Press on the IQ-204 mandrel a new oil deflector cap B (see photo), after lubricating it with engine oil. Install the plastic protective cap A on the valve stem. Insert a mandrel 10-204 onto the valve stem for pressing on the valve stem seals with a cap previously installed on it. By strongly pressing the certificate 10-204, press the oil seal to the stop. After removing the mandrel, make sure that the oil seal is pressed in correctly.
Note. The valve stem seals can be replaced without removing the cylinder heads as follows:
- remove the camshaft and remove the valve lifters;
- unscrew the spark plug;
- set the piston of the desired cylinder to BDC;
- fix the valve in the upper position with a lever through the spark plug hole;
- remove the valve springs;
- replace the oil seals as described above.
Install springs and spring plates. Install the cotters with the valve spring compressor.
Insert the valve lifters into the head holes, after lubricating them with engine oil to facilitate installation. Pay special attention to ensure that the pushers are put in their original position.
Install shims except for DT, DS and DZ models.
Install the camshaft with the outer journals on two prisms placed on the test plate, and measure the radial runout of the middle journal with an indicator, which should not exceed 0.04 mm. If the runout is greater, straighten the shaft on a straightening press.
Lubricate the bearing journals and camshaft cams with engine oil and place it in the cylinder head bearings so that the cams of the 1st cylinder point upwards.
Install bearing caps No. 2 and 4 alternately crosswise, screw the nuts onto the mounting studs, but do not tighten the nuts completely.
Install bearing caps No. 5, 1 and 3 and pre-tighten the fastening nuts, taking into account the position of the caps of these bearings that are offset relative to the axis.
Install the bearing caps completely into the landing bridges, lightly hitting the front flange of the camshaft with a mallet.
Finally tighten the nuts for fastening the bearing caps to a torque of 1.8-2.1 kgf·m, starting with the nuts of the bearing cap No. 5.
Press in new camshaft oil seal using drift 10 203.
Install the camshaft pulley and tighten its fastening bolt to 8 kgf·m.
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