Engine 2105
Wash the engine in a car wash, place it on a dismantling stand and drain the oil from the crankcase.
Remove the carburetor by disconnecting the hoses and throttle linkage from it, remove the fuel pump and ignition distributor. Key 67.7812.9514 (tubular face 21 mm) Remove spark plugs and coolant temperature gauge.
Remove the alternator drive belt and coolant pump, and then the alternator with bracket.
After disconnecting the fluid supply pipe from the heater from the pump and the exhaust manifold, remove the coolant pump.
From the cylinder head, remove the outlet pipe of the cooling jacket and the fluid outlet pipe to the heater.
Using tool A.60312, unscrew and remove the oil filter with gasket. Turn out the gauge of a control lamp of pressure of oil.
Remove the crankcase ventilation breather cap, oil sump and oil pump; remove the oil separator drain tube clamp attached to the bottom plane of the cylinder block; Remove the crankcase ventilation oil separator.
Remove the pulley 12 from the crankshaft (pic. 60) generator drive. To do this, block the flywheel with lock A.60330/R (pic. 61) and turn away with the key A.50121 (cap 38 mm) bolt 13 (see fig. 60) at the front end of the crankshaft.
Remove the top 1, middle 10 and bottom 11 protective covers of the camshaft belt drive. Remove the spring 3 of the tension roller bracket 2. Remove the bolts, remove the bracket with the tension roller, belt 4, and then the toothed pulley 9 from the crankshaft.
Holding the auxiliary drive shaft pulley and the camshaft pulley from turning with fixture 67.7811.9509, unscrew the bolts of their fastening and remove the pulleys. Remove the cover 5 of the camshaft drive with the gasket, and then the thrust flange 7 and the shaft 6 of the auxiliary drive.
Remove the cylinder head cover with gasket and bearing housing assembly with camshaft, oil seal holder and thrust flange. If necessary, then separately on the workbench, unscrew the nuts, remove the stuffing box holder, thrust flange and remove the camshaft from the bearing housing. This must be done carefully so as not to damage the surface of the bearing housing supports.
Turn away bolts of fastening of a head of cylinders and remove it together with a final collector and an inlet pipe.
Having unscrewed the nuts of the connecting rod bolts, remove the connecting rod caps with liners and carefully remove the pistons with connecting rods through the cylinders. When performing this operation, mark the piston, connecting rod, as well as the shells of the main and connecting rod bearings so that they can be installed in their original place during assembly.
Install retainer 5 in the bore of the cylinder block (pic. 61 a) A.60330/R, use wrench 1 to unscrew bolts 3, remove washer 4 and flywheel 2 from the crankshaft, and then remove the front cover 6 of the clutch housing.
Ejector А.40006 1 (pic. 62) with a collet tip, remove the gearbox input shaft bearing from its socket in the crankshaft. Remove the holder 2 of a back epiploon of a cranked shaft.
Having unscrewed the bolts of the main bearing caps, remove them together with the lower shells, then remove the crankshaft, upper shells and thrust half rings on the rear support.
Engines 2101, 2103
The procedure for disassembling these engines differs in disassembling the front of the engine, where the camshaft chain drive is located. Before removing the alternator drive pulley from the crankshaft, all disassembly operations are the same as on the 2105 engine.
After removing the pulley, perform the following operations:
- remove the cylinder head cover with gasket and the camshaft chain drive cover;
- unscrew the bolts securing the camshaft sprockets and the auxiliary drive shaft. Loosen cap nut 5 (pic. 63) chain tensioner 1, unscrew the nuts 4 securing it to the cylinder head, remove the tensioner and, unscrewing the bolt 2, remove the shoe 3 of the chain tensioner;
- Unscrew the chain stop pin, remove the camshaft and accessory drive shaft sprockets, and remove the chain. Loosen the bolts and remove the chain guide;
- loosen the camshaft thrust flange nuts. Having unscrewed the fastening nuts, remove the camshaft bearing housing;
- having unscrewed the nuts of the studs and, having removed the thrust flange, carefully, so as not to damage the surface of the bearing housing supports, remove the camshaft;
- unscrew the cylinder head bolts and remove it together with the exhaust manifold and intake pipe;
- key 4 (pic. 64 socket wrench 10mm) unscrew the two bolts 2 fastening the thrust flange 1 of the auxiliary drive shaft, remove the flange and remove the shaft 3 from the cylinder block. Using a universal puller, remove the sprocket from the crankshaft.
Next, the pistons are removed, the flywheel and crankshaft are removed, as on the 2105 engine.