Assembly
Notes: Clean the parts thoroughly before assembly; all contact surfaces must be coated with fresh engine oil; all gaskets and seals have been replaced with new ones.
1. Install the valves.
a) Insert the valves into the cylinder head bushing holes, making sure that the valves are installed correctly.
b) Install the spring seat and new oil seal.
c) Install the spring and valve plate (or a rotary device).
1 - Valve plate (or a rotary device),
2 - Rusks,
3; 7 - Spring,
4 - Oil deflector cap,
5 - Spring seat,
6 - Valve.
d) Using a spring compressor, install the crackers onto the valve stem.
d) Using a plastic-headed hammer, lightly tap the end of the valve stem to ensure that the crackers are securely seated.
2. Install the following parts:
a) Front and rear flange of the cylinder head.
b) Heater outlet pipe.
c) Coolant outlet pipe.
1 - Coolant outlet pipe,
2 - Cylinder head,
3 - Heater outlet pipe,
4 - Front flange,
5 - Rear flange.
3. Assemble the intake and exhaust manifolds.
a) Place the intake and exhaust manifold connector surfaces on a flat plate.
b) Connect the intake manifold, heat insulator and exhaust manifold with four bolts.
- Tightening torque - 20 Nm
c) Check the collectors for warping (non-flatness) (see above).
4. Install the intake and exhaust manifolds
- Tightening torque - 49 Nm
5. Install the carburetor.
Installation
1. Install the cylinder head.
a) Place a new gasket on the cylinder block, paying attention to the installation marks.
b) Place the cylinder head on the gasket.
c) Lubricate the bolt threads and holes with engine oil.
d) Install and tighten the 13 bolts evenly in several passes in the sequence shown in the figure.
Tightening torques for bolts:
- with 14 mm socket head - 88 Nm
- with 12 mm socket head - 19 Nm
2. Install the push rods and rocker arm assembly.
a) Make sure the push rods are installed correctly.
b) Install the rocker arm assembly onto the cylinder head.
Note: When tightening the bolts and nuts, the rods should not move away from the rocker arms.
Install and tighten the two bolts and three nuts evenly in several passes in the sequence shown.
- Tightening torque - 24 Nm
3. Install the cylinder head cover.
4. Install the spacers and spark plugs.
- Tightening torque - 18 Nm
Final assembly
1. Install the vacuum tube with vacuum hoses to the cylinder head and carburetor.
2. Install the heater tube bracket to the exhaust manifold.
3. Connect the fuel hoses to the fuel pump and carburetor.
4. If there is an AS system, install the AS system vibration valve together with the air supply manifold on the cylinder head.
5. Fill with coolant.