Repair Hyundai Getz

Hyundai Getz. The maintenance
+ 1. Operation and maintenance service
- 2. The engine
   Technical characteristics of engines
   Specifications of engines
   Technical characteristics of engines in working volume of 1,5 and 1,6 l
   Specifications of engines in working volume of 1,5 and 1,6 l
   Technical characteristics of cars with engines in working volume 1,1
   Engines in working volume of 1,1 and 1,3 l
   Technical condition of the engine
   Broad-brush observations on repair of engines
   Removal and installation of the power unit
   The general sequence of dismantling of the engine
   Обкатка the engine after repair
   Engine check on the car after repair
   The block of cylinders
   Shatunno-piston group
   Cranked shaft and flywheel
   Head of the block of cylinders
   Camshaft and its drive
   Cooling system
   Greasing system
   The power supply system
   System of release of the fulfilled gases
   Possible malfunctions of the engine, their reason and ways of elimination
   Malfunctions of hydraulic pushers of valves
   Malfunctions of system of giving of fuel and ways of their elimination
+ 3. Transmission
+ 4. A running gear
+ 5. A steering
+ 6. Brake system
+ 7. An electric equipment
+ 8. A body
9. Electric equipment schemes


Hyundai Getz>> The engine>> Head of the block of cylinders
Features of the device
The head of the block of cylinders is cast from an aluminium alloy, has запрессованные pig-iron saddles and directing plugs of valves. The top part of plugs is condensed резинометаллическими маслоотражательными with caps.
In spare parts directing plugs with the increased external diameter are delivered.
In the top part of a head of the block of cylinders support under camshaft necks are located. Support demountable: the top half is in cases of bearings, bottom – in a head of the block of cylinders. Apertures in support are processed in gathering with cases of bearings, therefore they невзаимозаменяемы and a head of the block of cylinders it is possible to replace only in gathering with cases.

The mechanism of a drive of valves  
Valves are put in action by camshaft cams through коромысла on the engine in working volume of 1,1 l, on other engines valves are resulted by camshaft cams through hydraulic pushers. Adjustment of backlashes in the mechanism of a drive of valves with hydraulic pushers is spent at engine work automatically.
Adjustment of backlashes in the mechanism of a drive of valves (only engines in working volume 1,1)  
Adjustment of backlashes in the mechanism of a drive of valves is spent at engine work automatically. Additional adjustment of backlashes in the mechanism of a drive of valves while in service the car is provided only for engines in working volume of 1,1 l.
Warm up the engine.
Uncover heads of the block of cylinders.

Fig. 2.7. Adjusting label ВМТ of the end of a step of compression of 1st cylinder


Turning a cranked shaft in a rotation direction (clockwise if to look from a forward end face of the engine), establish the piston of 1st cylinder in position ВМТ of the end of a step of compression (fig. 2.7). In this position adjust backlashes in a drive of valves in following cylinders.

№ the cylinder
1
2
3
4
Inlet valves
+
+


Final valves
+

+


Insert щуп between an end face of the adjusting screw коромысла and an end face of a core of the valve. Adjust a backlash and tighten a lock nut of the screw.
Turn a cranked shaft on one turn in a rotation direction (clockwise if to look from a forward end face of the engine) before position ВМТ of the end of a step of compression of the piston of 4th cylinder. Inserting щуп between end faces of adjusting screws коромысел and end faces of cores of valves, adjust backlashes in a drive of valves in following cylinders.

№ the cylinder
1
2
3
4
Inlet valves
+


+
Final valves
+
+
+
+


Fig. 2.8. Backlash adjustment between an end face of the adjusting screw коромысла and an end face of a core of the valve


Backlash adjustment between an end face of the adjusting screw коромысла and an end face of a core of the valve is shown on fig. 2.8.

Fig. 2.9. An inhaling of a lock nut of the adjusting screw


After adjustment tighten lock nuts of adjusting screws (fig. 2.9). Adjustment of backlashes (tab. 2.2) spend at position of the piston of 4th cylinder in ВМТ the end of a step of compression.

Table 2.2
Backlashes in the mechanism of a drive of valves
Engine temperature
Backlash
The inlet
Valves
The final
Valves
On the heated-up engine (nominal)
0,2
0,25
On the cold engine (for the inquiry)
0,1
0,17

Hydraulic pushers of valves  

       THE NOTE
Noise in газораспределительном the mechanism at engine start-up – the normal phenomenon. At the idle engine depending on position of cams from each pusher it is superseded various (большее or smaller) quantity of oil. It leads to noise occurrence until hydraulic pushers at the working engine will not be filled with oil. This process can last until the engine will not reach working temperature. For maintenance of excellent job of hydraulic pushers in a head of the block of cylinders it is provided oil заслонка, preventing a full devastation of oil channels in a head of the block of cylinders on the idle engine.

THE PREVENTION
At occurrence of knock of pushers at work of the engine do not suppose increase of frequency of rotation of a cranked shaft to 3000 mines-1 and more as it can lead to damage of pushers.

