1.15. Repair of a head of cylinders
Dismantling
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- The special tool 09221-32001, 09221-11000 in the sequence shown in the drawing for 2–3 passes turn out bolts of fastening of a head of the block of cylinders.
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- Special adaptation 09222 - 28000, 09222-28100 squeeze a spring of the valve and remove crackers from a valve core. Slowly release adaptation squeezing a spring and remove a valve spring, a plate springs and the valve from a head of the block of cylinders.
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For storage of valves prepare the numbered plastic bags or containers. |
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- Passatizhami 09222–29000 remove a maslootrazhatelny cap.
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Do not reuse a maslootrazhatelny cap. |
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Check
Head of the block of cylinders
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- Examine a head of the block of cylinders on absence of damage, cracks, leak of oil and cooling liquid. If necessary, replace a head of cylinders.
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- Remove scale, sealant and a deposit. Compressed air blow channels for lubricant.
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- Metal ruler and the probe in six A, B directions... check planeness of a head of the block of cylinders. If necessary, pereshlifuyta head of the block of cylinders.
Standard deviation from planeness: less than 0,03 mm.
Maximum permissible deviation from planeness: 0,05 mm.
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Valves
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- Wire brush clear the valve.
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- Examine each valve on existence of wear, damages and deformation in zones A and B and, if necessary, repair or replace it. If the end face of a core is corroded or worn-out, as required restore facets. This restoration has to be limited to the minimum removal of metal.
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Also check thickness of working edges.
Thickness of a working edge of the valve:
Inlet valves: 1,15 mm:
- l engines 1,8 and 2,0: 1,15 mm;
- engines of 1,6 l: 1,1 mm.
Final valves:
- l engines 1,8 and 2,0: 1,35 mm;
- engines of 1,6 l: 1,3 mm.
Maximum permissible thickness of a working edge of the valve:
Inlet valves: 0,8 mm;
Final valves: 1,0 mm.
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Valve spring
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- Examine each spring of the valve on lack of cracks and damages. Measure spring length in a free state.
- Establish a spring on a flat horizontal surface and measure a deviation of the top part of a spring from the vertical plane.
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L engines 1,8 and 2,0
Spring length without loading: 48,86 mm
Spring length under loading of 18,3 kg: 39 mm
Spring length under loading of 40,0 kg: 30,5 mm
Spring tolerance from the vertical plane: no more than 1,5 °
Maximum permissible deviation of a spring from the vertical plane: no more than 3 °
Engines of 1,6 l
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Spring length without loading: 44 mm
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Spring length under loading of 21,6 kg: 35 mm
Spring length under loading of 45,1 kg: 27,2 mm
Spring tolerance from the vertical plane: no more than 1,5 °
Maximum permissible deviation of a spring from the vertical plane: no more than 4 °
The directing valve plugs
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Check a gap between a core and the directing valve plug. If the gap exceeds maximum permissible value, replace the directing valve plug with the plug of the increased repair size.
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L engines 1,8 and 2,0
Gap between a core and the directing valve plug:
Inlet valves: 0,02–0,05 mm
Final valves: 0,035–0,065 mm
Maximum permissible gap between a core and the directing valve plug:
Inlet valves: 0,1 mm
Final valves: 0,13 mm
Engines of 1,6 l
Gap between a core and the directing valve plug:
Inlet valve: 0,03–0,06 mm
Final valve: 0,05–0,08 mm
Maximum permissible gap between a core and the directing valve plug:
Inlet valve: 0,1 mm
Final valve: 0,15 mm
Plug-in saddle of the valve
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Check a valve saddle for existence of an overheat and violation of the working surface contacting to a plate of the valve. If necessary repair or replace a valve saddle.
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Before replacement or repair of a saddle of the valve check wear of the directing valve plug. If the directing plug of the valve is worn-out, replace it.
Replacement of a saddle of the valve
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Any plug-in saddle of the valve which is worn out to a limit needs to be replaced at the room temperature with cutting of a wall, as shown in the drawing. |
- After removal of an old saddle of the valve it is necessary to chisel a nest under the increased valve saddle size. The sizes for processing are specified in the table.
