Slightly tension the belt with the tension roller by turning the roller axis counterclockwise.
Turn the crankshaft two turns clockwise and check that the alignment marks on the camshaft pulley and the rear protective cover match, and also whether the mark on the flywheel is against the middle division of the scale (see fig. 52).
If the marks do not match, then loosen the belt with a tension roller, remove it from the camshaft pulley, correct the position of the pulley, put the belt back on the pulley and slightly tighten the tension roller. Again, check the coincidence of the installation marks by turning the crankshaft two turns.
If the alignment marks match, then adjust the belt tension, as indicated in Sec. «Engine settings», and install the front toothed belt guard. Adjust the clearances in the valve drive mechanism and install the cylinder head cover.
Install the accessory housing and fuel pump (see the description of the operation in sec. «Fuel pump»). The ignition distribution sensor is installed so that the average division of the scale on its body is against the mark on the body of auxiliary units. At the same time, the high voltage wire bracket is fixed. Connect wires and a vacuum hose to the ignition distributor.
Attach the air and throttle control cables to the carburetor and adjust the drive (see «Engine settings»). Install the air filter and attach the hoses of the crankcase ventilation system and warm air intake.
Connect the wire to the terminal «minus» battery, check and adjust the ignition timing (see ibid).