Check of hydraulic pushers of valves

THE PREVENTION
Hydraulic pushers of valves are necessary for checking up, if in газораспределительном the mechanism there are knocks and noise after achievement by the engine of working temperature.

Warm up the engine and leave it to idle, the radiator fan will not join yet.
Increase frequency of rotation of a cranked shaft of the engine to 2500 mines-1 approximately for 2 minutes
If hydraulic pushers of valves continue to rustle, muffle the engine and uncover heads of the block of cylinders.

THE PREVENTION
Do not rotate a cranked shaft for a bolt of fastening of a gear pulley of a camshaft as it is thus overloaded gear приводной a belt. Cranked and distributive shaft can be turned also as follows: establish the car on an equal surface, include the fifth transfer and shift the car a little, pushing it forward or back.

Turn a camshaft so that the cam of the checked cylinder has been turned upwards. For this purpose establish a transmission control lever in neutral position, tighten the lever of lay brake system and turn a suitable wrench a cranked shaft in a rotation direction for a bolt of fastening of a pulley of a belt of a drive of auxiliary units.
Press on a pusher a wooden or plastic wedge. If it is thus felt люфт as size more than 0,1 mm, replace a pusher.

THE PREVENTION
After installation of a new hydraulic pusher it is impossible to start up the engine during 30 mines, otherwise the valve plate can face the piston that will lead to their damage.

Removal and installation of a head of the block of cylinders on the car
Cars with engines in working volume of 1,1 and 1,3 l  

       THE NOTE
Remove a head of the block of cylinders only on the cooled engine (room temperature).

Removal
Disconnect a cable of "weight" from the storage battery.

Fig. 2.10. A drain stopper of a radiator of system of cooling


Merge cooling liquid (fig. 2.10) and disconnect bringing hose of a radiator of system of cooling.

THE PREVENTION
The faulty head of the block of cylinders is defined to one or several following signs:
– Capacity loss;
– Leak of a cooling liquid. A white smoke from an exhaust pipe on the warm engine;
– Oil leak;
– The cooling liquid in engine oil, oil level does not decrease, can increase. Grey colour of engine oil, foam traces on маслоизмерительном щупе, oil разжижено;
– Engine oil in a cooling liquid;
– The cooling liquid strongly rages;
– There is no compression in two next cylinders.

Disconnect a ventilation hose картера from the air filter and a cover of a head of the block of cylinders.

THE PREVENTION
At switching-off of a cable of weight from the storage battery from memory of a radio receiver the protective code of a radio receiver and adjustment of radio stations are erased. The battery can be disconnected only at the switched off ignition, otherwise it is possible to damage the electronic block of management of system of injection.

Disconnect bringing air branch pipe of the power supply system.
Disconnect a vacuum hose, a fuel hose and a hose of a supply of a cooling liquid.
Disconnect high-voltage wires of system of ignition from spark plugs.
Remove the ignition coil.

Fig. 2.11. A rack of fastening of a receiver of the power supply system


Remove a rack of fastening of a receiver of the power supply system (fig. 2.11).
Remove the inlet pipeline.
Remove a heat-shielding casing and a final collector.
Remove a pulley of a drive of the pump of a cooling liquid and a pulley of a cranked shaft.
Uncover a camshaft drive.
Displace a tension roller of a belt of a drive of the mechanism timing towards the pump of a cooling liquid and temporarily fix it in this position.
Remove a belt of a drive of the mechanism timing.
Uncover heads of the block of cylinders.

Fig. 2.12. An order отворачивания bolts of fastening of a head of the block of cylinders of the engine in working volume of 1,1 l (the arrow specifies in a direction of a forward part of the engine)


Fig. 2.13. An order отворачивания bolts of fastening of a head of the block of cylinders of the engine in working volume of 1,3 l (the arrow specifies in a direction of a forward part of the engine)


Remove a head of the block of cylinders, having turned away bolts of its fastening in 2.12 in fig. 2.12 and 2.13 order by means of a key for bolts of fastening of a head of the block of cylinders.
Remove the rests of a material of a lining with привалочных surfaces of a head and the block of cylinders.

       THE NOTE
Watch, that particles of a material of a lining have not got to cylinders.

Installation
Before installation release a head and the block of cylinders from the rests of linings approaching шабером. Watch, that the dirt has not got to apertures of the block of cylinders. Close apertures a rag.
Check up, that in apertures of bolts of a head of the block of cylinders there was no oil. Remove oil if necessary.
Check up a head of the block of cylinders on presence of deformation by means of a steel ruler and щупа in different places of a head of the block of cylinders. The ruler is established on plane diagonals, in the middle, in a longitudinal direction and across. The admission of planeness of 0,1 mm.
Establish on a head of the block of cylinders a new lining.
Hermetic on a lining do not put, the removed lining always replace new.

Fig. 2.14. Sequence of an inhaling of bolts of fastening of a head of the block of cylinders of the engine in working volume of 1,1 l (the arrow specifies in a direction of a forward part of the engine)


Wrap bolts of fastening of a head of the block of cylinders since the top average. A key for bolts of a head of the block of cylinders tighten bolts in the sequence specified in fig. 2.14 and 2.15.

