Upper radiator shroud, plastic brace and pin
Bolt of fastening of a suspension bracket of a pipe of the cooling system
Installing the chain tensioner
Releasing the plunger of the chain tensioner
Fixing the plunger of the chain tensioner
Alternator drive belt tensioner bolt
Power steering pump drive belt tensioner bolt
1. Turning the crankshaft by the central bolt of the vibration damper, install the piston of 1 cylinder to the ignition point (12°before TDC). Correct installation can be checked by removing the ignition distributor cap, while the distributor rotor must be aligned with the contact of the high-voltage wire going to cylinder number 1.
2. Remove ground wire from battery.
3. Remove the air filter cover along with the air flow sensor and hoses.
4. Remove the oil filler cap.
5. Drain the coolant from the cooling system.
6. Disconnect the hose connecting the water pump and the expansion tank.
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7. Remove the upper radiator shroud and radiator.
8. Remove fan from water pump hub.
Attention! The fan mounting nut has a left-hand thread.
9. Disconnect the coolant hoses from the water pump fittings.
10. Remove the coolant hose hanger bolt from the front cover.
11. Remove the auxiliary drive belt.
12. Unscrew 4 bolts and remove the crankshaft pulley.
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13. Block the crankshaft by the flywheel ring gear, unscrew the central bolt of the vibration damper and remove it using a special puller.
14. Drain engine oil from engine.
15. Disconnect the wires, unscrew and remove the starter.
16. Using a hoist, carefully lift the motor and then unscrew the motor holders.
17. Check that the steering wheel is in the straight ahead position and mark the position of the intermediate shaft lower collar and steering gear with paint or marker, then disconnect the intermediate shaft from the steering gear.
18. Disconnect the brake pipes from the front suspension beam.
19. Support the beam with a suitable hoist and a wide plank.
20. Unscrew the bolts securing the beam to the bottom of the car. Tilt the beam so that access to the oil sump is free.
21. Unscrew the bolts and nuts securing the oil sump and remove it from under the engine.
22. Unscrew the 9 bolts securing the timing cover and remove the cover together with the water pump.
23. Check that labels (indicated by arrows) on the stars are directed towards each other. Otherwise, tighten the crankshaft until the marks are aligned.
24. Unscrew and remove the timing chain tensioner.
25. Fix the camshaft sprocket and unscrew the sprocket mounting bolt.
26. Remove the camshaft sprocket along with the chain and remove the chain from the crankshaft sprocket.
27. If necessary, remove the keyed sprocket and chain guide from the crankshaft.
28. Thoroughly clean mating surfaces from traces of old gaskets.
29. Check the position of the keyways on the camshaft and crankshaft. They should be directed towards each other.
30. Install the chain guide and keyed sprocket onto the crankshaft.
31. Install the chain on the crankshaft sprocket.
32. Install the chain on the camshaft sprocket and install the sprocket together with the chain on the camshaft, while the camshaft key should fit into the groove of the sprocket.
33. Screw in the camshaft sprocket bolt.
34. Compress the chain tensioner by pushing in the tensioner plunger and holding it in this state by tying it with an appropriate tape.
35. Install the chain tensioner in place, while removing the tape holding the plunger.
36. Install the front timing cover gasket.
37. Replace the O-ring on the front cover of the timing mechanism.
38. Install the front timing cover.
39. Center the hole in the cover relative to the crankshaft, and also align it with respect to the installation plane of the oil pan.
40. Screw the bolts of the front cover of the gas distribution mechanism (indicated by arrows).
41. Thoroughly clean mating surfaces of cylinder block and oil sump.
42. Install a new gasket in the oil sump grooves.
43. Apply sealant to the front and rear sections of the oil pan.
44. Apply an anti-screw compound to the bolt threads, install the oil sump and tighten the bolts.
45. Lubricate the sealing ring sealing lips and the ring mating surface of the vibration damper with engine oil and install the vibration damper on the crankshaft.
46. Screw in the central bolt of the vibration damper to the appropriate torque.
47. Install the crankshaft pulley.
48. Install the beam and brake pipes.
49. Connect intermediate shaft to steering gear.
50. Install starter and connect wires.
51. Install the auxiliary drive belt.
52. Install fan and heatsink.
53. Install the air filter cover.
54. Fill the engine with engine oil and coolant into the engine cooling system.
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