Examination
Cylinder head
1. Carefully inspect the head surfaces for cracks and damage. If any damage is found, contact a specialist.
2. Using a ruler and feeler gauge, check the deformation of the surface of the head, if necessary, the head must be machined. To do this, contact the experts.
Camshaft
1. Inspect the cams and camshaft bearing journals for wear and damage. If necessary, it is necessary to replace the camshaft, head and bearing caps.
2. Measure the free play of the camshaft using a special measuring device.
3. Check the lubrication clearance of each camshaft bearing.
4. Clean bearings and bearing caps with solvent. Install the shafts. Place a strip of measuring plastic on each bearing. Install the bearing caps and tighten the cap bolts.
5. Unscrew bolts and remove covers. Compare the width of the compressed strip with the measurement chart. If necessary, replace the camshaft or cylinder head.
6. Clean off any leftover plastic.
Valves
1. Inspect the valve heads and seats. If the heads and seats are slightly burnt, you can sand them yourself with a special abrasive paste, but it is better if you contact the experts.
2. Measure the diameters of the valve stems.
3. Check the gap between the valve stem and the guide sleeve, if it exceeds the allowable limits, contact a specialist.
4. Inspect the valve springs for damage and compare their length with the length of the new springs. Replace springs if necessary.
5. Check that the springs are straight.
Assembly
1. In order to achieve complete tightness between the valve and its seat, it is necessary to grind the mating surfaces of the valve and seat.
2. Apply a special abrasive paste to the valve head, insert it into place and use a special tool to turn it to the sides.
3. Install the spring seats.
4. Lubricate the valve stems with oil and insert them into place.
5. Put plastic caps on the stems.
6. Install stem seals and remove protective caps.
7. Install springs.
8. Install the spring plates.
9. Compress the springs and insert the cone bushings.
10. Lubricate and install pushrods.
ADR engines
1. Lubricate the bearings and shaft cams and install the shafts. Install the shaft seals, install the automatic shaft adjuster. Lubricate and install bearing caps.
2. Tighten cover bolts N2 and 4.
3. Tighten the cover bolts N1.
4. Remove the shaft adjuster stopper and apply sealant to the contact surfaces of the combination cover. Install the cover and tighten the bolts.
5. Tighten cover bolts N3 and 5.
Proper lid placement
Engines AAE, ABK, AAD, 1Z, AHU
1. Lubricate bearings and shaft cams.
2. Install the shaft.
3. Lubricate with oil and install the camshaft oil seal.
4. Install covers N2 and 4 and tighten the bolts.
5. Apply sealant to the joints of cover N1, install covers N1, 3 and 5 and tighten the bolts.
ACE engines
1. Lubricate the bearings and shaft cams and install the shafts.
2. Install the chain on the camshaft sprockets. Align the timing marks.
3. Install the exhaust valve shaft seal.
4. Cap marks (arrow) bearings must point towards the intake manifold.
5. Install covers N2 and 4 and tighten the nuts, then install the remaining covers and tighten their nuts.
AAR, AAN, AAS engines
1. Lubricate the bearings and shaft cams and install the shafts.
2. Install the camshaft and shaft seals.
3. Apply sealant to the joints of the N4 cover.
4. Install covers N2 and 4 and tighten the bolts.
5. Apply sealant to the joints of cover N1.
6. Install covers N1 and 3 and tighten the bolts.
ABP, AAT, AEL engines
1. Lubricate the bearings and shaft cams and install the shafts.
2. Install the camshaft and its seals.
3. Apply sealant to the joints of the N4 cover.
4. Install covers N2 and 4 and tighten the nuts.
5. Apply sealant to the joints of cover N1. Install covers N1 and 3 and tighten the bolts.
All types of engines
Install the remaining parts. Install the coolant pipe.
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