Disconnect the wiring harness connector and vacuum hose from the spark timing sensor. Unscrew the mounting nuts and remove the spark timing sensor. Remove the fuel pump with gaskets, pusher and heat-insulating spacer, and then remove the auxiliary unit housing with the sealing ring.
Remove the cylinder head cover with the gasket and rubber bushings. Remove the front toothed belt cover and turn the crankshaft clockwise to a position where the mark on the camshaft pulley is opposite the timing mark on the rear toothed belt cover (see figure 20), and the mark on the flywheel was opposite the middle division of the scale (see figure 67).
Loosen the axle mounting nut 7 (see figure 7) 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 67.7811.9513, unscrew its mounting bolt and remove the pulley with the key. Instead of the named device, you can use some kind of lever with grips for the pulley holes.
Remove the cylinder head cover and the camshaft bearing housing by unscrewing the fastening nuts. Remove the camshaft from the cylinder head beds and remove the seal from it.
Before installing the camshaft, check whether the camshaft bearing housing mounting bushings are in place (put on the studs, see figure 48). Clean the mating surfaces of the cylinder head and bearing housing from the remains of the old gasket, dirt and oil.
Put a new oil seal on the camshaft, lubricating the end of the shaft with engine oil. Lubricate the bearing journals and cams of the camshaft with engine oil and place it together with the oil seal in the cylinder head supports. Install the camshaft pulley with the key and turn it until the mark on the pulley aligns with the mark on the rear protective cover. Do not install the pulley mounting bolt.
On the surfaces of the cylinder head that are mated with the bearing housing, in the area of the extreme supports of the camshaft, apply a sealant of the SUPER THREE BOND No.50 type or a similar domestically produced sealant of the KLT-75T type (see figure 48). It is necessary to keep in mind that the engine may not be started earlier than 1 hour after the sealant has been applied. The sealant may be exposed to air for no more than 10-12 minutes.
The bearing housing is installed and the nuts are tightened in two steps:
- 1st step - pre-tighten the nuts in the sequence shown in Figure 21 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 21.6 Nm 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.
Degrease the threaded part of the camshaft pulley mounting bolt and apply UG-6 sealant to it. Hold the camshaft pulley from turning with device 67.7811.9513 and secure it with a bolt and washer. When securing 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 2 pulley teeth, otherwise the valves of the 2nd 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.
(The information is published on the website: VAZBOOK.RU)
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 67).
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 specified in the "Engine Adjustment" section, and the valve drive mechanism clearances. Install the cylinder head cover with gasket and the front toothed belt cover.
Install the auxiliary unit housing and fuel pump (see description of the operation in section. "Fuel pump"). Install the spark timing sensor so that the middle division of the scale on its body is opposite the mark on the auxiliary unit body. When installing the sensor, turn its shaft to such a position that the clutch cams of the shaft are opposite the asymmetrical grooves of the camshaft. Connect the wires and vacuum hose to the spark timing sensor.
Install the air filter and reattach the crankcase ventilation and warm air intake hoses. Install the ignition coil, high-voltage wires, and windshield washer reservoir.
Connect the wire to the negative terminal of the battery, check and adjust the ignition timing (see section. "Engine adjustment"). Install the spare wheel.