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 sump; 11 - oil filter; 12 - cylinder block; 13 - flywheel; 14 - fuel pump
Attention! Be sure to hold the flywheel.
1. Place the engine on solid stands.
2. Loosen the three starter mounting nuts.
3. Remove the starter.
4. Turn away three bolts and a nut of fastening of a transmission to the block of cylinders.
5. Carefully remove the gearbox. Make sure that the splined end of the input shaft does not rest on the petals of the diaphragm spring.
6. Insert the mandrel into the pressure plate hole.
It is possible to remove the clutch without a mandrel, but at the same time it is necessary to hold the driven disk - it may fall out of the clutch housing.
The mandrel can be made to the dimensions of the input shaft, or an old input shaft can be used instead.
7. Remove the six bolts securing the clutch cover to the flywheel, blocking the flywheel with a screwdriver. To stop the screwdriver, install a bolt of a suitable diameter.
8. Carefully remove the clutch cover together with the driven disc.
9. Remove the upper cover of the clutch housing from the dowel pins, rotate it and remove it from behind the flywheel
10. Loosen the six bolts securing the flywheel, securing it from turning. Remove the lock plate while holding the flywheel.
11. Remove the flywheel from the crankshaft.
12. Set the piston of the first cylinder to the top dead center. compression stroke. To do this, turn the crankshaft with a key for the bolt until the mark on the crankshaft pulley matches the long mark on the front cover.
13. Remove wire ends from spark plugs.
14. Disconnect the hose from the vacuum corrector.
15. Turn away three nuts of fastening of the distributor of ignition. Remove the high voltage wiring bracket.
16. Remove the ignition distributor.
17. Loosen the clamp and disconnect the hose from the fuel pump.
18. Loosen the two nuts securing the fuel pump.
19. Carefully remove the fuel pump so as not to damage the gasket.
20. Carefully remove the heat-insulating spacer with the stem without damaging the shims.
21. Turn away a bolt with an internal hexagon of fastening of the case of a drive of the distributor of ignition (auxiliary units).
22. Remove the ignition distributor drive housing (auxiliary units).
23. Remove the three screws securing the front cover.
24. Remove the front cover.
25. Loosen the alternator fastening nuts.
26. Turn the generator towards the block.
27. Remove the alternator drive belt.
28. Turn away a bolt of fastening of a tension level to the block of cylinders.
29. Completely unscrew the alternator mounting nut.
30. Remove the bolt holding the alternator and remove it from the engine.
31. Loosen the two cap nuts securing the valve covers.
32. Carefully remove the valve cover along with the gasket.
33. Loosen the camshaft pulley bolt, holding it from turning, for which rest the 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, loosening the belt tension.
36. Remove the belt from the camshaft pulley, idler pulley and water pump pulley.
37. Loosen the camshaft pulley bolt and remove it together with the washer.
38. Carefully, so as not to damage the oil seal, press the camshaft pulley with a puller and remove it. If a puller is not available, use two screwdrivers.
39. Remove the back cover.
40. Loosen the four bolts and nut of the rear cover fastening stud.
41. Loosen the crankshaft pulley bolt while holding the crankshaft from turning.
42. Remove the crankshaft pulley, toothed pulley and timing belt.
To fix the crankshaft from turning, wrap the two flywheel mounting bolts into the holes in the crankshaft flange and insert a large screwdriver or spudger between them.
43. Unscrew the fastening nut and disconnect the bracket from the water pump inlet pipe.
44. Unscrew the ten bolts securing the head of the block with a special key for an internal hexagon.
45. Remove bolts with washers.
The location of the head bolts.
46. Remove the cylinder head.
47. Remove the cylinder head gasket.
48. Remove the two mounting bolts and remove the water pump inlet pipe.
Operation 46 warning. Do not drive a screwdriver or other tools between the head and 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 sump up and remove the sixteen oil sump bolts.
51. Remove the oil pan and gasket.
Use a wrench to remove the oil filter. If there is no key, and the filter cannot be unscrewed by hand, pierce its housing with a screwdriver and unscrew the filter, using the screwdriver as a lever.
52. Unscrew the oil filter. Remove the two bolts securing the oil pump receiver to the crankshaft support cover and the bolt securing 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 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 cap nuts.
59. Remove the connecting rod cap and bearing. If the cover is difficult to remove, knock it off with light blows from a hammer.
60. Push the connecting rod with the piston into the cylinder so that the connecting rod does not touch its walls. Otherwise, the cylinder mirror may be damaged.
Location of connecting rod nuts (white arrows) and bolts of fastening of covers of radical bearings (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 rest of the pistons in the same way. If the bushings remain on the shaft, remove them.
62. Turn away bolts of fastening of covers of radical bearings.
63. Remove the main bearing caps and lower bearings. Remove the crankshaft from the cylinder block.
64. Take out the top loose leaves of radical bearings from beds of the block of cylinders. Remove the support half rings from the middle support.
When disassembling the engine, we recommend replacing the liners.