Engine assembly

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1. Lubricate the camshaft support bearings and insert it into the cylinder block.

2. Install the camshaft mounting plate and check its axial play.

3. Install pushers to their original positions.

4. Install and secure with grease the main bearing shells and thrust washers so that the grease grooves point towards the crankshaft.

5. Install the key and sprocket onto the crankshaft.

6. Lubricate the crankshaft journals with engine oil and install it in the cylinder block.



7. Install the main bearing caps with liners in accordance with the markings and tighten the bolts.



8. Check the axial movement of the crankshaft using a dial gauge. If the movement exceeds the allowable limits, it is necessary to install thrust half rings of greater thickness.




9. Rotate the crankshaft so that the mark on the sprocket is in line with the connecting axis of the camshaft and crankshaft (the marks on the camshaft and crankshaft are indicated by arrows).

10. Install the drive chain on the crankshaft sprocket and camshaft sprocket, screw the sprocket to the camshaft flange. The bolt holes on the sprocket must match the holes on the camshaft flange, and the alignment marks must also point towards each other. You may need to rotate the camshaft to align the bolt holes. Secure the bolts against unscrewing by bending the tabs on the fixing plate.

11. Install the chain tensioner.

12. Install the flinger on the sprocket side of the crankshaft so that its convex side points towards the sprocket.



13. Screw on the drive cover with a new gasket and a pre-installed new O-ring. One bolt (indicated by an arrow) Do not screw in the cover fasteners before installing the water pump.


14. Install water pump.

15. Lubricate the sealing lips, install the crankshaft pulley and tighten the mounting bolt.

16. Install the crankshaft rear O-ring cover and tighten the bolts.

17. Install the rear shield to the cylinder block.

18. Install the flywheel on the crankshaft and screw it on.

19. Install the clutch, having previously centered it.

20. Lubricate the cylinders and install the pistons with rings and connecting rods. The arrows on the pistons should point towards the timing gear, and the oil passage holes on the connecting rods should be on the left. Screw on the connecting rod caps.

21. Install the oil pan and oil drain plug.

22. Install the oil pressure sensor.

23. Turning the crankshaft, set the piston of the first cylinder to TDC, while the marks on the crankshaft pulley and on the drive cover must match. Install oil pump with filter.



24. Install fuel pump.

25. Install the cylinder head.

26. Install the pushers in the same places where they stood.

27. Install the axle with levers on the head.

28. Adjust valve clearances.



29. Install inlet (on the image) and exhaust manifolds.


30. Install the carburetor and connect the fuel line from the fuel pump.

31. Install spark plugs and coolant temperature sensor.

32. Install thermostat and thermostat housing cover.

33. Install the water pump pulley.

34. Install the generator, put on the drive belt and adjust its tension.

35. Install the ignition distributor.

36. Install the ignition distributor cap and connect the high-voltage wires to the spark plugs.

37. Install the coolant hose located on the side of the engine.

38. Install the crankcase breather hose to the intake manifold and oil filler cap.



39. Screw the gearbox to the engine and check that the lock (1) the gear selector shaft is installed together with the spring (2) and pin (3).







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