Fig. 2.15. Sequence of an inhaling of bolts of fastening of a head of the block of cylinders of the engine in working volume of 1,3 l (the arrow specifies in a direction of a forward part of the engine)


Repeat operation, tightening all bolts the specified moment.
The moment of an inhaling of bolts of fastening of a head of the block of cylinders, Н·м:  
Engines in working volume of 1,1 l:
On the cold engine.... 60–70
On the hot engine....... 70–75
Engines in working volume of 1,3 l:        
23–27         
+ To tighten on 60-62 °
+ Again to tighten on 60-62 °

THE PREVENTION
The inhaling of bolts of a head of the block of cylinders should be spent cautiously. Before an inhaling it is necessary to check up accuracy динамометрического a key. Bolts of a head of the block of cylinders should be tightened on the cold engine.

Displace a tension roller of a belt of a drive газораспределительного the mechanism towards the pump of a cooling liquid and fix it.
Establish a drive belt газораспределительного the mechanism on a gear pulley of a camshaft and pull a leading branch of a belt, having turned a gear pulley in a direction, the return to a normal direction of rotation. Check up combination of adjusting labels.
Adjust a drive газораспределительного the mechanism as it is specified in subsection «the Camshaft and its drive».
Establish a cover of a head of the block of cylinders and tighten bolts of its fastening by the specified moment.
The moment of an inhaling of bolts of fastening of a cover of a head of the block of cylinders 8–10 Н·м.
Establish a drive cover газораспределительного the mechanism.
Establish a new lining of the inlet pipeline and the inlet pipeline. Tighten bolts and nuts of fastening of the inlet pipeline the moment 15–20 Н·м.
Establish a new lining of a final collector and a final collector. Tighten fastening nuts the specified moment.
Establish a receiver and tighten nuts and bolts of fastening of a receiver to the inlet pipeline the moment 15–20 Н·м.
Establish the ignition coil.
Establish bringing air branch pipe of system of an admission.
Attach a vacuum hose, a hose of giving of fuel and a hose of a cooling liquid.
Attach a ventilation hose картера.

THE PREVENTION
The storage battery can be connected only at the switched off ignition, the electronic block of management of system of injection otherwise will be damaged.

Fill with a liquid system of cooling of the engine.
Check up oil level in картере the engine. If the lining of a head of the block of cylinders was faulty, replace oil.
Warm up the engine to working temperature, check up level of a cooling liquid and tightness of connections of all hoses.
Check up correctness of installation of a corner of an advancing of ignition.
Check up frequency of rotation of the engine idling and the maintenance WITH.
Check up a compression in engine cylinders.

Cars with engines in working volume of 1,5 and 1,6 l  

       THE NOTE
Remove a head of the block of cylinders only on the cooled engine (room temperature).

THE PREVENTION
The faulty head of the block of cylinders is defined to one or several following signs:
– Capacity loss;
– Leak of a cooling liquid. A white smoke from an exhaust pipe on the warm engine;
– Oil leak;
– The cooling liquid in engine oil, oil level does not decrease, can increase. Grey colour of engine oil, foam traces on маслоизмерительном щупе, oil разжижено;
– Engine oil in a cooling liquid;
– The cooling liquid strongly rages;
– There is no compression in two next cylinders.

Removal
Disconnect a cable of "weight" from the storage battery.

THE PREVENTION
At switching-off of a cable of "weight" from the storage battery from memory of a radio receiver the protective code of a radio receiver and adjustment of radio stations are erased. The battery can be disconnected only at the switched off ignition, the electronic block of management of system of injection otherwise will be damaged.

Fig. 2.16. A drain stopper of a radiator (it is specified by an arrow)


Merge cooling liquid (fig. 2.16) and disconnect bringing hose of a radiator of system of cooling.
Disconnect a ventilation hose картера from the air filter and a cover of a head of the block of cylinders.
Disconnect bringing air branch pipe of the power supply system.
Disconnect a vacuum hose, a fuel hose and a hose of a supply of a cooling liquid.
Disconnect high-voltage wires of system of ignition from spark plugs.
Remove the ignition coil.

Fig. 2.17. A rack of fastening of a receiver of the power supply system


Remove a rack of fastening of a receiver of the power supply system (fig. 2.17).
Remove the inlet pipeline.
Remove a heat-shielding casing and a final collector.
Remove a pulley of a drive of the pump of a cooling liquid and a pulley of a cranked shaft.
Uncover a camshaft drive.
Displace a tension roller of a belt of a drive of the mechanism timing towards the pump of a cooling liquid and temporarily fix it in this position.
Remove a belt of a drive of the mechanism timing.
Uncover heads of the block of cylinders.

Fig. 2.18. An order отворачивания bolts of fastening of a head of the block of cylinders of engines in working volume of 1,5 and 1,6 l


Remove a head of the block of cylinders, having turned away bolts of its fastening in 2.18 order specified in fig. by means of a key for bolts of fastening of a head of the block of cylinders.
Remove the rests of a material of a lining with привалочных surfaces of a head and the block of cylinders.

