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>> Greasing system
Features of the device  
Greasing system the combined: разбрызгиванием and under pressure. Under pressure support of camshafts are greased radical and шатунные bearings. The system consists from oil картера, шестеренчатого the oil pump with маслоприемником, полнопоточного the oil filter, the gauge of pressure of oil and oil valves.
The oil pump takes away oil from the oil pallet of the engine and submits it to the oil filter. From outside forcings of the oil pump is перепускной the valve. At too high pressure of oil the valve opens also an oil part flows down back in the engine pallet.
Through the middle of a filtering element of the oil filter pure oil arrives in the main oil highway. At a contamination of the filter bypass the valve located in the case of the oil filter, submits not filtered oil directly to the main oil highway. In a branch pipe of the oil filter there is a return valve which interferes with a devastation of oil channels and hydraulic pushers of valves of the engine. Channels depart from the main oil highway for greasing of bearings of a cranked shaft. Through inclined apertures in cranked to a shaft oil moves to шатунным to bearings, and therefrom is sprayed on piston fingers and cylinders. Simultaneously on ascending channels oil moves in a head of the block of cylinders and provides greasing of bearings of a camshaft and work of hydraulic pushers.

The oil expense
Speaking about the oil expense in an internal combustion engine, we mean only that its quantity which is spent at combustion (the expense on charcoal fumes). At all it is not necessary to confuse the expense of oil to loss of oil because of негерметичности the oil pallet, a cover of a head of the block of cylinders and so forth the Normal expense of oil arises owing to small amount combustion in cylinders, and also because of tap of the rests of combustion and particles of products of deterioration. Oil grows old under the influence of a heat and pressure in engine cylinders. On the oil expense render a great influence and external factors, such as a driving manner, and also accuracy of manufacturing of details of the engine.
As much as possible admissible at operation the oil expense can make 1 l on 1000 km of run.
On reaching a label «MIN» it is necessary to add oil (the volume of added oil should not exceed 1).

Choice of oil for system of greasing of the engine  
All-weather oil is applied to greasing of engines of cars Hyundai. It can be used both in winter, and in summertime. A basis of all-weather oils are liquid seasonal oils (for example, a viscosity class 15W). At the expense of so-called thickeners oil is stabilised in a hot condition, therefore for each condition necessary lubricant properties are provided. The letter «W» on classification SAE specifies that the given oil can be used in the winter.
Legkohodnye oils represent all-weather oils with antifrictional additives, at their application the economy of fuel to 2 % is possible. Legkohodnye oils have low viscosity (for example, 10W-30). They demand a special basis (synthetic oils).
Recommended class of quality of oil on API – not more low SG or SH.
Recommended class of viscosity of oil on SAE – depending on the expected temperature of air before the following replacement of oil.

Check of level of oil
Establish the car on an equal horizontal platform.
Start up and warm up the engine.

       THE NOTE
After long idle time of the car  warm up the engine approximately within 20 minutes

Stop the engine, wait for 2-3 mines and check up oil level.
Oil level should be between labels маслоизмерительного щупа. At decrease in level below a label «L» add oil to a label «F».
Be convinced that oil pure, without impurity of a cooling liquid or gasoline and has demanded viscosity.

THE PREVENTION
On the cars equipped with engines with каталитическим by neutralizer, it is necessary to watch that oil level on маслоизмерительному щупу was not above maximum. If in the car with каталитическим neutralizer too much oil is filled in, it is necessary to remove its surplus from картера means plum or отсоса (the special vacuum pump), otherwise not burnt down oil will get into system of release of the fulfilled gases and can destroy каталитический neutralizer.

Oil replacement in the engine
Start up and warm up the engine to normal working temperature.
Stop the engine.

Fig. 2.127. A stopper маслосливного apertures in the oil pallet (it is designated by an arrow)


Remove a stopper маслоналивной mouths, turn away a stopper маслосливного apertures (on the oil pallet), as is shown in fig. 2.127, and merge oil from the engine.
Wrap a stopper and tighten its moment 35–45 Н·м.
Fill in in the engine fresh oil through a bulk mouth.
Establish a stopper маслоналивной mouths.
Start up the engine and allow to it to work.
Stop the engine, check up level of oil and if necessary restore it to norm.
Capacity of system of greasing of the engine, l:
Working volume of 1,1 l:         
2,8 (without replacement of the oil filter);
3,1  (with replacement of the oil filter)
Working volume 1,3; 1,5 and 1,6 l:        
3,0 (without replacement of the oil filter);
3,3  (with replacement of the oil filter)

Replacement of the oil filter
All engines Hyundai equip with demountable oil quality filters which are recommended to be used for replacement by all cars. Filters available on sale are various on quality. For maintenance of effective maintenance service it is necessary to use only quality filters. Before installation of the new filter remove with привалочной surfaces of the block of cylinders the rests of a rubber lining of the old filter.
Turn away the oil filter by means of a special key.

