Removing the cylinder head of the cylinder 4A-GE (AE92, ASH1 1 and AT160)

Removing the cylinder head of the cylinder 4A-GE (AE92, ASH1 1 and AT160)
1. Disconnect the negative-terminal battery ba ¬ tarei.
2. Drain the coolant (see "Cooling System").
3. Disconnect the wiring from the motion of the cover gatelya № 4 timing belt, first disable the plug ¬ emy distributor of ignition and dates ¬ chica oil pressure.
a) Disconnect the vacuum hoses from the vacuum tube.
b) removing and clearing the bolt, remove the vacuum modulator.
c) Remove the bypass (socket ¬ ny)bolt, 4 mounting bolts and remove the valve system retsirku ¬ modulation, and gasket assembly of tubes.
6. Remove the exhaust manifold. a) Remove the 6 bolts (or 4 bolts and 2 nuts) and remove the upper heat insulator ¬ howl (screen) of the exhaust manifold.
b) (AE92 and AT160)
Remove the 3 bolts and nuts and remove those ¬ right and left support legs of the exhaust manifold.
(ASH11)
Remove the bolt and nut and remove the rack supporting the right exhaust manifold.
7. Disconnect the hose system of forced ventilation crankcase from the intake manifold.
8. Disconnect the wiring motion gatelya from the intake manifold, from returning ¬ 2 bolts and pre ¬ keys of connectors: knock sensor, throttle position sensor for ¬ slonki, injector cold start valve and the engine controller re ¬ decay fuel pressure (the latter only for the models for Europe .)
9. Remove the nozzle cold zapus ¬ ka engine (see chapter "Fuel Injection System").
10. Remove the common fuel line (the collector) and the injector nozzle (see also "injection system, top ¬ Lebanon with an electronically controlled").
11. Remove the vacuum tube (only for engines with retsirku ¬ modulation of exhaust gases) and the rear cylinder head cover.
(Engines without recirculation of exhaust-tion)
a) Disconnect the connectors: relay time ¬ Meni cold start injector ¬ gatelya motion and temperature sensors oh ¬ lazhdayuschey fluid.
b) Remove the 2 screws and remove the rear head cover of the cylinder.
(Engines with EGR)
a) Disconnect the connectors: the relay of time cold start injector motion gatelya, temperature sensor Okhla-maintainer of the liquid and elektropnev-matic valve system re-circulation of exhaust gases.
b) Disconnect the vacuum hoses from the throttle body and the vacuum tube (vacuum tubes).
c) Remove the 4 screws, remove the vacuum tube smart (or block vacuum tubes), rear cover of the cylinder head and clamp (clamp) wiring.
12. Remove the throttle over-slonki (see also chapter "Fuel Injection System").
The cylinder head 4A-GE (AE92, AT160 and ASH11) (production version). 1 - right-hand engines prop ¬ la number 1, 2 - bolt right engine mount (MH = 39 Nm)
3 - right engine bracket number 2,
4 - bolt right engine mount number 2 (MV = 21 Nm), 5 - for-Szczytno cover № 4 timing belt, 6 - a tube for supplying cooling water cooling fluid to the cylinder head of the cylinder, 7 - O-ring ¬ ring tube supply of coolant, 8 - laying pipe discharge coolant, 9 - carrying a hook (eye) engine, 10 - spark plug, 11 - tube removal coolant from the cylinder head cylinder ditch, 12 - Intake manifold support column, 13 - intake gasket ¬ On the collector, 14 - bolt intake manifold (MH = 27 Nm)
15 - intake manifold with the air intake chamber (cavity)
16 - tube for supplying fuel to form a cold start-sunke engine
17 - bolt-fitting tube for supplying fuel to the injector cold empty motor-ka (MS = 15 nm), 18 - gaskets intake tube fitting that the nozzle-Pliva cold start, 19 - camshaft oil seal, 20 and 21 - camshafts respectively inlet and outlet valves, 22 - camshaft bearing cap, 23 - bolt camshaft bearing cap (MH = 13 N m), 24 - under-water pipe fuel to a common fuel-wire (collector) injector, 25 - Bolt -fitting tube supplying fuel to the collector nozzle (MH = 29 N m), 26 - gaskets shtutse ¬ ra tube supplying fuel to the collector nozzle, 27 - the central cylinder head cover, 28 and 29 - cylinder head cover ¬ Lindrum 30 - hose in the crankcase ventilation nuditelnoy ¬ 31 - ¬ protective cover high volt wires of ignition ¬ Gahnia, 32 - valve system retsir ¬ kulyatsii exhaust with pipes in the collection, 33 - flange gasket pipe system recirculation ¬ tion of exhaust gases, 34 - gaskets choke tube system re ¬ circulation of exhaust gases, 35 - vacuum tubes, 36 - ¬ regulate the gauge plate (for adjusting the thermal gap in valves), 37 - valve tappet 38, - crackers,
39 - valve spring plate,
40 - valve spring, 41 - stop-ring valve guide,
42 - valve guides,
43 - valve stem cap
44 - a saddle valve spring,
45 - total fuel line (the collector) injector, 46 - bolt collector nozzles (MZ = 17 nm), 47 - bolt cylinder head (pre-
MV = 29 Nm, then successively dovernut each bolt to 90 °, in which again the following dovernut each bolt to 90 °), 48 and 49 - Rear Roof ¬ ka cylinder head gaskets and the rear lid, 50 - socket ( MZ = 29 nm), 51 - cylinder head cylinder ¬ Lindrum, 52 - cylinder head gasket, 53 - transported the gauge hook (eye) engine, 54 - valve engine, 55 - gauge distributor ignition system of 56 - Bolt the sensor-valve (MV = 20 Nm)
57 - upper heat insulating casing of the exhaust manifold,
58 - Left support the collector outlet, 59 - exhaust manifold, 60 - exhaust gasket collec-tor, 61 - bolt release-tion collector (MZ = 25 nm), 62 - the right support the collector outlet, 63 - lower thermal insulation -regulating exhaust hood collec-tor.