       THE NOTE
Watch, that the lining rests have not got to cylinders.

Installation
Before installation release a head and the block of cylinders from the rests of linings approaching шабером. Watch, that the dirt has not got to apertures of the block of cylinders. Close apertures a rag.
Check up, that in apertures of bolts of a head of the block of cylinders there was no oil. Remove oil if necessary.
Check up a head of the block of cylinders on presence of deformation by means of a steel ruler and щупа in different places of a head of the block of cylinders. The ruler is established on plane diagonals, in the middle, in a longitudinal direction and across. The admission of planeness of 0,1 mm.
Establish on a head of the block of cylinders a new lining, marks on a lining should be turned towards a head of the block of cylinders.
Do not put hermetic on a lining, always replace new the removed lining.

Fig. 2.19. Sequence of an inhaling of bolts of fastening of a head of the block of cylinders of engines in working volume of 1,5 and 1,6 l


Wrap bolts of fastening of a head of the block of cylinders. Tighten bolts of a head of the block of cylinders a key for bolts in 2.19 sequences specified in fig.
The moment of an inhaling of bolts of fastening of a head of the block of cylinders, Н·м:
Engines in working volume of 1,5 l        
30 + to tighten on 90 °
+ To release all bolts
+30 + to tighten on 90 °
Engines in working volume of 1,6 l        
35 + to tighten
On 90 ° + to release all bolts + 35
+ To tighten on 90 °

THE PREVENTION
The inhaling of bolts of a head of the block of cylinders should be carried out carefully. Before an inhaling it is necessary to check up accuracy динамометрического a key. Bolts of a head of the block of cylinders should be tightened on the cold engine.

Displace a tension roller of a belt of a drive газораспределительного the mechanism towards the pump of a cooling liquid and fix it.
Establish a drive belt газораспределительного the mechanism on a gear pulley of a camshaft and pull a leading branch of a belt, having turned a gear pulley in a direction, the return to a normal direction of rotation. Check up combination of adjusting labels.
Adjust a drive газораспределительного the mechanism as it is specified in subsection «the Camshaft and its drive».
Establish a cover of a head of the block of cylinders and tighten bolts of its fastening by the moment 8–10 Н·м.
Establish a drive cover газораспределительного the mechanism.
Establish a new lining of the inlet pipeline and the inlet pipeline. Tighten bolts of fastening of the inlet pipeline the moment 15–20 Н·м.
Establish a new lining of a final collector and a final collector. Tighten fastening nuts the specified moment.
Establish a receiver, tighten nuts and bolts of fastening of a receiver to the inlet pipeline the moment 15–20 Н·м.
Establish the ignition coil.
Establish bringing air branch pipe of system of an admission.
Attach a vacuum hose, a hose of giving of fuel and a hose of a cooling liquid.
Attach a ventilation hose картера.

THE PREVENTION
The storage battery can be connected only at the switched off ignition, the electronic block of management of system of injection otherwise will be damaged.

Fill with a liquid system of cooling of the engine.
Check up oil level in картере the engine. If the lining of a head of the block of cylinders is faulty, replace oil.
Warm up the engine to working temperature, check up level of a cooling liquid and tightness of connections of all hoses.
Check up correctness of installation of a corner of an advancing of ignition.
Check up frequency of rotation of the engine idling and the maintenance WITH.
Check up a compression in engine cylinders.

Dismantling and assemblage of a head of the block of cylinders  
Cars with engines in working volume of 1,1 l
Dismantling
If it is required to replace only any one detail it is possible not to assort completely a head of the block of cylinders, and to remove only that is necessary for replacement.

Fig. 2.20. Коромысла a drive of valves of a head of the block of cylinders of the engine in working volume of 1,1 l


Коромысла a drive of valves of a head of the block of cylinders of the engine in working volume of 1,1 l are shown on fig. 2.20.
Disconnect a ventilation hose картера and a hose of compulsory ventilation картера.
Remove a pulley of the pump of a cooling liquid and a pulley of a cranked shaft.
Uncover a mechanism drive timing.
Displace a tension roller of a belt of a drive of the mechanism timing towards the pump of a cooling liquid and fix it in this position.
Remove a belt from a gear pulley of a camshaft.
Remove a gear pulley of a camshaft.
Remove the ignition coil.
Uncover heads of the block of cylinders.
Remove axes коромысел with коромыслами. For this purpose turn away bolts with a fillet and remove axes коромысел in gathering with коромыслами and распорными springs коромысел.
Turn away bolts and remove from axes коромысла and распорные springs.
Take out a camshaft in a direction to a forward end face of the engine.

Fig. 2.21. Camshaft removal


Remove a camshaft, as is shown in fig. 2.21.
Assemblage
Before installation check up camshaft palpation. Limiting palpation of a camshaft makes 0,01 mm. Check of palpation of a camshaft should be spent at servicing deport.

