Hyundai Getz>> Engine>> Head of the block of cylinders
Features of the device
The head of the block of cylinders is cast from an aluminum alloy, has the pressed pig-iron saddles and directing plugs of valves. The top part of plugs is condensed with rezinometallichesky maslootrazhatelny 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. Openings in support are processed assembled with cases of bearings therefore they are not interchangeable and it is possible to replace a head of the block of cylinders only assembled with cases.

Mechanism of a drive of valves 
Valves are put in action by camshaft cams through yokes on the engine in working volume of 1,1 l, on other engines valves are given by camshaft cams through hydraulic pushers. Adjustment of gaps in the mechanism of a drive of valves with hydraulic pushers is carried out at operation of the engine automatically.
Adjustment of gaps in the mechanism of a drive of valves (only engines in working volume of 1,1 l) 
Adjustment of gaps in the mechanism of a drive of valves is carried out at operation of the engine automatically. Additional adjustment of gaps in the mechanism of a drive of valves in use 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 of VMT of the end of a step of compression of the 1st cylinder


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

cylinder No.
1
2
3
4
Inlet valves
+
+


Final valves
+

+


Insert щуп between an end face of the adjusting screw of a yoke and an end face of a core of the valve. Adjust a gap and tighten a lock nut of the screw.
Turn a cranked shaft on one turnover of the rotation direction (clockwise if to look from a forward end face of the engine) to the provision VMT of the end of a step of compression of the piston of the 4th cylinder. Inserting щуп between end faces of adjusting screws of yokes and end faces of cores of valves, adjust gaps in a drive of valves in the following cylinders.

cylinder No.
1
2
3
4
Inlet valves
+


+
Final valves
+
+
+
+


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


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

Fig. 2.9. Inhaling of a lock nut of the adjusting screw


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

Table 2.2
Gaps in the mechanism of a drive of valves
Engine temperature
Gap
the inlet
valves
the final
valves
On the heated-up engine (nominal)
0,2
0,25
On the cold engine (for the reference)
0,1
0,17

Hydraulic pushers of valves 

       NOTE
Noise in the gas-distributing mechanism at engine start-up – the normal phenomenon. At the idle engine depending on the provision of cams from each pusher it is forced out various (bigger or smaller) amount of oil. It leads to noise emergence 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 ensuring excellent job of hydraulic pushers in a head of the block of cylinders the oil zaslonka preventing a full devastation of oil channels in a head of the block of cylinders on the idle engine is provided.

PREVENTION
At emergence of knock of pushers at operation of the engine do not allow 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

PREVENTION
Hydraulic pushers of valves are necessary for checking, if in the gas-distributing 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 turn on 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.

PREVENTION
Do not rotate a cranked shaft for a bolt of fastening of a gear pulley of a camshaft as the gear driving belt is thus overloaded. 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 was turned up. For this purpose establish a transmission control lever in neutral situation, tighten the lever of lay brake system and turn a suitable wrench a cranked shaft in the 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.

PREVENTION
After installation of a new hydraulic pusher it is impossible to start up the engine during 30 mines, otherwise the plate of the valve 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 

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

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

Fig. 2.10. 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.

PREVENTION
The faulty head of the block of cylinders is determined by one or several following signs:
– capacity loss;
– leakage of cooling liquid. A white smoke from an exhaust pipe on the warm engine;
– leakage of oil;
– cooling liquid in engine oil, level of oil does not decrease, can increase. Gray color of engine oil, foam traces on masloizmeritelny щупе, oil razzhizheno;
– engine oil in cooling liquid;
– cooling liquid strongly rages;
– there is no compression in two next cylinders.

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

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

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

Fig. 2.11. Rack of fastening of a receiver of a power supply system


Remove a rack of fastening of a receiver of a 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 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 of a gazoraspredeleniye towards the pump of cooling liquid and temporarily fix it in this situation.
Remove a belt of a drive of the mechanism of a gazoraspredeleniye.
Uncover heads of the block of cylinders.

