To disassemble and repair a car engine, you will need: keys "8", "10", "13", "17", "19", replaceable heads "10", "13", "17", "19", keys for bolts with an internal Allen key "5" and "10", a ratchet, pliers, a screwdriver, a set of flat feeler gauges, micrometers (with measurement ranges of 0-25, 25-50 and 75-100 mm), bore gauge, dial indicator with indicator stand, torque wrench, oil filter remover.
1. Remove the engine from the vehicle (see "Removal and installation the engine").
2. Place the engine on strong supports.
3. Disconnect the gearbox from the engine (see "Removal and installation the gearbox").
4. Remove the clutch from the engine (see "Removal and installation the clutch").
5. Remove the timing belt (camshaft drive), tension roller and a spacer washer installed underneath it (see "Timing Belt Replacement (camshaft drive) and tension roller").
6. Remove the camshaft timing pulley (see "Replacing the cylinder head gasket").
7. Remove four bolts (three of them also hold the water pump) and the timing belt rear cover fastening nut, remove the rear cover.
8. Insert a screwdriver between the flange of the water pump housing and the block, move the pump from its seat. Remove the water pump.
9. Remove the head from the cylinder block (see "Replacing the cylinder head gasket").
10. Unscrew the sixteen oil pan mounting bolts and remove it together with the gasket.
11. Remove the three oil receiver mounting bolts (spring washers are installed under the bolt heads) and take it off.
12. Turn the crankshaft so that the piston being removed is at BDC (bottom dead center). Unscrew the two nuts securing the connecting rod cover.
13. Remove the connecting rod cover. If the connecting rod cap is difficult to remove, first knock it off with light hammer blows. The cylinder number on the connecting rod cap may not be visible, in this case mark the connecting rod cap with the cylinder number.
14. Push the connecting rod into the cylinder with the handle of the hammer and carefully remove the piston with the connecting rod from the cylinder. When doing this, make sure that the lower head of the connecting rod does not touch the cylinder mirror, otherwise the mirror may be damaged. Remove the remaining pistons in the same manner.
15. Remove the flywheel (see "Removal, inspection and installation of the flywheel").
16. Remove six bolts (spring washers are installed under their heads), remove the crankshaft rear oil seal retainer and gasket.
17. Remove the toothed pulley from the crankshaft. If the key does not fit tightly in the crankshaft groove, remove it so as not to lose it.
18. Remove six bolts (spring washers are installed under their heads), remove the oil pump and gasket.
19. Remove two bolts securing the five main bearing caps.
20. Remove the main bearing caps. The main bearing caps are marked with notches in accordance with the cylinder numbers. If these marks are not clearly visible, be sure to additionally mark the main bearing caps to install them in their original locations: main bearing caps are not interchangeable (the cylinder block is machined together with the main bearing caps).
21. Remove the crankshaft.
22. Remove the crankshaft thrust half rings on the middle support.
23. Remove the liners from the main bearing caps and block beds.
24. If it is not intended to replace the main bearing shells, when removing them, mark the shells on the non-working side relative to the covers and beds.
25. If it is necessary to remove the generator brackets and the right engine support, unscrew the three bolts that secure them.
26. Remove the piston rings using a special puller. If it is not there, remove the rings from the piston by carefully spreading the ring locks.
27. Remove the oil scraper ring expander from the piston.
28. Remove the retaining rings holding the piston pin from both sides of the piston. For ease of removal of piston rings, recesses are made in the piston bosses.
29. Using a suitable drift, push the piston pin out of the piston and remove the piston from the connecting rod.
30. Remove the bearing shells from the connecting rod and its cap. If the bearings remain on the crankshaft, remove them from the shaft. If the bearings are not to be replaced, when removing them, mark them on the non-working surface relative to the connecting rods and caps.