Removal and installation of a head of cylinders

Removing

Disconnect the wire from the negative battery terminal.

Disconnect the supply hose from the radiator and drain the coolant.

Remove air filter.

Disconnect the fuel supply hose from the fuel pump, and the fuel drain hose from the carburetor, and close the openings of the hoses and fittings with plugs.

Remove the fuel drain compensation valve.

Disconnect the vacuum hoses from the carburetor.

Disconnect the connectors of the electrical components installed on the cylinder head, disconnect the block from the intake manifold heater.



Disconnect the crankcase ventilation hose from the cylinder head cover.

Disconnect the wires from the spark plugs, remove the cover and the rotor of the ignition distributor.

Remove spark plugs.

Disconnect the throttle cable and attach it to the left side of the engine compartment.

Disconnect the outlet hose from the radiator. Disconnect the interior heating hoses.


Loosen the bolts securing the muffler exhaust pipe flange to the exhaust manifold.

Remove intake pipe.

Turn the engine crankshaft to the position corresponding to the TDC of the end of the compression stroke of the piston of the 1st cylinder, aligning the mark on the crankshaft pulley with the edge of the protrusion «ABOUT» indicator on the cylinder block.

Remove the front toothed belt guard.

Loosen the toothed belt tension and remove it from the camshaft pulley.

Remove the camshaft sprocket.

Remove rear toothed belt guard.

Remove cylinder head cover.

Loosen the cylinder head bolts.

Remove cylinder head.

Installation

Clean all removed parts and check their technical condition. Wash mating surfaces with a suitable solvent. Never clean the mating surfaces with a scraper or abrasive materials. Replace gaskets during reassembly.

Install the cylinder head gasket so that the marked side of the gasket faces the cylinder head.

Reinstall the cylinder head and tighten bolts 8 and 10 (see photo) for its centering.

Install new cylinder head bolts with new washers.

Tighten the cylinder head bolts in three steps, following the order (see photo) and tightening torques:

• 1st reception: 4 kgf.m;
• 2nd reception: 6 kgf.m;
• 3rd trick: turn 180s.

Install the camshaft drive belt and adjust its tension (see above).

Check valve clearances and adjust if necessary.

Install the exhaust manifold and fix the muffler exhaust pipe flange with a new gasket on it.

Install intake pipe.

Connect the outlet hose to the radiator. Connect heater hoses. Connect the inlet hose to the radiator.

Connect the throttle cable.

Screw in the spark plugs.

Connect the crankcase ventilation hose to the cylinder head cover.

Connect the electrical connectors of the electrical components mounted on the cylinder head. Connect the block to the intake manifold heater.

Connect vacuum hoses to carburetor.

Install the fuel drain compensation valve in the tank.

Connect the fuel supply hose to the fuel pump and the fuel drain hose to the carburetor.

Install the air filter.

Fill the engine cooling system with fluid.

Check the oil level in the engine crankcase.

Connect the wire to the negative terminal of the battery.

If the cylinder head was disassembled, adjust the ignition timing, engine idling, check the clearance adjustment in the valve drive mechanism on a hot engine.