       THE NOTE
At installation of the camshaft which was in the use on engines with the big run or in the presence of noise in газораспределительном the mechanism it is expedient to check up an axial free wheeling. The limiting free wheeling of a camshaft makes 0,15 mm.

Establish a camshaft, preliminary having greased its basic necks with engine oil.
Establish the ignition coil.
Establish axes коромысел with коромыслами. For this purpose establish коромысла and распорные springs on an axis коромысел, and axes коромысел in gathering on a head of the block of cylinders.
Tighten bolts of fastening of axes коромысел the moment 20–27 Н·м.
At installation коромысел, springs and axes коромысел it is necessary to watch their correct position (the left or right party).
Raspornye springs of axes коромысел inlet and final valves are identical. Installation should be spent so that a facet located between two parts of an axis коромысла, settled down from outside a mechanism drive timing.
Оправкой for запрессовки a camshaft epiploon (adaptation number under catalogue НМС 09221-21000) запрессуйте a shaft epiploon, preliminary having greased with engine oil an external surface of an epiploon.

Fig. 2.22. Запрессовка an epiploon of a camshaft with the help оправки


For запрессовки it is necessary to put on an epiploon a sock of a camshaft and запрессовать against the stop hammer blows on оправке, as is shown in fig. 2.22.
Establish a gear pulley of a camshaft and tighten a bolt of fastening by the moment 80–100 Н·м.

Fig. 2.23. Label combination on gear to a pulley of a camshaft with an adjusting label on a head of the block of cylinders


Fig. 2.24. Label combination on gear to a pulley of a cranked shaft with an adjusting label on the block of cylinders of the engine


Establish the piston of 1st cylinder in ВМТ the end of a step of compression, thus labels on gear pulleys of distributive and cranked shaft should be combined with corresponding adjusting labels on a head of the block of cylinders and the block of cylinders of the engine, as is shown in fig. 2.23 and 2.24.
Lay a lining in a groove of a cover of a head of the block of cylinders.
Temporarily establish a cover of a head of the block.
Start up the engine and allow to it to work idling.
Establish a cover of a head of the block of cylinders and tighten bolts of fastening by the moment 8–10 Н·м.
Establish a drive cover газораспределительного the mechanism.
Establish a pulley of the pump of a cooling liquid and a pulley of a cranked shaft.

Cars with engines in working volume of 1,3 l  
Dismantling
If replacement only is required to any one detail it is possible not to assort completely a head of the block of cylinders, and to remove only that is necessary for replacement.

Fig. 2.25. Коромысла a drive of valves of a head of the block of cylinders of the engine in working volume of 1,3 l


Коромысла a drive of valves of a head of the block of cylinders of the engine in working volume of 1,3 l are shown on fig. 2.25.
Disconnect a ventilation hose картера and a hose of compulsory ventilation картера.
Remove a pulley of the pump of a cooling liquid and a pulley of a cranked shaft.
Uncover a mechanism drive timing.
Displace a tension roller of a belt of a drive of the mechanism timing towards the pump of a cooling liquid and fix it in this position.
Remove a belt from a gear pulley of a camshaft.
Remove a gear pulley of a camshaft.
Uncover heads of the block of cylinders.
Remove axes коромысел with коромыслами. For this purpose turn away bolts with a fillet and remove axes коромысел in gathering with коромыслами and распорными springs коромысел.
Turn away bolts and remove from axes коромысла and распорные springs.
Remove covers of bearings of a camshaft.

Fig. 2.26. Camshaft removal


Remove a camshaft, as is shown in fig. 2.26.
Assemblage
Before installation check up camshaft palpation. Limiting palpation of a camshaft makes 0,01 mm. Palpation check should be spent at servicing deport.

       THE NOTE
At installation of the camshaft which was in the use on engines with the big run or in the presence of noise in газораспределительном the mechanism it is expedient to check up an axial free wheeling. The limiting free wheeling of a camshaft makes 0,15 mm. Measurement is made at the removed pushers and the established covers of bearings №1 and 5.

Establish a camshaft, preliminary having greased its basic necks with engine oil.
Establish covers of bearings of a camshaft.
Establish axes коромысел with коромыслами. For this purpose establish коромысла and распорные springs on an axis коромысел, and axes коромысел in gathering on a head of the block of cylinders.
Tighten bolts of fastening of axes коромысел the moment 20–27 Н·м.
At installation коромысел, springs and axes коромысел it is necessary to watch their correct position (the left or right party).
Raspornye springs of axes коромысел inlet and final valves are identical. Installation should be spent so that a facet located between two parts of an axis коромысла, settled down from outside a mechanism drive timing.
Оправкой for запрессовки a camshaft epiploon (adaptation number under catalogue НМС 09221-21000) запрессуйте a shaft epiploon, preliminary having greased with engine oil an external surface of an epiploon.
For запрессовки an epiploon he needs to be put on a sock of a camshaft and запрессовать against the stop hammer blows on оправке, as is shown in fig. 2.22.
Establish a gear pulley of a camshaft and tighten a bolt of fastening by the moment 80–100 Н·м.