Fig. 2.128. Greasing of a rubber lining of the oil filter before installation


Put pure engine oil on a rubber lining of the new filter (fig. 2.128).

Fig. 2.129. An arrangement of the oil filter in a motor compartment (the car bottom view)


Wrap the oil filter and tighten its moment 12–16 Н·м (fig. 2.129).
Start up the engine and be convinced of absence of leaks of oil.
Stop the engine, check up level of oil and if necessary finish it to norm.

Cars with engines in working volume of 1,1 and 1,3 l   

Fig. 2.130. Elements of system of greasing of the engine in working volume of 1,3 l: 1 – a forward epiploon of a cranked shaft; 2 – a forward cover of the block of cylinders; 3 – a leading gear wheel of the oil pump; 4 – a conducted gear wheel of the oil pump; 5 – a cover of the oil pump; 6 – a lining of a forward cover of the block of cylinders; 7 – a lining маслоприемника; 8 – маслоприемник; 9 – oil картер; 10 – the oil filter; 11 – a stopper редукционного the valve; 12 – a lining редукционного the valve; 13 – a spring редукционного the valve; 14 – плунжер редукционного the valve


Fig. 2.131. Elements of system of greasing of the engine in working volume of 1,1 l: 1 – a forward epiploon of a cranked shaft; 2 – a forward cover of the block of cylinders; 3 – a leading gear wheel of the oil pump; 4 – a conducted gear wheel of the oil pump; 5 – a cover of the oil pump; 6 – a lining маслоприемника; 7 – маслоприемник; 8 – oil картер; 9 – плунжер редукционного the valve; 10 – a stopper редукционного the valve; 11 – a spring редукционного the valve


Elements of system of greasing of the engine in working volume of 1,3 l are shown on fig. 2.130, the engine in working volume of 1,1 l – on fig. 2.131.
The oil pump
Removal
Remove a drive belt газораспределительного the mechanism.
Turn away bolts of fastening oil картера.
Remove oil картер.
Remove маслоприемник the oil pump.
Remove a forward cover of the block of cylinders (the case of the oil pump) in gathering.
Uncover the oil pump.

Fig. 2.132. The oil pump in gathering: 1 – the case of the oil pump; 2 – a leading gear wheel; 3 – a conducted gear wheel; 4 – adjusting labels


Take out leading and conducted gear wheels from a forward cover of the block of cylinders (fig. 2.132). Adjusting labels (fig. 2.132 see) are put On leading and conducted gear wheels.
Turn away a stopper редукционного the valve, take out a spring and плунжер the valve.
Check of a technical condition
Check up oil картер on presence of damages or cracks and if necessary replace it.
Check up маслоприемник on presence of breakages, damages or cracks and if necessary replace it.
Check up surfaces of contact of the case and gear wheels of the oil pump on absence of deterioration (especially step).
Check up teeths of gear wheels on absence of deterioration or damages.

Fig. 2.133. Backlash check between external diameter and a nest of a conducted gear wheel in the case of the pump by means of flat щупа


Check up a backlash between external diameter of a conducted gear wheel and a nest of a conducted gear wheel in the pump case (fig. 2.133).
Radial backlash between external diameter and a nest of a conducted gear wheel in the pump case, mm:
Engines in working volume of 1,3 l...... 0,12–0,18
Engines in working volume of 1,1 l...... 0,10–0,18

Fig. 2.134. Backlash check between teeths of gear wheels by means of flat щупа


Check up a backlash between teeths of gear wheels (fig. 2.134).
Nominal backlash between teeths of gear wheels, mm:
Engines in working volume of 1,3 l...... 0,025–0,069
Engines in working volume of 1,1 l...... 0,06–0,18

Fig. 2.135. Backlash check between an end face of a conducted gear wheel and a plane of the case of the pump by means of flat щупа


Check up a backlash between an end face of a conducted gear wheel and a plane of the case of the pump (fig. 2.135).
Nominal backlash between an end face of a conducted gear wheel and a plane of the case of the pump, mm:
Engines in working volume of 1,3 l..... 0,04–0,087
Engines in working volume of 1,1 l..... 0,04–0,095
Assemblage and installation

Fig. 2.136. Adjusting labels of gear wheels of the oil pump


Establish in a forward cover of the block of cylinders (the case of the oil pump) leading and conducted gear wheels, watching their correct arrangement on labels, as is shown in fig. 2.136.
Establish a cover of the oil pump and
Tighten bolts of fastening by the moment
8–12 Н·м. After an inhaling of bolts check up smoothness of rotation of gear wheels of the pump.
Establish плунжер and a spring редукционного the valve, put engine oil on плунжер. Tighten a valve stopper the specified moment.
The moment of an inhaling of a stopper редукционного the valve of the oil pump, Н·м:
Engines in working volume of 1,3 l..... 40–50
Engines in working volume of 1,1 l..... 20–30
Check up working edges of an epiploon of a cranked shaft on absence of deterioration, коробления or damages.
Check up, whether the epiploon spring is weakened.