Fig. 2.12. An order of an otvorachivaniye 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 the direction of a forward part of the engine)


Fig. 2.13. An order of an otvorachivaniye 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 the direction of a forward part of the engine)


Remove a head of the block of cylinders, having unscrewed bolts of its fastening in the order specified fig. 2.12 and 2.13 by means of a key for bolts of fastening of a head of the block of cylinders.
Remove the remains of a material of laying from privalochny surfaces of a head and the block of cylinders.

       NOTE
Watch, that particles of a material of laying did not get to cylinders.

Installation
Before installation release a head and the block of cylinders from the remains of laying by a suitable shaber. Watch, that dirt did not get to openings of the block of cylinders. Close openings a rag.
Check, that in openings of bolts of a head of the block of cylinders there was no oil. Remove oil if necessary.
Check a head of the block of cylinders on deformation existence 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 the longitudinal direction and across. Admission of planeness of 0,1 mm.
Establish on a head of the block of cylinders new laying.
Hermetic on laying do not put, the removed laying 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 the 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 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 the direction of a forward part of the engine)


Repeat operation, tightening all bolts the specified moment.
Moment of an inhaling of bolts of fastening of a head of the block of cylinders, N · 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 °

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 accuracy of a dinamometrichesky 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 of the gas-distributing mechanism towards the pump of cooling liquid and fix it.
Establish a belt of a drive of the gas-distributing mechanism on a gear pulley of a camshaft and pull a leading branch of a belt, having turned a gear pulley in the direction, the return to the normal direction of rotation. Check combination of adjusting labels.
Adjust a drive of the gas-distributing mechanism as it is specified in subsection «A camshaft and its drive».
Establish a cover of a head of the block of cylinders and tighten bolts of its fastening the specified moment.
Moment of an inhaling of bolts of fastening of a cover of a head of the block of cylinders of 8-10 N · m.
Establish a cover of a drive of the gas-distributing mechanism.
Establish new laying of the inlet pipeline and the inlet pipeline. Tighten bolts and nuts of fastening of the inlet pipeline the moment of 15-20 N · m.
Establish new laying of a final collector and a final collector. Tighten nuts of fastening the specified moment.
Establish a receiver and tighten nuts and bolts of fastening of a receiver to the inlet pipeline the moment of 15-20 N · m.
Establish the ignition coil.
Establish bringing air branch pipe of system of an admission.
Attach a vacuum hose, a hose of supply of fuel and a hose of cooling liquid.
Attach a hose of ventilation of a case.

PREVENTION
The storage battery can be connected only at the switched-off ignition, the electronic control unit of system of injection otherwise will be damaged.

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

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

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

PREVENTION
The faulty head of the block of cylinders is determined by one or several following signs:
– capacity loss;
– leakage of cooling liquid. A white smoke from an exhaust pipe on the warm engine;
– leakage of oil;
– cooling liquid in engine oil, level of oil does not decrease, can increase. Gray color of engine oil, foam traces on masloizmeritelny щупе, oil razzhizheno;
– engine oil in cooling liquid;
– cooling liquid strongly rages;
– there is no compression in two next cylinders.

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

PREVENTION
At disconnection of a cable of "weight" from the storage battery from memory of a radio receiver the protective code of a radio receiver and control of radio stations are erased. The battery can be disconnected only at the switched-off ignition, the electronic control unit 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 hose of ventilation of a case from the air filter and a cover of a head of the block of cylinders.
Disconnect bringing air branch pipe of a power supply system.
Disconnect a vacuum hose, a fuel hose and a hose of a supply of cooling liquid.
Disconnect high-voltage wires of system of ignition from spark plugs.
Remove the ignition coil.

Fig. 2.17. Rack of fastening of a receiver of a power supply system


Remove a rack of fastening of a receiver of a 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 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 of a gazoraspredeleniye towards the pump of cooling liquid and temporarily fix it in this situation.
Remove a belt of a drive of the mechanism of a gazoraspredeleniye.
Uncover heads of the block of cylinders.

Fig. 2.18. Order of an otvorachivaniye of 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 unscrewed bolts of its fastening in the order specified fig. 2.18 by means of a key for bolts of fastening of a head of the block of cylinders.
Remove the remains of a material of laying from privalochny surfaces of a head and the block of cylinders.

       NOTE
Watch, that the remains of laying did not get to cylinders.

