Disassembly
If only a part needs to be replaced, then you can not completely disassemble the cylinder head, but remove only the damaged parts. Completely disassemble the cylinder head in the following sequence:
- install the cylinder head on a stand, unscrew the nuts and remove the carburetor with gasket, intake pipe and exhaust manifold (remove the hot air intake at the same time). Remove the outlet pipe of the cooling jacket and the fluid outlet pipe to the heater;
- unscrew the fastening nuts and remove the bearing housing together with the camshaft, gland holder and pulley. On engines 2101, 2103, remove the bearing housing with the camshaft and thrust flange;
- remove the valve levers with springs. Loosening the locknuts, turn out the adjusting bolts and, if necessary, their bushings. Fit tool A.60311/R, compress the valve springs and loosen the cotters. Instead of the portable tool A.60311/R, the fixed tool 02.7823.9505 can also be used;
- remove the valve springs with plates and support washers. Turn the cylinder head and remove the valves from the underside;
- remove the oil seals from the guide bushings.
Assembly
Before assembling, check if the circlips 2 are in place (pic. 14) guide bushings 3. Thoroughly clean the upper plane of the cylinder head from dirt, oil and residues of old sealant (on engines 2105). Check if the camshaft bearing housing dowels are in place (shown by arrows on rice. 21). Install (if they were removed) locking plates 16 lever springs and bushings 15 adjusting bolts. Screw the adjusting bolts 13 with lock nuts 14.
Lubricate valves 1 and new oil seals 4 with engine oil (do not use old). Mandrel 41.7853.4016 (pic. 15) press the caps onto the valve guides. Insert the valves into the guide bushings, and then install the support washers 5 (see fig. 14) and 6, springs 7, 8 and plates 9. Compressing the springs with tool A.60311/R, install crackers 10. Install springs 12 and valve levers 11.
On 2105 engines, assemble the bearing housing with the camshaft, pulley, gland holder and thrust flange according to section «Camshaft and its drive».
On engines 2101, 2103, insert the camshaft lubricated with engine oil into the bearing housing and secure it with a thrust flange. Put the sprocket on the camshaft (without fixing it) and turn it until the alignment marks on the sprocket and bearing housing are aligned (see fig. eleven). Remove the sprocket and, without violating the position of the camshaft, install the bearing housing on the cylinder head.
Check that the dowel sleeves fit into the holes in the bearing housing, and then tighten the bearing housing mounting nuts in the sequence shown on rice. 23.
Install the cooling jacket outlet pipe and the fluid outlet pipe to the heater. Install the gasket, intake pipe and exhaust manifold with hot air intake. Install the carburetor with a gasket and close it with a technological plug.