Fig. 2.27. Combination of a label And on gear to a pulley of a camshaft with an adjusting label In on a head of the block of cylinders


Fig. 2.28. Label combination on gear to a pulley of a cranked shaft with an adjusting label on the block of cylinders of the engine


Establish the piston of 1st cylinder in ВМТ the end of a step of compression, labels on gear pulleys of distributive and cranked shaft should be combined with corresponding adjusting labels on a head of the block of cylinders and the block of cylinders of the engine, as is shown in fig. 2.27 and 2.28.
Lay a lining in a groove of a cover of a head of the block of cylinders.
Temporarily establish a cover of a head of the block of cylinders.
Start up the engine and allow to it to work idling.
Establish a cover of a head of the block of cylinders and tighten bolts of fastening by the moment 8–10 Н·м.
Establish a drive cover газораспределительного the mechanism.
Establish a pulley of the pump of a cooling liquid and a pulley of a cranked shaft.

Cars with engines in working volume of 1,5 l  
Dismantling

Fig. 2.29. A head of the block of cylinders: 1 – a bolt of fastening of a gear pulley of a camshaft; 2 – a camshaft epiploon; 3 – a cover of the forward bearing of a camshaft; 4 – a camshaft of inlet valves; 5 – a chain of a drive of a camshaft of inlet valves; 6 – a camshaft of final valves; 7 – a hydraulic pusher of the valve; 8 – a head of the block of cylinders


The head of the block of cylinders of engines in working volume of 1,5 l is shown on fig. 2.29.
Disconnect ventilation hoses картера.
Remove a pulley of the pump of a cooling liquid and a pulley of a cranked shaft.
Uncover a mechanism drive timing.
Ослабьте a bolt of a tension roller of a belt of a drive of the mechanism timing also fix a roller.
Remove a belt of a drive of the mechanism timing from a camshaft pulley.
Remove the bottom cover of a head of the block of cylinders, having turned away bolts of its fastening.
Remove the ignition coil.

Fig. 2.30. The top cover of a head of the block of cylinders


Remove the top cover of a head of the block of cylinders (fig. 2.30), having turned away bolts of its fastening.
Remove a gear pulley of a camshaft.
Remove covers of bearings of camshafts and приводную a chain.
Remove camshafts.
Remove hydraulic pushers of valves.
Assemblage
Establish hydraulic pushers of valves.

Fig. 2.31. Adjusting labels on приводной a chain and asterisks of shaft (are designated by arrows)


Establish приводную a chain, thus labels on a chain should be combined with labels of asterisks of shaft, as is shown in fig. 2.31.

Fig. 2.32. Installation of camshafts in support in a head of the block of cylinders


Lay camshafts in support of a head of the block of cylinders, preliminary having greased with engine oil basic necks of shaft, as is shown in fig. 2.32.
Establish covers of bearings of camshafts. Covers are marked as follows:

Fig. 2.33. The scheme of installation of covers of bearings of camshafts


I – covers of bearings of a camshaft of inlet valves (fig. 2.33);
Е – covers of bearings of a camshaft of final valves.
Tighten bolts of fastening of covers of bearings in two-three receptions by the moment 12–14 Н·м.

Fig. 2.34. Запрессовка a camshaft epiploon


Оправкой for запрессовки a camshaft epiploon (adaptation number under catalogue НМС 09221-21000) запрессуйте an epiploon, preliminary having greased with engine oil its working edges. For this purpose put on an epiploon the forward end of a shaft and запрессуйте it against the stop easy blows of a hammer (fig. 2.34).

Check of a technical condition and repair  
Head of the block of cylinders
Carefully wash up a head of the block of cylinders and clear oil channels. Remove a metal brush a deposit from chambers of combustion and from a surface of final channels. Examine a head of the block of cylinders. On support under necks of a camshaft and in apertures under pushers of valves should not be задиров and damages. Cracks in any places of a head of the block of cylinders are not supposed. At suspicion on hit of a cooling liquid in oil check up tightness of a head of the block of cylinders.
For tightness check close apertures of a cooling shirt заглушками and force the pump in a shirt of cooling of a head of the block of cylinders water under the pressure of 0,5 МПа (5 kgs/sm 2). During 2 mines it should not be observed leaks of water from a head.
It is possible to check up tightness of a head of the block of cylinders the compressed air for what muffle apertures of a shirt of cooling заглушками, lower a block head in a bath with the water which has been warmed up till 60-80 °С, and allow to it to get warm within 5 minutes Then submit in a head the compressed air under the pressure of 0,15–0,2 МПа (1,5–2 kgs/sm 2). During 1–1,5 mines it should not be observed an exit of vials of air from a head.
Valves

Fig. 2.35. Engine valves in working volume of 1,3 l: 1 – crackers; 2 – a spring plate; 3 – a valve spring; 4 – маслоотражательный a cap; 5 – a basic washer of a spring; 6 – the directing plug of the final valve; 7 – a saddle of the inlet valve; 8 – the inlet valve; 9 – the final valve; 10 – a saddle of the final valve; 11 – the directing plug of the inlet valve; 12 – a basic washer of a spring; 13 – маслоотражательный a cap; 14 – a valve spring; 15 – a spring plate; 16 – crackers


Engine valves in working volume of 1,3 l are shown on fig. 2.35.

