Remove the right wheel.
Remove the right mudguard.
Remove spark plugs.
Disconnect the high voltage wire.
Disconnect the oil control valve connector (OCV).
Remove the ventilation hose.
Remove the cylinder head cover. Make sure the engine is cold.
Remove the drive belt.
Remove the right combined shaft from the intermediate propeller shaft.
Pic. 2.78. Lower plug of the front engine cover: 1 - plug
Remove the lower plug of the front engine cover (pic. 2.78).
Remove the top cap from the front engine cover.
Pic. 2.79. The bottom plug of the block of cylinders: 1 - plug
Remove the bottom plug of the cylinder block (pic. 2.79).
Pic. 2.80. Installation of a special device
Install special tool (pic. 2.80).
Turn the crankshaft clockwise to TDC on cylinder #1.
Loosen the timing chain.
- A) Using a suitable screwdriver or similar tool, unlock the chain tensioner ratchet.
- b) Turn the exhaust camshaft clockwise using the appropriate wrench (hexagon) and loosen the timing chain.
Pic. 2.81. Locking the chain guide in the loose position
- V) By placing the appropriate bolt (M6 1.0 length 25-35 mm) in the top plug hole of the engine front cover, lock the chain guide in the loose position (pic. 2.81).
Pic. 2.82. Fixing the exhaust camshafts
Lock the exhaust camshaft using the appropriate wrench (hexagon) (pic. 2.82).
Pic. 2.83. The bottom plug of the block of cylinders: 1 - intake camshaft sprocket
Remove the exhaust camshaft sprocket (pic. 2.83).
Pic. 2.84. Procedure for loosening the camshaft bolts
Loosen the camshaft bolts in several steps in the order shown (pic. 2.84).
Note. The cylinder head and camshaft bearing caps are numbered to facilitate reinstallation to their original reassembly position. After removal, keep the covers together with the cylinder head from which they were removed. Do not mix lids.
Remove the distributor.
Remove the valve lifter.
Select the appropriate shim according to the following diagram and notes taken during the initial inspection:
- new shim = removed shim + measured valve clearance - standard valve clearance.
- inlet - 0.25 mm;
- outlet - 0.30 mm.
Standard (on a cold engine):
- inlet - 0.22–0.28 mm (0.25±0.03mm);
- outlet - 0.27–0.33 mm (0.30±0.03mm).
Install the camshaft, the piston of cylinder No. 1 should be in the TDC position.
Pic. 2.85. Camshaft Bolt Tightening Order
Tighten the camshaft bolt in two steps (pic. 2.85):
- torque 5.0–9.0 Nm;
- torque 14.0–17.0 Nm.
Install the exhaust camshaft sprocket (see fig. 2.83).
Note. Do not tighten the camshaft sprocket bolt. First check the opening or closing timing of the valve, then tighten the bolt.
Pic. 2.86. Installing the special tool on the camshaft
Install the special tool on the camshaft (pic. 2.86).
Remove the bolt (M6x1.0, length 25–35 mm) from the front cover of the engine to tension the timing chain.
Turn the crankshaft clockwise to TDC on cylinder #1.
Hold the exhaust camshaft using a suitable wrench (hexagon) (see fig. 2.82).
Tighten the exhaust camshaft sprocket bolt to 69–75 Nm.
Remove the special tool from the camshaft.
Remove the special tool from the bottom plug hole of the block.
Turn the crankshaft clockwise two turns to TDC. If the TDC position is not reached, loosen the crankshaft pulley bolt and carry out all operations, starting with the installation of the special tool (see fig. 2.80).
Apply silicone sealant to the top plug of the engine front cover.
Install the upper plug of the engine front cover, tightening it with a tightening torque of 10 Nm.
Establish the bottom plug of the block of cylinders, having tightened it with the moment of an inhaling of 18–22 Н·м.
Install a new engine front cover lower plug, tightening it to 12 Nm.
Install the right intermediate drive shaft and combined shaft.
Install the drive belt.
Install the cylinder head cover.
Connect the ventilation hose.
Connect the oil control valve connector (OCV).
Connect the high voltage wire.
Screw in the spark plugs.
Install the right mudguard.
Install the right wheel.