Fig. 2.137. Installation of a forward epiploon on a sock of a cranked shaft


Establish оправку (or a piece of a pipe of suitable diameter) for запрессовки a forward epiploon of a cranked shaft on a sock of a cranked shaft. Put engine oil on an external surface оправки and pull effort of a hand a new epiploon on a sock of a shaft before contact with a forward cover of the block of cylinders (fig. 2.137). Always establish only a new epiploon.

Fig. 2.138. Запрессовка a forward epiploon of a cranked shaft


Запрессуйте an epiploon оправкой (fig. 2.138).
Establish a gear pulley of a cranked shaft, a drive belt газораспределительного the mechanism and a pulley of a cranked shaft.
Establish маслоприемник.
Clear привалочные surfaces oil картера and the block of cylinders.

Fig. 2.139. Hermetic drawing on a flange oil картера


Put hermetic in a groove of a flange oil картера, as is shown in fig. 2.139.

       THE NOTE
The thickness of the platen of hermetic should make about 4 mm. Oil картер should be established not later than through 15 mines after hermetic drawing.

Establish oil картер and tighten bolts of its fastening by the moment 6–8 Н·м.

The gauge of a control lamp of pressure of oil  
Check

Fig. 2.140. Stock-taking of an electric chain between a conclusion and the case of the gauge by means of an ohmmeter


Check up presence of an electric chain between a conclusion and the gauge case (fig. 2.140). In the presence of chain breakage replace the gauge.

Fig. 2.141. Check by means of an ohmmeter of presence of an electric chain between a conclusion and the gauge case by pressing a sensitive element of the gauge: 1 – the gauge of a control lamp of pressure of oil; 2 – a sensitive element of the gauge; 3 – an ohmmeter


Check up presence of an electric chain between a conclusion and the gauge case by pressing a sensitive element of the gauge (fig. 2.141). If by pressing a sensitive element the chain is not disconnected, replace the gauge.
Create in the gauge depression 50 кПа through an aperture for an oil supply. If thus the electric chain between a conclusion and the gauge case is absent, the gauge is serviceable.
Be convinced of tightness of the gauge. Leak presence specifies in breakage of a diaphragm of the gauge. The gauge with the damaged diaphragm replace.

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

Fig. 2.142. Elements of system of greasing of engines in working volume of 1,5 and 1,6 l: 1 – a forward epiploon of a cranked shaft; 2 – a forward cover of the block of cylinders; 3 – a leading gear wheel of the oil pump; 4 – a conducted gear wheel of the oil pump; 5 – a cover of the oil pump; 6 – a lining of a forward cover of the block of cylinders; 7 – the block of cylinders; 8 – oil картер; 9 – a lining маслосливной stoppers; 10 – маслосливная a stopper; 11 – плунжер редукционного the valve; 12 – the oil filter; 13 – a stopper редукционного the valve; 14 – маслоприемник; 15 – a lining маслоприемника; 16 – a spring редукционного the valve


Elements of system of greasing of engines in working volume of 1,5 and 1,6 l are shown on fig. 2.142.
The oil pump
Removal
Remove a drive belt газораспределительного the mechanism.
Turn away bolts of fastening oil картера.
Remove oil картер.
Remove маслоприемник the oil pump.

Fig. 2.143. The oil pump in gathering


Remove a forward cover of the block of cylinders (the case of the oil pump) in gathering (fig. 2.143).
Take out leading and conducted gear wheels from a forward cover of the block of cylinders. Labels are put on leading and conducted gear wheels.
Check of a technical condition
Check up a forward cover of the block of cylinders on absence of cracks or damages and if necessary replace it.
Check up a forward epiploon of a cranked shaft on absence of deterioration or damage of working edges.
Check up oil картер on absence of breakages, damages or cracks and if necessary replace it.
Check up маслоприемник on absence of breakages, damages or cracks and if necessary replace it.
Check up surfaces of contact of the case of the oil pump with pump gear wheels on absence of damages or deterioration.
Check up teeths of gear wheels on absence of deterioration or damages.