The cylinder head 4A-GE (AE92, AT160 and ASH11) (version with the theme of the combustion system ¬ ¬ still lean mixtures). 1 - belt alternator and water pump, 2 - protective cover number 2 of the belt under ¬ water timing, 3 • the timing belt, 4 - right engine bracket, 5 - to cover Szczytno ¬ № 3 timing belt, 6 and 7 - toothed pulleys drive the camshaft, respectively, inlet and outlet clusters ¬ pans, 8 - bolt sprocket timing for distribu ¬ relatively shaft (MZ = 47 nm), 9 - carrying a hook (eye) engine, 10 protective cover № 4 belt Russ, 11 - candle-ignition Gahnia, 12 - tube cooling water discharge cooling fluid from the cylinder head of the cylinder, 13 - laying pipe discharge coolant, 14 - support column inlet the collector, 15 - Spacer (housing) to ¬ ditional Managed honored ¬ evaluations, 16 • additional housing gasket ¬ tional controlled dampers, 17 - inlet collector gasket ¬ ra, 18 - bolt the intake manifold (MH = 27 nm), 19 - ¬ intake manifold with Noah air intake chamber (cavity) 20 - tube for supplying fuel to the injector cold engine start ¬ Nogo, 21 and 22 - the bolt-fitting tube fitting gaskets and supply fuel to the injector cold engine start ¬ Nogo, 23 and 24 - considered predelitelnye ¬ ¬ tively shafts corresponding intake and exhaust valve ¬ new, 25 - cap bearing races ¬ predelitelnogo shaft, 26 - bolt cap bearing races ¬ predelitelnogo shaft (MZ = 13 nm), 27 and 29 - cylinder head cover ¬ Lindrum, 28 - center of the cylinder head cover, 30 - cluster ¬ pan recirculation otrabo ¬ tavshih gas tube assembly, 31 • gasket flange tube system we ¬ ¬ ha EGR call, 32 - tube fitting gasket EGR gas-Shih, 33 - adjusting shai-ba (to adjust the heat zazo Mr. in valves), 34 - valve tappet-on, 35 - Rusks, 36 - plate (holding-Tel), valve springs, 37 - valve spring, 38 - locking ring on the guide valve, 39 - direction lyayuschaya valve, 40 - valve stem cap valve, 41 - a saddle valve pruzhi ¬ HN, 42 - general toplivopro ¬ water (reservoir) injector, 43 - yn lotnitelnoe ring nozzle, 44 - nozzle, 45 - bolt cylinder head (pre ¬ Preliminary MZ = 29 nm, then ¬ dovernut therefore each bolt to 90 °, then / again to return ¬ each bolt to 90 °), 46 and 47 - back cover of the cylinder head gasket and the rear lid, 48 - cylinder head cylinder ¬ ditch 49 - cylinder head gasket, 50 - transportirovoch ny-hook (ring) motor, 51 - cluster pan motor, 52 - gauge, the distribution of the divisor of the ignition system, 53 - upper heat insulating ¬ zhuh to the exhaust manifold, 54 - ¬ le Vai support the exhaust manifold, 55 - exhaust manifold, 56 - ¬ laying about the exhaust manifold, 57 - bolt exhaust manifold (MZ = 25 nm), 58 - right prop exhaust manifold, 59 - lower heat insulating ¬ zhuh to the exhaust manifold.
13. (Only for engines with a change in geometry intake nyaemoy the collector or bleed air system for throttle valve) Remove the pan ¬ Electro-cluster systems for air bypass the throttle valve and a vacuum tank (a "vacuum reservoir") by removing two screws and disconnecting hoses pre- valve from the bypass air from actuator.