Fig. 2.36. Engine valves in working volume of 1,1 l: 1 – коромысло the final valve; 2 – crackers; 3 – a spring plate; 4 – a valve spring; 5 – маслоотражательный a cap; 6 – a basic washer of a spring; 7 – the directing plug of the final valve; 8 – a saddle of the inlet valve; 9 – the inlet valve; 10 – the final valve; 11 – a saddle of the final valve; 12 – the directing plug of the inlet valve; 13 – a basic washer of a spring; 14 – маслоотражательный a cap; 15 – a valve spring; 16 – a spring plate; 17 – crackers; 18 – коромысло the inlet valve


Engine valves in working volume of 1,1 l are shown on fig. 2.36.

Fig. 2.37. Valves of engines in working volume of 1,5 and 1,6 l: 1 – crackers; 2 – a spring plate; 3 – a valve spring; 4 – маслоотражательный a cap; 5 – a basic washer of a spring; 6 – the directing plug of the final valve; 7 – a saddle of the inlet valve; 8 – the inlet valve; 9 – the final valve; 10 – a saddle of the final valve; 11 – the directing plug of the inlet valve; 12 – a basic washer of a spring; 13 – маслоотражательный a cap; 14 – a valve spring; 15 – a spring plate; 16 – crackers


Fig. 2.38. The adaptation for removal and installation клапанных springs on engines in working volume of 1,1 and 1,3 l


Engine valves in working volume of 1,5 and 1,6 l are shown on fig. 2.38.
Removal


Fig. 2.39. The adaptation for removal and installation клапанных springs on engines in working volume of 1,5 and 1,6 l


Compress клапанную a spring, using the adaptation for removal and installation клапанных springs, and remove valve crackers, then a spring plate, клапанную a spring, a basic washer of a spring and the valve (fig. 2.38 and 2.39).

       THE NOTE
Arrange the removed details one after another to establish them on former places.

Fig. 2.40. Nippers for removal маслоотражательных caps


Nippers remove маслоотражательные caps (fig. 2.40).

       THE NOTE
Removed маслоотражательные caps are not subject to a reuse.

Check of a technical condition and repair
Springs of valves. Be convinced that on springs of valves there are no cracks.
Check up length клапанных springs in a free condition and under loading. At a deviation of length of springs from norm replace them.

       THE NOTE
Check of deformation of springs under loading is spent on the special adaptation at servicing deport.

Check up a square a deviation of springs from a vertical. At excess of a maximum deviation from a vertical replace springs.
Nominal length of a spring a free condition, mm:
1,3 l..... 42,03
1,1 l..... 40,50
1,5 and 1,6 l..... 44,00
Nominal length of a spring under loading, mm:
1,3 l (24,7 kg)..... 34,50
1,1 l [(15,6±0,9) kg]..... 32,00
1,5 l (21,60 kg)..... 35,00
1,5 l (45,10 kg)..... 35,00
1,6 l (21,60 kg)..... 27,2
1,6 l (45,10)..... 27,2
Deviation from a vertical, hailstones, no more:
1,3 l..... No more than 1,5 °
1,1 l..... No more than 1,5 °
1,5 l..... No more than 4 °
1,6 l..... No more than 4 °

Fig. 2.41. Backlash measurement between cores of valves and directing plugs


Fig. 2.42. Measurement of diameter of a core of the valve


Directing plugs of valves. Check up a backlash between cores of valves and directing plugs (fig. 2.41 and 2.42). If the backlash size leaves for the specified limits, replace plugs, having established plugs of the next repair size.
Backlash rating values between cores of valves and directing plugs, mm:
Inlet valves of the engine:
1,3 l..... 0,030–0,060
1,1 l..... 0,020–0,047
1,5 l..... 0,030–0,060
1,6 l..... 0,030–0,060
Final valves:
1,3 l..... 0,035–0,065
1,1 l..... 0,050–0,082
1,5 l..... 0,050–0,080
1,6 l..... 0,050–0,080
Replacement of directing plugs of valves. Directing plugs of valves запрессованы in a head of the block of cylinders. To replace directing plugs as it is described more low, it is possible by means of the adaptation for запрессовки directing plugs of valves 09221-21200 (engines in working volume 1,3), 09222-02100 (engines in working volume 1,1) or other suitable adaptation.

