Place the hydraulic compensator in a reservoir with engine oil.
Caution: Do not insert the rounded rod with great force, as the check valve ball spring is extremely weak.
By lightly pressing on the check valve ball with a rounded rod (diameter approximately 1.0 mm), remove air by moving the plunger up and down.
Press the end of the plunger into the oil and make sure there is no feeling of pushing out. Otherwise, it is necessary to replace the hydraulic compensator with a new one.
2. Visually inspect the surface of the hydraulic compensator that contacts the rocker arm for wear or damage. If any defects are found, replace the gyro compensator with a new one.
3. Install the hydraulic compensator in its original position in the cylinder head.
4. Apply engine oil to the hydraulic lifters and the ends of the valve stems, then install the rocker arms in the original positions they occupied before removal.
Note:apply oil.
5. Apply transmission oil (SAE 90 or similar) or motor oil to the following areas:
- Each support in the cylinder head.
- Needle bearings and rocker arm contact surfaces.
Note:apply oil.
6. Apply transmission oil (SAE 90 or similar) or engine oil on the following surfaces of each camshaft:
- Contact surfaces of gears.
- Front journal thrust surfaces
Note: When applying oil to the front camshaft cover, do not apply oil to the thrust surface of the front camshaft journal.
7. Place the camshafts into the cylinder head and align the timing marks on the gears as shown in the figure.
8. Apply transmission oil (SAE No.90 or equivalent) or engine oil to the center of each camshaft journal as shown in the illustration.
Note:apply oil.
9. Apply adhesive (Loctite 962T) on the rear side of the cylinder head or on the rear cover of the camshafts.
Attention.
- Make sure that no adhesive gets on the camshaft journal.
- To prevent premature hardening of the adhesive, install the rear camshaft cover and cylinder head within 10 minutes of application. Tighten the mounting bolts immediately.
Note: Adhesive bead width: 1.0-3.0mm.
10. Apply engine oil to the new O-ring and install it into the rear camshaft cover.
Caution: Be careful not to damage or drop the O-ring when installing the rear camshaft cover.
11. Apply transmission oil (SAE 90 or similar) or engine oil on the thrust surface of the front camshaft cover.
Note: If oil is applied to the thrust surface of the front journal of each camshaft, there is no need to apply oil to the front camshaft cover.
12. Install the camshaft caps in numbered order (according to the markings on the lids) and evenly tighten the cap bolts in two or three steps in the sequence shown in the figure.
13. Tighten the camshaft cover bolts in two stages in the sequence shown in the figure:
- Stage 1: 3.0-6.0 Nm.
- Stage 2: 8-11 Nm.
14. Pull the drive chain with the camshaft sprocket and remove the rope with which they were tied to the bolt in the cylinder head.
15. Align the dowel pin on the end of the exhaust camshaft with the groove in the camshaft sprocket and install the sprocket.
Note: Align the dowel pin with the groove by turning the camshaft in the desired direction.
16. Tighten the camshaft sprocket bolt:
- Tighten the camshaft sprocket mounting bolt.
- Holding the exhaust camshaft by the hexagonal part with an adjustable wrench, tighten the camshaft sprocket bolt to a torque of 123-140 Nm.
Note: If you do not have a suitable tool to tighten the camshaft sprocket bolt to the specified torque, you can use the method shown in the figure. In this case, you must take into account the additional leverage created by the length of the additional wrench.
17. Remove the wire or rolled up paper securing the timing chain tensioner plunger to create tension on the timing chain.
18. Turn the crankshaft clockwise two turns and check that all timing marks on the timing mechanism drive are aligned.
Note: If the timing marks are incorrect, remove the front engine cover and reinstall the drive chain on each sprocket.
19. Remove the temporarily installed cylinder head cover bolt.
20. Install a new plug into the service hole of the front engine cover and tighten to a torque of 8-11 Nm.
Note:replace the part with a new one after each removal.
Caution: Make sure that the covers and rubber seals are not pinched by the sound insulation mounting bolts.
21. Install the soundproof cover with rubber seal in the sequence shown in the figure.
22. Install the engine control unit as follows:
Connect the connector and install the wiring harness protector.
Tighten the bolts shown in the figure.
Tighten the engine control unit mounting bolts to a torque of 9-10 Nm in the sequence shown in the figure.
23. Install the ground cable to the engine control unit bracket.
24. Install the oil spray tube and tighten the mounting bolts in the sequence shown in the figure.
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25. Install the remaining engine components in the reverse order of removal.
26. Start the engine and check the idle speed.