The increased sizes of a plug-in saddle of the valve of engines 1,8 and 2,0 l3
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Description
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Size tag
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Height of a saddle, mm
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Diameter of a nest in a head of cylinders, mm
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| The saddle of the inlet valve increased by 0,3 mm |
30
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7,5–7,7
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33,300–33,325
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| The saddle of the inlet valve increased by 0,6 mm |
60
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7,8–8,0
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33,600–33,625
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| The saddle of the final valve increased by 0,3 mm |
30
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7,9–8,1
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28,800–28,821
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| The saddle of the final valve increased by 0,6 mm |
60
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8,2–8,4
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29,100–29,121
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The increased sizes of a plug-in saddle of the valve of engines of 1,6 l
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Description
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Size tag
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Height of a saddle, mm
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Diameter of a nest in a head of cylinders, mm
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| The saddle of the inlet valve increased by 0,3 mm |
30
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5,1–5,3
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30,700–30,721
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| The saddle of the inlet valve increased by 0,6 mm |
60
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5,4–5,6
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31,000–31,021
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| The saddle of the final valve increased by 0,3 mm |
30
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6,2–6,4
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27,300–27,3211
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| The saddle of the final valve increased by 0,6 mm |
60
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6,5–6,7
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27,600–27,621
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- Heat a head of cylinders to temperature of 250 °C and press a new saddle of the valve of the repair size. At a press fitting the saddle of the valve has to have room temperature.
- After installation of a new saddle of the valve it is necessary to execute grinding in of the valve. Width of a working facet of a saddle of the valve has to be within technical requirements.
Width of a working facet of a saddle of the inlet valve:
- l engines 1,8 and 2,0: 1,1–1,5 mm;
- engines of 1,6 l: 0,8–1,2 mm.
Width of a working facet of a saddle of the final valve: 1,3–1,7 mm
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Replacement of the directing valve plug
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- Using adaptation of 09221 - 22000 A/B to a vypressuyta the valve plug from a head of cylinders towards the block of cylinders.
- Put the new directing plug of the valve of the increased repair size to an opening of a head of cylinders.
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- The device for installation of the directing plug of the valve 09221-22000 A/B press the plug in a head of cylinders. Adaptation provides a plug press fitting on strictly certain depth. Measure a vystupaniye of the top part of the directing valve plug from a head of cylinders. Pay attention that vystupany the directing valve plug variously for inlet and final valves.
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- After a press fitting of the directing plugs of valves insert new valves and check a gap.
- Check every time when replacing of the directing plugs of valves and, if necessary, replace saddles of valves.
The increased sizes of the directing valve plug
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The increased sizes
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Size tag
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Diameter of an opening in a head of the block of cylinders
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0,05
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5
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11,050–11,068
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0,25
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25
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11,250–11,268
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0,5
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50
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11,500–11,518
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Assembly
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- Before installation clear all details.
- Apply a thin film of engine oil on all surfaces of sliding.
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- Establish a spring saddle. Using special adaptation 09222 - 22001, establish a maslootrazhatelny cap.
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- Do not reuse old maslootrazhatelny caps.
- The wrong installation of a maslootrazhatelny cap adversely influences its working edge due to eccentricity and leads to leak of engine oil via the directing valve plugs.
At installation be careful not to overwind a maslootrazhatelny cap.
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- Oil a valve core engine and install the valve. At installation of the valve do not make great efforts not to damage a maslootrazhatelny cap. Check smoothness of movement of the valve.
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- Establish springs and holders of springs. Springs need to be established by the party enameled to holders of springs.
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- Special adaptation 09222 - 28000, 09222-28100 squeeze a spring. Establish crackers and remove the special device for compression of a spring.
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At compression of a spring be convinced that the maslootrazhatelny cap is not clamped by the device for compression of a spring. |
- Clear all privalochny surfaces of the block of cylinders and a head of the block of the cylinder.
- Check existence of marking on laying of a head of cylinders.
- Establish new laying of a head of the block of cylinders so that the surface with marking was directed to a head of cylinders.
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- In the sequence shown in the drawing tighten bolts of fastening of a head of cylinders.
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Moment of an inhaling of bolts of fastening of a head of cylinders of engines 1,8 and 2,0 of l
M10: 25 N • to tighten m on a corner 60–65 ° to tighten on a corner 60–65 °
M12: 30 N • to tighten m on a corner 60–65 ° to tighten on a corner 60–65 °
Moment of an inhaling of bolts of fastening of a head of cylinders of engines of 1,6 l:
30 N • to tighten m on a corner 90 ° to weaken all bolts of 30 N • m to tighten on a corner 90 °
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