Fig. 2.144. Check of a radial backlash between external diameter of a conducted gear wheel and a nest in the case of the pump by means of flat щупа


Check up a backlash between external diameter of a conducted gear wheel and a nest in the pump case (fig. 2.144).
The radial backlash between external diameter of a conducted gear wheel and a nest in the pump case should make 0,120–0,185 mm.
The backlash between teeths of gear wheels should be 0,025–0,069 mm.
Backlash between end faces of gear wheels and a plane of the case of the pump, mm:
Conducted gear wheel..... 0,04–0,09
Leading gear wheel..... 0,040–0,085

Fig. 2.145. Backlash check between teeths of gear wheels by means of flat щупа


Check up a backlash between teeths of gear wheels of the pump (fig. 2.145).

Fig. 2.146. Backlash check between end faces of gear wheels and a plane of the case of the pump by means of flat щупа


Check up a backlash between end faces of gear wheels and a plane of the case of the pump (fig. 2.146).
Check up ease of moving плунжера редукционного the valve in a nest of the case of the pump.
Check up a spring редукционного the valve on absence of deformation and breakage of coils.
Length of a spring редукционного the valve, mm:
In a free condition..... 46,6
Under loading 6,1 кгс..... 40,1
Assemblage and installation
Establish in a forward cover of the block of cylinders (the case of the oil pump) leading and conducted gear wheels, watching their correct arrangement on labels.
Establish a cover of the oil pump and tighten bolts of fastening by the moment 8–12 Н·м. After an inhaling of bolts check up smoothness of rotation of gear wheels of the pump.
Establish плунжер and a spring редукционного the valve, preliminary having covered плунжер with engine oil. Tighten a stopper редукционного the valve the moment 40–50 Н·м.

Fig. 2.147. Fastening bolts (A, B, C, D) a forward cover of the block of cylinders


Establish a forward cover of the block of cylinders with a new lining and tighten fastening bolts (fig. 2.147) the moment 20–27 Н·м.
Length of bolts (fig. 2.147 see), mm:
А...... 30
В...... 45
С...... 60
D....... 22

Fig. 2.148. Запрессовка a forward epiploon of a cranked shaft


Запрессуйте оправкой an epiploon in an aperture of a forward cover of the block of cylinders (fig. 2.148).
Establish маслоприемник.
Clear both parties of a lining oil картера and привалочную a surface of the block of cylinders.

Fig. 2.149. Hermetic drawing on a flange oil картера


Put hermetic in a flute of a flange oil картера (fig. 2.149).
Establish oil картер and tighten bolts of its fastening by the moment 10–12 Н·м.

       THE NOTE
The thickness of the platen of hermetic should make about 4 mm.
Oil картер should be established not later than through 15 mines after    hermetic drawing  .

The gauge of a control lamp of pressure of oil

Fig. 2.150. The Installation site of the gauge of a control lamp of pressure of oil on the block of cylinders of the engine


The gauge of a control lamp of pressure of oil is shown on fig. 2.150.
Check

Fig. 2.151. Stock-taking of an electric chain between a conclusion and the case of the gauge by means of an ohmmeter


Check up an ohmmeter presence of an electric chain between a conclusion and the gauge case (fig. 2.151). In the presence of chain breakage replace the gauge.

Fig. 2.152. Check by means of an ohmmeter of presence of an electric chain between a conclusion and the gauge case by pressing a sensitive element of the gauge: 1 – the gauge of a control lamp of pressure of oil; 2 – a sensitive element of the gauge; 3 – an ohmmeter


Check up presence of an electric chain between a conclusion and the gauge case by pressing a sensitive element of the gauge (fig. 2.152). If by pressing a sensitive element the chain is not disconnected, replace the gauge.
Create in the gauge depression in size 50 кПа through an aperture for an oil supply. If thus the electric chain between a conclusion and the case of the gauge is not present, the gauge is serviceable.
Be convinced of tightness of the gauge. Leak presence specifies in breakage of a diaphragm of the gauge. The gauge with the damaged diaphragm replace.

That it is necessary to know at oil replacement  
First, it is recommended not only to give to old oil completely to flow down but also to turn a cranked shaft of the engine on 5–7 turns, to remove the remained oil from oil highways. It is useful to wash out also the engine (for this purpose apply special oil to washing) during 20–25 mines, thus the engine should work in an idling mode.
Changing oil, always it is necessary to replace and the filter. Old though and washed out, will be «as a fly in the ointment».
Oil should be changed indoors where there is no dust and a wind.
At check of level of oil in картере the engine the rag which wipe маслоизмерительный щуп, should be pure. Even, apparently, the insignificant particles of the dust which has got to the engine, considerably reduce term of its service.
At oil replacement change also a lining of a stopper of a drain aperture in the oil pallet of the engine, and also the case of the oil filter (if it is established). The lining is included into the complete set of the oil filter.
After oil replacement it is useful to fix car run, replacement date, oil mark that at its subsequent replacement or доливке was less problems.
It is not necessary to be afraid of that oil will darken already after 1000 km of run. It testifies only that it "works" correctly – keeps in itself a deposit and washes surfaces of details.