Engine disassembly

Note. When disassembling, put marks on the removed parts suitable for further use in order to install them in their original places and in their original position during assembly.

Separate the engine from the gearbox. Drain oil from oil sump. Remove the intake manifold and exhaust manifold. Remove the ignition distributor, alternator and drive belt.

On vehicles with a carburetor power system, remove the fuel pump.

Remove water pump. Remove the oil pan, then the crankshaft pulley and the camshaft drive belt guards. Loosen the nut securing the axle of the toothed belt tensioner and remove the belt.

Remove cylinder head. Loosen the bolts securing the clutch cover to the flywheel and remove the cover assembly with the pressure plate. This releases the clutch disc. Remove flywheel. Loosen the mounting bolts and remove the holders of the front and rear crankshaft oil seals using two screwdrivers, resting them on the tides. Remove intermediate shaft from cylinder block. after removing the holder together with the stuffing box. Place the cylinder block on the stand. Check for marks on the connecting rod caps and crankshaft main bearing caps.

If necessary, mark the connecting rods, crankshaft main bearing caps, and appropriate cylinders. Loosen the connecting rod nuts and remove the connecting rod caps. Remove the pistons with connecting rods through the cylinders. Remove the connecting rod bearing shells and determine the degree of wear of the shells. If the earbuds can be reused, mark the earbuds to identify their position («top», «bottom»), and mark the corresponding connecting rods. Unclip and remove piston pin circlips with pliers (pic. 2-2) and press out the fingers with a mandrel.




Check the axial free play of the crankshaft. Unscrew the bolts securing the main bearing caps and remove the caps together with the lower shells. Remove the crankshaft from the bearing seats, and then the upper liners.

The main bearing caps are marked with the numbers 1-5, indicating the order in which they are installed when assembling the engine. If main bearing shells are to be reused, both the lower and upper shells must be noted.