14. Remove nipple discharge cooling fluid and giving up the bypass coolant (with spacers), after returning from ¬ 3 bolts and removing the lever ¬ regulation during transport belt drive re ¬ oscillator.
15. Remove the pipe entering the cooling fluid which gives (see "Cooling System").
16. Remove the intake manifold.
a) Remove the rack supporting the intake manifold of ¬.
17. Remove the pump pulley ¬ ing cooling fluid and drive belt re ¬ oscillator and the coolant pump.
18. Remove the protective cover number 3 and number 2 (with pads) the timing belt by removing the seven screws.
19. Remove the cylinder head cover: first, the central cover (with gasket), Hole ¬ nuv 6 bolts, and then two side covers (with pads), by removing eight screws and removing the cap sealing washer nye.
Remove the spark plugs.
Set the piston of the 1st cylinder at TDC pa ¬ compression stroke.
b) Remove the intake manifold, from returning ¬ 7 screws and 2 nuts.
a) Turn the crankshaft pulley and align the groove on the pulley with the sync mark "0" on the protective cover of the belt leads number 1 ¬ da timing (for the AE92 and AT160) or with a pointer (to DI11).
b) Ensure that the valve lifters ¬ new 1st cylinder at the same time released ¬ HN (free), and valve tappets ¬ new 4th cylinder - tightened. Otherwise, turn the shaft to ¬ lenchaty for one turn (360 °).
22. Remove the timing belt pulley with timing of camshafts,
a) Apply the mounting marks on the toothed pulleys and toothed re ¬ less timing.
c) Remove the timing belt with a tooth-chatyh pulley BOXIES shafts.
Notes:
• Hold the belt in such a ¬ a way as to prevent the change equation ¬ link belt with zubcha ¬ Tym crankshaft pulley.
• Do not insert any objects into the guard timing belt.
• Keep the less re-oil, water or dirt.
23. Remove the toothed pulleys distribution of dividing walls (see "Removing rem ¬ AEs timing").
24. Remove the right engine mount number 1 and number 2.
25. Remove the protective cover № 4 timing belt by removing the 7-bol comrade.
26. Remove the camshafts, a) Loosen the bolts evenly distribu ¬ bearing caps Tel'nykh shaft passing through a few ¬ charges in the sequence shown in Figure ¬ Noah, and remove the bolts.
b) Remove the cover camshaft bearings, seals and then the camshafts themselves.
27. Disconnect the hose at-nuditepnoy crankcase ventilation of the cylinder head, preliminarily removing the two clamps (clamp).
Warning: warping or cracking ¬ tion head of the block may be due to a breach sequence sequence ¬ ¬ crepe loose bolts leniya cylinder head.
b) Raise the head of the block of wood with a cylindrical mounting pins and ¬ lozhite her on the bench, tucked under her wooden blocks. Caution: If removing the cylinder head ¬ etsya hard, you can use the powerful screwdriver by inserting it into the ha ¬ zovy junction, as shown in the figure. However, be careful not to damage the surface of the head and block, and head gasket.
29. Remove the two shipping hook (ryma) engine, preliminarily removing 2 bolts and removing the pro-treatment "grounding" rechargeable ba ¬ tarei.
28. Remove the cylinder head. a) Using a suitable adapted ¬ soblenie, evenly, over several passes, release and remove the cylinder head bolts in the sequence shown in the figure.
30. Remove the choke.
The cylinder head 4A-GE (AE101, AE111). 1 - the rope-drive Drosia selnoy valves, 2 - wire throttle-valve control (automatic transmission), 3 - duct, 4 - the cover of the chamber air inlet, 5 - pipes, 6, 1 1, 43 - gaskets, 7 - chamber air inlet, 8 - vacuum hoses, 9 • yn lotnitelnaya washer, 10 - cylinder head cover, 12 - camshaft bearing cap inlet valves, 13 - camshaft intake valves GOVERNMENTAL ¬ 14, - lower support bearing camshaft intake valves, 15 - Hose fuel return, 16, 24, 26, 35 - O-ring, 17-tube for supplying fuel to the collector, 18 - heat pipes la, 19 - hose inlet coolant, 20 - drainage hose Okhla ¬ maintainer of the liquid, 21 - head gasket, 22 - gasket, 23 - receiving pipe exhaust system, 25 - pump coolant fluid ¬ dice, 27 - dipstick guide, 28 - "mass", 29 - dipstick, 30 - bracket of the generator, 31 - the generation of a torus, 32 - Protective cap number 4 timing belt, 33 - camshaft timing pulley exhaust valves, 34 - carrying a hook (eye), 36 - camshaft timing pulley intake valves with VVT at UBC ¬ D, 37 - cylinder head with inlet and outlet manifold assembly ¬ E, 38 - seal, 39 - front bearing cover switchgear ¬ shaft inlet valves, 40 - wiring harness engine, 41 - support column number 2, 42 - support column number 1.