Installation
Before installation release a head and the block of cylinders from the remains of laying by a suitable shaber. Watch, that dirt did not get to openings of the block of cylinders. Close openings a rag.
Check, that in openings of bolts of a head of the block of cylinders there was no oil. Remove oil if necessary.
Check a head of the block of cylinders on deformation existence 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 the longitudinal direction and across. Admission of planeness of 0,1 mm.
Establish on a head of the block of cylinders new laying, marking on laying should be turned towards a head of the block of cylinders.
Do not put hermetic on laying, always replace new the removed laying.

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 fig.
Moment of an inhaling of bolts of fastening of a head of the block of cylinders, N · 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 °

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 accuracy of a dinamometrichesky 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 of the gas-distributing mechanism towards the pump of cooling liquid and fix it.
Establish a belt of a drive of the gas-distributing mechanism on a gear pulley of a camshaft and pull a leading branch of a belt, having turned a gear pulley in the direction, the return to the normal direction of rotation. Check combination of adjusting labels.
Adjust a drive of the gas-distributing mechanism as it is specified in subsection «A camshaft and its drive».
Establish a cover of a head of the block of cylinders and tighten bolts of its fastening the moment of 8-10 N · m.
Establish a cover of a drive of the gas-distributing mechanism.
Establish new laying of the inlet pipeline and the inlet pipeline. Tighten bolts of fastening of the inlet pipeline the moment of 15-20 N · m.
Establish new laying of a final collector and a final collector. Tighten nuts of fastening the specified moment.
Establish a receiver, tighten nuts and bolts of fastening of a receiver to the inlet pipeline the moment of 15-20 N · m.
Establish the ignition coil.
Establish bringing air branch pipe of system of an admission.
Attach a vacuum hose, a hose of supply of fuel and a hose of cooling liquid.
Attach a hose of ventilation of a case.

PREVENTION
The storage battery can be connected only at the switched-off ignition, the electronic control unit of system of injection otherwise will be damaged.

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

Dismantling and assembly 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. Yokes of a drive of valves of a head of the block of cylinders of the engine in working volume of 1,1 l


Yokes of 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 hose of ventilation of a case and a hose of compulsory ventilation of a case.
Remove a pulley of the pump of cooling liquid and a pulley of a cranked shaft.
Uncover a drive of the mechanism of a gazoraspredeleniye.
Displace a tension roller of a belt of a drive of the mechanism of a gazoraspredeleniye towards the pump of cooling liquid and fix it in this situation.
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 of yokes with yokes. For this purpose unscrew bolts with a fillet and remove axes of yokes assembled with yokes and rasporny springs of yokes.
Unscrew bolts and remove from axes of a yoke and rasporny springs.
Take out a camshaft in the direction to a forward end face of the engine.

Fig. 2.21. Camshaft removal


Remove a camshaft, as is shown in fig. 2.21 .
Assembly
Before installation check camshaft palpation. Limiting palpation of a camshaft makes 0,01 mm. Check of palpation of a camshaft should be carried out at service station.

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

Establish a camshaft, previously having greased his basic necks with engine oil.
Establish the ignition coil.
Establish axes of yokes with yokes. For this purpose establish yokes and rasporny springs on an axis of yokes, and axes of yokes assembled on a head of the block of cylinders.
Tighten bolts of fastening of axes of yokes the moment of 20-27 N · m.
At installation of yokes, springs and axes of yokes it is necessary to watch their correct situation (the left or right side).
Raspornye springs of axes of yokes of inlet and final valves are identical. Installation should be carried out so that a facet located between two parts of an axis of a yoke, settled down from a drive of the mechanism of a gazoraspredeleniye.
Opravka for a press fitting of an epiploon of a camshaft (adaptation number according to the NMS 09221-21000 catalog) press a shaft epiploon, previously having greased with engine oil an external surface of an epiploon.

Fig. 2.22. A press fitting of an epiploon of a camshaft by means of an opravka


For a press fitting the epiploon needs to be put on a sock of a camshaft and to press against the stop in hammer blows on an opravka, as is shown in fig. 2.22 .
Establish a gear pulley of a camshaft and tighten a bolt of fastening the moment of 80-100 N · m.