Fig. 2.43. The scheme запрессовки directing plugs клапанов:1 – the adaptation for запрессовки directing plugs of valves; 2 – a head of the block of cylinders; 3 – the directing plug of the valve


With the help оправки adaptations for запрессовки directing plugs and a press выпрессуйте directing plug in a direction to the block of cylinders (fig. 2.43).
Develop an aperture in a head of the block of cylinders under directing plug for installation of the plug of the repair size with the increased external diameter.
Запрессуйте the plug of the repair size by means of the adaptation for запрессовки directing plugs of valves. The adaptation запрессовывает directing plugs, providing their certain size выступания concerning a head of the block of cylinders. Запрессовку spend in a direction to a surface of interface of a head of the block of cylinders with the block of cylinders. Directing plugs of inlet and final valves of different length.
After installation of directing plugs of valves establish in plugs new valves and check up a backlash between cores of valves and directing plugs.
At replacement of directing plugs it is necessary to check up also density of landing of valves in saddles and if necessary прошлифовать saddles.

Fig. 2.44. Polishing of a saddle of the valve by a mill


Saddles of valves. Check up saddles of valves on presence of traces of an overheat and non-uniform прилегания working facets of valves. If necessary прошлифуйте (fig. 2.44) or replace saddles of valves.

Fig. 2.45. A saddle of the final valve of engines in working volume of 1,1 and 1,3 l


Fig. 2.46. A saddle of the inlet valve of engines in working volume of 1,1 and 1,3 l


Fig. 2.47. A saddle of the final valve of engines in working volume of 1,5 and 1,6 l


Fig. 2.48. A saddle of the inlet valve of engines in working volume of 1,5 and 1,6 l


Before saddle polishing check up degree of deterioration of the directing plug of the valve. In case of deterioration of the directing plug replace it and прошлифуйте a saddle of the valve with the grinding machine or a mill, watching preservation of the demanded width of a working facet of a saddle and its centering concerning a working facet of the valve. Configurations of facets of saddles of valves are shown on fig. 2.45, 2.46, 2.47, 2.48.
Replacement of saddles of valves. At deterioration of a saddle of the valve, exceeding maximum permissible, remove a saddle, having removed by means of a mill the basic part of a wall of a saddle.

       THE NOTE
To delete a saddle it is necessary at a room temperature.

After saddle removal process a nest under a saddle development or a mill.
Heat up a head of the block of cylinders approximately to 250 °С and запрессуйте in a nest a saddle of the valve of the increased repair size.

       THE NOTE
The valve saddle should have a room temperature.

After installation of a new saddle process its working facet.

Fig. 2.49. Clearing of the valve by a metal brush


Valves. Remove from valves a deposit, as is shown in fig. 2.49.
Check up, whether the valve core, and absence of cracks on a plate is deformed. The damaged valve replace.

Fig. 2.50. The valve


Check up each valve on presence of deterioration, damage and коробления a head and a valve core in area In (fig. 2.50). If necessary carry out repairs or editing of a core of the valve. Remove development or deterioration at an end face of a core of the valve in area And, the metal minimum quantity thus should act in film. Прошлифуйте also working facets of valves.
Replace the valve at reduction of a thickness of a cylindrical part of a head to maximum permissible value.
Nominal height of a head of the inlet valve, mm:
1,3 l..... 1,1
1,1 l..... 0,8
1,5 l..... 1,1
1,6 l..... 1,1
Nominal height of a head of the final valve, mm:
1,3 l..... 1,4
1,1 l..... 1,2
1,5 l..... 1,3
1,6 l..... 1,3
Maximum permissible height of a head of inlet valves, mm:
1,3 l..... 0,8
1,1 l..... 0,5
1,5 l..... 0,8
1,6 l..... 0,8
Maximum permissible height of a head of final valves, mm:
1,3 l..... 1,1
1,1 l..... 0,9
1,5 l..... 1,0
1,6 l..... 1,0

Installation of valves

       THE NOTE
Before assemblage clear all details.
Put engine oil on rubbing and rotating details.

Establish basic washers клапанных springs and easy blows of a hammer on оправке adaptations for напрессовки маслоотражательных caps напрессуйте caps on directing plugs.

Fig. 2.51. The installation scheme маслоотражательного a cap: 1 – маслоотражательный a cap; 2 – a basic plate of a spring


Adaptation application provides напрессовку caps in the necessary position (fig. 2.51). Wrong напрессовка leads to deformation and эксцентриситету a condensing edge of a cap and thereof to oil leak in the cylinder through directing plug. Therefore at напрессовке it is necessary to watch that there was no cap warp. Removed маслоотражательные caps are not subject to a reuse.
Grease cores of valves with engine oil. Insert valves into directing plugs, without making effort for core passage through маслоотражательный a cap. Check up smoothness of sliding of the valve in the plug.
Establish клапанные springs and plates of springs. Springs establish so that the party of a spring with an enamel covering has been turned towards a plate.
Compress клапанную a spring the adaptation for removal and installation клапанных springs, watching that the bottom part of a plate of a spring did not deform маслоотражательный a cap.
Establish valve crackers. After valve installation check up correctness of landing of crackers.
Clear привалочные surfaces of the block and a head of the block of cylinders.
Check up marks of a lining of a head of the block of cylinders.
Establish a lining of a head of the block of cylinders marks to a block head.
Establish a head of the block of cylinders.