Petrol 4-cylinder engines
1. Install the mounting bracket into the exhaust manifold screw hole on the cylinder head.
2. Remove the spark plugs, distributor, spark plugs, upper water hose and all other parts installed on the head.
3. Lock the camshaft pulley and loosen the pulley bolt.
4. Remove the rocker arm shaft, camshaft and engine mounting lugs.
5. Remove the valves with a special puller. Install it on the head and compress the springs until the valve crackers come out, which you can remove with pliers (see illustration). Remove the valve puller and remove the valve plate, springs and spring support washer one by one. All parts of one set must be numbered and put in a separate box or bag.
5.5 Removing valves with a special puller
6. Remove the valves from the guide bushings one by one and arrange them in a sequence convenient for assembly.
7. If you do not have a special puller, use a piece of tube. Place the tube on the valve spring plate and hit the tube to compress the spring. The valve crackers fall inside the tube. After this, you can remove the remaining parts.
8. The rocker shaft is equipped with a filter ("1" in the illustration), which must always be changed when disassembling the shaft. Before removing the rocker shaft, install a safety pin (2) made of a hard material. Now begin disassembling. To remove the rocker shaft, unscrew the plug (1) from the end of the shaft. Remove the safety pin (2), remove the remaining parts from the shaft one by one and mark each of them in turn. When assembling, adhere to the following points:
5.8 Rocker arm axle assembly. The pin (2) holds the shaft in the hinge bracket No.5. There is a filter under the plug (1)
9. Rocker arm axle posts #1, 2, 3 and 4 are identical but still need to be numbered if they are to be reinstalled. The rocker arms have a lubrication hole (1, see illustration) for camshaft lubrication, screw hole (2) for cylinder head cover stud (only for hinge brackets 1 and 3) and the adjustment tab. It should be turned towards the sprocket.
5.9 Rocker arm hinge bracket with bearing mounting locations No.1, 2, 3 and 4
10. Bearing No.5 has two additional screw holes (1, see illustration) for fixing the camshaft key (for adjusting axial clearance) and a 3mm pin (2) to hold the rocker mechanism.
5.10 Hinge brackets 1,2, 3 and 4 for rocker arm axle
11. Clean everything thoroughly.
Petrol 6-cylinder engine (V6)
12. Unscrew the spark plugs, remove the camshaft key, unscrew the coolant outlet plug, remove the mounting lugs and all other parts mounted on the head. Finally, remove the generator suspension on the left cylinder head.
13. Remove the valves in the manner described earlier (see illustrations 3.7b and 5.5). Mark all valve parts for installation. The disassembled valves are shown in the illustration.
5.13 Camshafts, rocker shaft and valves on the V6 engine. The "X" spacers vary in thickness
14. To remove the rocker shaft, unscrew the bolts from the hinge brackets and remove the individual parts from the shaft. Mark the parts in the order in which they were removed. When assembling, refer to Illustration 5.13 and observe the following points:
15. The left and right shafts are not the same. They only fit the corresponding cylinder head.
16. The rocker arm shaft must be installed with the lubrication holes facing down.
17. The thickness of the spacer washers varies. Pay attention to where they are installed.
18. The rocker arms have bolts for adjusting the valve drive clearance either on the left or right side. The lever must be marked accordingly before disassembling.
19. The rocker arm pivot bracket has a flat bead on one side. This side should be facing outward, i.e. pointing towards the snap ring at the end of the axle.
20. After disassembling, thoroughly clean all parts and check them as described below.
Diesel engine
21. Disconnect the cable from the glow plugs, disconnect the fuel outlet line and remove the injectors together with the sealing washers from the cylinder head
firewood. Remove the fireproof washers installed between the sprayers and the cylinder head. Remember how they were installed (see illustration).
5.21 Cylinder Head Components - Turbocharged Diesel Engine
22. Remove the glow plugs.
23. Properly lock the camshaft sprocket and remove the bolt from its center.
24. If necessary, knock out the pre-chambers from the cylinder head. To do this, insert a small punch into the nozzle hole and knock out the pre-chamber.
25. Remove the rocker arm shaft, camshaft, mounting lugs and thermostat housing.
26. Remove the valves in the same way as described for a 4-cylinder petrol engine. The valve puller is also suitable for diesel engines (see illustration 5.5). There is an oil filter on the rocker shaft, which must be replaced when the shaft is removed. The rocker arms are shown in the illustration. When disassembling the shaft, remove the plug (3) from the end of the shaft and take out the filter. Remove the parts from the shaft one by one, marking them along the way. Pay attention to the following points:
5.26 Rocker Arm Shaft Assembly - Turbocharged Diesel Engine. Letter and number designations are given in the text
27. The rocker arm pivot brackets A, B, C and D are similar and must be marked for subsequent installation. They have lubrication holes (2, see illustration) to the camshaft bearing lubrication channel and replaceable elements (1) and (3); the last one is from the flywheel side.
5.27 Rocker arm axle pivot brackets. Numerical designations are given in the text
28. The hinge bracket "E" has two additional threaded holes (5, see illustration 5.27) for fastening the camshaft plate (it regulates the axial clearance) and a threaded hole (4) for fixing the rocker arm shaft. The rocker arm shaft lubrication holes must be directed towards the camshaft.
29. The intake and exhaust rocker arms are identical and must be marked accordingly. All rocker arms have a channel in the bottom surface for lubrication of the camshaft cam. Clean all parts and inspect them carefully.