Water pump
1 - water pump pulley; 2 - body; 3 - gasket; 4 - pump shaft; 5 - seal; 6 - impeller
Oil pump
1 - outer gear; 2 - dividing partition; 3 - internal gear
Crank mechanism
1 - piston rings; 2 - piston pin; 3 - piston; 4 - root bearing; 5 - front sealing ring; 6 - key; 7 - persistent half rings; 8 - connecting rod; 9 - crankshaft; 10 – a back sealing ring; 11 – a cover of the radical bearing
Engine block
1 – block of cylinders of the engine; 2 - cork; 3 - plugs of oil channels; 4 - oil separator; 5 - rear flange of the crankshaft; 6 - gasket; 7 - plug for draining water
1. Loosen the lower mounting bolts, unscrew the upper alternator tension bolt, tilt the alternator towards the engine and remove the drive belt.
2. Remove the alternator mounting bracket bolts and remove the alternator.
3. Remove the heater hose from the water pump.
4. Drain engine oil.
5. Fix the flywheel by the ring gear, unscrew the mounting bolt and remove the pulley from the crankshaft.
6. Unscrew the 4 bolts securing the toothed belt cover and remove it.
7. On engine models made from 2/82, the timing belt cover consists of two parts, each with its own rubber gasket. On the bottom cover there is a mark for setting the first cylinder to TDC. The bottom cover can only be removed after removing the pulley from the crankshaft.
8. Loosen the bolts of the toothed belt tension roller and use a screwdriver to remove the tension roller from the belt, compress the spring and tighten the bolts.
9. To reinstall the toothed belt, note the direction of its movement.
10. Remove toothed belt.
11. Disconnect the ignition distributor cap and remove it together with the high voltage wires.
12. Unscrew the spark plugs.
13. Remove the crankcase breather hose.
14. Unscrew the mounting bolts and remove the carburetor, having previously disconnected the fuel and vacuum tubes.
15. Remove the cylinder head cover.
16. Remove the cylinder head.
17. Position the engine horizontally and remove the oil pan.
18. Unscrew the bolts securing the leading part of the clutch to the flywheel alternately crosswise, blocking the flywheel ring gear with a screwdriver.
19. Remove drive gear and clutch disc.
20. Unscrew the flywheel mounting bolts and, being careful, remove the flywheel.
21. Remove the rear engine cover.
22. Unscrew the bolts and remove the crankshaft rear O-ring cover.
23. Unscrew the bolts securing the toothed belt tensioner pulley, remove the tensioner and remove the spring.
24. Remove water pump (see fig. Water pump).
25. Remove the crankshaft pulley and thrust washer.
26. Unscrew the oil pump mounting bolts and remove it together with the oil intake (see rice. Oil pump).
27. Remove the oil pressure sensor.
28. Rotate the crankshaft until all pistons are in the middle of their stroke.
29. If there is carbon deposits on the top of the cylinder, remove it using a soft scraper.
30. Check the markings on the main bearing caps. Main bearings are marked with numbers from 1 to 5 with arrows pointing towards the timing gear.
31. Check the numbers on the connecting rod caps and connecting rods and their position. Connecting rod No. 1 is located on the drive side of the gas distribution system, and the numbers should be on the side of the oil filter.
32. Turn the crankshaft by the pulley bolt until the piston of the first cylinder is in the BDC position. Unscrew the connecting rod cap and remove it together with the connecting rod bearing.
33. Remove the piston with the connecting rod up (see fig. crank mechanism).
34. Remove the rest of the pistons in the same way.
35. Unscrew the main bearing caps and remove the crankshaft.
36. Pull down the spring levers of the oil separator of the engine crankcase ventilation system and remove the oil separator (indicated by an arrow).
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