Engine appearance: 1 - carburetor; 2 - valve cover; 3 - cylinder head; 4 - front cover; 5 - water pump; 6 - generator; 7 - crankshaft pulley; 8 - oil pump; 9 - drain plug; 10 - oil pan; 11 - oil filter; 12 - cylinder block; 13 - flywheel; 14 - fuel pump
Caution! Be sure to hold the flywheel.
1. Place the engine on sturdy supports.
2. Unscrew the three starter mounting nuts.
3. Remove the starter.
4. Remove the three bolts and nut securing the gearbox to the cylinder block.
5. Carefully remove the gearbox, making sure that the splined end of the input shaft does not rest on the diaphragm spring petals.
6. Insert the mandrel into the hole in the pressure plate.
You can remove the clutch without a mandrel, but you need to hold the driven disk - it can fall out of the clutch housing.
The mandrel can be made to the dimensions of the primary shaft or the old primary shaft can be used instead.
7. Unscrew the six bolts securing the clutch housing to the flywheel, blocking the flywheel with a screwdriver. Install a bolt of a suitable diameter to support the screwdriver.
8. Carefully remove the clutch cover together with the driven disk.
9. Remove the upper clutch housing cover from the mounting pins, rotate it and remove it from behind the flywheel
10. Loosen the six flywheel mounting bolts, securing it from turning. Remove the locking plate while holding the flywheel.
11. Remove the flywheel from the crankshaft.
12. Set the piston of the first cylinder to TDC of the compression stroke. To do this, turn the crankshaft with a wrench by the bolt until the mark on the crankshaft pulley coincides with the long mark on the front cover.
13. Remove the spark plug wire caps.
14. Disconnect the hose from the vacuum corrector.
15. Unscrew the three nuts securing the ignition distributor. Remove the bracket securing the high-voltage wires.
16. Remove the ignition distributor.
17. Loosen the clamp and disconnect the hose from the fuel pump.
18. Unscrew the two fuel pump mounting nuts.
19. Remove the fuel pump carefully to avoid damaging the gasket.
20. Carefully remove the heat-insulating spacer with the rod, without damaging the adjusting linings.
21. Remove the Allen key bolt securing the distributor drive housing (auxiliary units).
22. Remove the distributor drive housing (auxiliary units).
23. Remove the three bolts securing the front cover.
24. Remove the front cover.
25. Loosen the generator mounting nuts.
26. Turn the generator towards the block.
27. Remove the alternator drive belt.
28. Loosen the bolt securing the tension bar to the cylinder block.
29. Completely loosen the generator mounting nut.
30. Remove the bolt while holding the generator and remove it from the engine.
31. Unscrew the two cap nuts securing the valve cover.
32. Carefully remove the valve cover together with the sealing gasket.
33. Loosen the camshaft pulley mounting bolt, holding it from turning by pressing a screwdriver against the rear cover mounting stud.
1 – tension roller; 2 – camshaft pulley; 3 – camshaft drive belt; 4 – generator pulley; 5 – alternator belt; 6 – crankshaft pulley; 7 – water pump pulley
34. Loosen the tension roller nut.
35. Turn the tension roller to loosen the belt tension.
36. Remove the belt from the camshaft pulley, tensioner pulley and water pump pulley.
37. Loosen the camshaft pulley mounting bolt and remove it together with the washer.
38. Carefully, so as not to damage the seal, press the camshaft pulley with a puller and remove it. If you do not have a puller, use two screwdrivers.
39. Remove the back cover.
40. Remove the four bolts and nut securing the rear cover.
41. Loosen the crankshaft pulley mounting bolt while holding the shaft from turning.
42. Remove the crankshaft pulley, timing pulley and timing belt.
To prevent the crankshaft from turning, tighten the two flywheel mounting bolts into the holes in the crankshaft flange and insert a large screwdriver or pry bar between them.
43. Loosen the mounting nut and disconnect the bracket from the water pump inlet pipe.
44. Unscrew the ten cylinder head mounting bolts using a special Allen key.
45. Remove the bolts and washers.
Location of cylinder head mounting bolts.
46. Remove the cylinder head.
47. Remove the cylinder head gasket.
48. Loosen the two mounting bolts and remove the water pump inlet pipe.
Warning for operation 46: Do not insert a screwdriver or other tools between the head and the cylinder block.
To pry the head off the block, insert a screwdriver under the exhaust manifold. Using it as a lever, lift the head.
49. Remove the water pump by prying it out with a screwdriver.
50. Turn the engine over with the oil pan facing up and remove the sixteen oil pan mounting bolts.
51. Remove the oil pan and sealing gasket.
To remove the oil filter, use a special key. If you don't have a key and you can't unscrew the filter by hand, punch through its housing with a screwdriver and unscrew the filter, using the screwdriver as a lever.
52. Unscrew the oil filter. Unscrew the two bolts securing the oil pump receiver to the crankshaft support cover and the bolt securing it to the oil pump.
53. Remove the receiver tube from the oil pump and remove the receiver.
54. Remove the six oil pump mounting bolts.
55. Remove the oil pump by sliding it off the nose of the crankshaft.
56. Remove the six bolts securing the rear oil seal holder.
57. Carefully remove the holder by pressing it away from the block with a screwdriver.
58. Loosen the connecting rod cover fastening nuts.
59. Remove the connecting rod cap and the bearing shell. If the cap is difficult to remove, knock it off with light hammer blows.
60. Push the connecting rod with the piston into the cylinder so that the connecting rod does not touch its walls. Otherwise, the cylinder wall may be damaged.
Location of connecting rod mounting nuts (white arrows) and bolts for fastening the main bearing caps (red arrows).
61. Carefully remove the piston assembly with the connecting rod and upper bearing from the block, being careful not to damage the cylinder bore. Remove the remaining pistons in the same manner. If the bearings remain on the shaft, remove them.
62. Loosen the main bearing cap mounting bolts.
63. Remove the main bearing caps and lower bearing shells. Remove the crankshaft from the cylinder block.
64. Remove the upper main bearing shells from the cylinder block beds. Remove the support half rings from the middle support.
When disassembling the engine, we recommend replacing the liners.