You will need: a 6-point hex key, 12-point, 13-point, 14-point sockets, a small chisel, a hammer
Drain the cooling system.
Remove the cooling system radiator.
Remove the power steering pump and fan pulley drive belt.
Remove the alternator and water pump drive belt.
Loosen the supply hose clamp and remove the hose.
Remove the cylinder head cover.
Remove the four bolts and remove the front cylinder head cover assembly with the fan drive clutch and fan (the viscous clutch and fan have been removed for clarity).
Remove the water pump.
Remove the crankshaft speed sensor (timing sensor).
Remove the two bolts and remove the upper chain hydraulic tensioner cover with the gasket.
Remove the cover carefully, as it is affected by the hydraulic tensioner spring.
Then remove the hydraulic tensioner.
Remove the lower chain hydraulic tensioner in the same way.
Unscrew the two bolts and remove the plastic chain guide.
Remove the gears from the camshafts by unscrewing the bolts securing the gears to the camshaft flanges.
Remove the crankshaft pulley.
The chain cover can be removed without removing the block head. But in this case, damage to the head gasket is possible, since when installing it, adhesive sealant was applied to the upper end of the cover.
However, when installing the cover in place, it is difficult to achieve accurate alignment of the cuff on the crankshaft bushing, which will lead to its rapid wear.
Therefore, when disassembling the gas distribution mechanism drive, remove the cylinder head (see Replacing the head gasket ZMZ-406 GAZ-3110).
Using a 14mm socket, unscrew the four bolts securing the clutch housing amplifier to the block.
Using wrenches 14 and 17, unscrew the two bolts securing the amplifier to the clutch housing and remove the amplifier.
We unscrew the four nuts with a 13mm head and a 12mm wrench on the eleven bolts securing the oil pan to the cylinder block.
Carefully, trying not to damage the gasket, remove the pallet from the studs and place it on the beam.
Use a 6mm hex key to unscrew the 7 screws securing the cover.
Use a screwdriver to remove the chain cover.
Remove the upper chain from the intermediate shaft sprocket.
Using a 6mm hex wrench, unscrew the axis of the upper chain hydraulic tensioner shoe and remove the shoe.
If necessary, use a 14mm wrench to unscrew the shoe axle extension.
Using a 6mm hex wrench, unscrew the axle of the lower hydraulic tensioner shoe and remove the shoe.
Use a chisel to bend the edges of the locking plate.
Using a screwdriver, holding the intermediate shaft sprocket, using a 12mm wrench, unscrew the two bolts.
Remove the sprocket together with the lower chain from the axis of the intermediate shaft.
Use a 6mm hex key to unscrew the two screws and remove the lower chain guide.
Assemble in the reverse order.
Before assembling the gas distribution mechanism drive, we clean the mating surfaces of the cylinder block and chain cover from gasket and sealant residues.
After removal, wash the chains and gears in gasoline, wipe and dry them.
Inspect the chains. If the chain bushings are cracked, chipped, or show significant wear, replace the chains.
Replace gears whose teeth are chipped or chipped.
Replace damaged chain guides.
The tensioner sprockets must rotate freely on the axles. If the sprocket teeth are chipped or chipped, replace the tensioners.
If you removed the gear from the crankshaft, press it onto the crankshaft, install the O-ring and bushing.
Rotate the crankshaft so that mark 1 on the crankshaft gear aligns with mark 2 on the cylinder block. In this case, the piston of the 1st cylinder will take the TDC position.
Install chain guide 4 without tightening bolts 3 securing the guide.
Place chain 5 onto the crankshaft gear, having previously lubricated it with engine oil.
Place the chain on driven gear 1 and install the gear on the countershaft 2 so that the pinion pin fits into the hole in the countershaft.
In this case, mark 4 on the gear must coincide with mark 5 on the cylinder block, and the chain branch passing through damper 3 must be tensioned.
Install the countershaft drive gear so that its locating pin fits into the hole in the driven gear.
Screw in the two bolts securing the intermediate shaft gears, placing a locking plate under them.
Tighten the bolts to a torque of 22–25 Nm (2.2–2.5 kgf m) and secure them by bending the edges of the locking plate on the edge of the bolt heads.
Press the tensioner lever, tension the chain and check the alignment of the marks on the gears and the cylinder block.
Tighten the chain guide bolts.
Lubricate the upper chain with engine oil and then slide it onto the countershaft drive gear through the hole in the cylinder head
Put the chain on gear 2 and, turning the exhaust camshaft slightly clockwise, install gear 2 with the chain on it.
Pin 8 of the camshaft must fit into the gear hole.
Screw in bolt 1.
Turn the camshaft using a wrench using the square on the camshaft.
Then, slightly turn the camshaft counterclockwise to tighten the chain.
The intermediate and crankshafts should not turn.
Mark “A” should coincide with the top surface of the cylinder head.
Unscrew bolt 6 and remove gear 4 from the intake camshaft.
Put the chain on gear 4 and install gear 4 with the chain on the camshaft, turning the camshaft slightly clockwise.
Pin 5 of the camshaft must fit into the gear hole.
Turn the chain by turning the camshaft slightly counterclockwise.
Mark “A” on gear 4 should align with the top surface of the cylinder head.
The remaining shafts should not rotate.
Screw in bolt 6. Tighten bolts 1 and 6 to a torque of 46–74 Nm (4.6–7.4 kgf m), holding the camshafts from turning with a wrench using the squares.
Install damper 3 by pushing it into the hole in the block head.
Install damper 7.
Install the chain cover and water pump. Apply a thin layer of sealant to the surfaces of the cover adjacent to the cylinder block and cylinder head.
When installing the chain cover, be careful not to damage the crankshaft oil seal.
Install the hydraulic tensioners for the upper and lower chains. Install the crankshaft pulley.
Screw in the crankshaft pulley mounting bolt, then, engaging fifth gear and braking the car with the parking brake, tighten the bolt to a torque of 104–128 Nm (10.4–12.8 kgf m), holding the crankshaft from turning.
When the ratchet is tightened, the pulley is pressed onto the crankshaft.
Turn the crankshaft two turns using the ratchet and set the piston of the 1st cylinder to the TDC position (see operation 3).
Check that the marks match.
Install the front cylinder head cover, first apply a layer of sealant to the surface of the cover adjacent to the cylinder head.
Tighten the cover mounting bolts to a torque of 12–18 Nm (1.2–1.8 kgf m).
Install the cylinder head cover. Tighten the cover mounting bolts to a torque of 6.0–12 N·m (0.6–1.2 kgf·m).
Connect the hose and crankcase ventilation tube to the fittings on the valve cover, and the wires to the ignition coils.
Place the ends of the high-voltage wires onto the spark plugs.
Install the previously removed attachments.