Cylinder Block Assembly
1 – oil pan; 2 – oil pan gasket; 3 – cylinder block; 4 – rear crankshaft seal; 5 – fuel pump gasket; 6 – Coolant pump gasket; 7 – front cylinder block cover; 8 – gasket; 9 – main bearing cap
1. Place the engine on a suitable frame.
2. Drain the oil from the oil pan, unscrew the oil filter and remove the oil level indicator.
3. Remove the drive part and the clutch disc (mark the direction of its installation).
4. Unscrew the spark plugs and remove the distributor, marking its position to facilitate subsequent installation. Disconnect the vacuum line.
5. Remove the timing belt and coolant pump pulley covers.
6. Remove the cylinder head cover.
7. Remove the generator and fan drive V-belt, and coolant pump pulley.
8. Unscrew the mounting bolts and remove the pulley from the crankshaft.
9. Unscrew and remove the bolt, washer and intermediate shaft pulley.
10. Loosen the timing belt tensioner, move it against the spring resistance and fix it in a position away from the belt.
11. Remove the timing belt.
12. Remove the pulleys from the crankshaft (if necessary, using puller 21.028), intermediate shaft and camshaft.
13. Disconnect the fuel line from the carburetor.
14. Loosen the cylinder head mounting bolts in the reverse order of tightening (see Fig. Cylinder Head Bolt Tightening Sequence) and remove it together with the intake and exhaust manifolds.
15. Remove the two bolts from the coolant outlet chamber (from the cylinder head), remove the mounting ring and remove the thermostat and gasket.
16. Remove the oil pump, pushrod and fuel lines.
17. Unscrew the oil pressure sensor and use a screwdriver to remove its sump.
18. Remove the oil pan.
19. Remove the front cylinder block cover.
20. Remove (after unscrewing two bolts) the intermediate shaft support bearing.
21. Using puller 22.036, remove the clutch shaft bearing from the hole in the rear of the crankshaft.
22. Set the pistons at half the height of the cylinders to allow removal (using a scraper) of carbon deposits from the top of the cylinders.
23. Tilt the engine to drain any remaining oil from the cylinder block.
24. Remove the coolant pump.
25. Remove the oil pump (tool 21.012) and also remove its drive shaft.
26. Check for the presence of main bearing markings (on the engine covers and cylinder block) and connecting rod bearing markings (on the connecting rods and covers). If they are missing, mark the bearings using a center punch or indelible pencil.
27. Unscrew the connecting rod bolts, remove their caps, remove the connecting rod bearings and remove the pistons together with the connecting rods from the cylinders.
28. Remove the flywheel.
29. Unscrew the main bearing cap bolts, remove the main bearing caps and take out the liners.
30. Remove the crankshaft and its rear seal from the cylinder block.
31. Remove the crankshaft thrust half rings from the middle main bearing.