Fig. 2.23. Label combination on gear to a camshaft pulley 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 the 1st cylinder in VMT of the end of a step of compression, thus labels on gear pulleys of distributive and cranked shaft should be combined with the 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 laying 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 let's to it work idling.
Establish a cover of a head of the block of cylinders and tighten bolts of fastening the moment of 8-10 N · m.
Establish a cover of a drive of the gas-distributing mechanism.
Establish a pulley of the pump of cooling liquid and a pulley of a cranked shaft.

Cars with engines in working volume of 1,3 l 
Dismantling
If replacement to only any one detail is required, 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. Yokes of a drive of valves of a head of the block of cylinders of the engine in working volume of 1,3 l


Yokes of 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 hose of ventilation of a case and a hose of compulsory ventilation of a case.
Remove a pulley of the pump of cooling liquid and a pulley of a cranked shaft.
Uncover a drive of the mechanism of a gazoraspredeleniye.
Displace a tension roller of a belt of a drive of the mechanism of a gazoraspredeleniye towards the pump of cooling liquid and fix it in this situation.
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 of yokes with yokes. For this purpose unscrew bolts with a fillet and remove axes of yokes assembled with yokes and rasporny springs of yokes.
Unscrew bolts and remove from axes of a yoke and rasporny springs.
Remove covers of bearings of a camshaft.

Fig. 2.26. Camshaft removal


Remove a camshaft, as is shown in fig. 2.26 .
Assembly
Before installation check camshaft palpation. Limiting palpation of a camshaft makes 0,01 mm. Check of palpation should be carried out at service station.

       NOTE
At installation of the camshaft which was in the use on engines with big run or in the presence of noise in the gas-distributing mechanism it is expedient to check 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 No. 1 and 5.

Establish a camshaft, previously having greased his basic necks with engine oil.
Establish covers of bearings of a camshaft.
Establish axes of yokes with yokes. For this purpose establish yokes and rasporny springs on an axis of yokes, and axes of yokes assembled on a head of the block of cylinders.
Tighten bolts of fastening of axes of yokes the moment of 20-27 N · m.
At installation of yokes, springs and axes of yokes it is necessary to watch their correct situation (the left or right side).
Raspornye springs of axes of yokes of inlet and final valves are identical. Installation should be carried out so that a facet located between two parts of an axis of a yoke, settled down from a drive of the mechanism of a gazoraspredeleniye.
Opravka for a press fitting of an epiploon of a camshaft (adaptation number according to the NMS 09221-21000 catalog) press a shaft epiploon, previously having greased with engine oil an external surface of an epiploon.
For a press fitting of an epiploon he needs to be put on a sock of a camshaft and to press against the stop in hammer blows on an opravka, as is shown in fig. 2.22 .
Establish a gear pulley of a camshaft and tighten a bolt of fastening the moment of 80-100 N · m.

Fig. 2.27. Combination of a label And on gear to a camshaft pulley 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 the 1st cylinder in VMT of the end of a step of compression, labels on gear pulleys of distributive and cranked shaft should be combined with the 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 laying 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 let's to it work idling.
Establish a cover of a head of the block of cylinders and tighten bolts of fastening the moment of 8-10 N · m.
Establish a cover of a drive of the gas-distributing mechanism.
Establish a pulley of the pump of cooling liquid and a pulley of a cranked shaft.

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

Fig. 2.29. Head of the block of cylinders: 1–bolt of fastening of a gear pulley of a camshaft; 2–camshaft epiploon; 3–cover of the forward bearing of a camshaft; 4–camshaft of inlet valves; 5–chain of a drive of a camshaft of inlet valves; 6–camshaft of final valves; 7–hydraulic pusher of the valve; 8–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 hoses of ventilation of a case.
Remove a pulley of the pump of cooling liquid and a pulley of a cranked shaft.
Uncover a drive of the mechanism of a gazoraspredeleniye.
Weaken a bolt of a tension roller of a belt of a drive of the mechanism of a gazoraspredeleniye and fix a roller.
Remove a belt of a drive of the mechanism of a gazoraspredeleniye from a camshaft pulley.
Remove the bottom cover of a head of the block of cylinders, having unscrewed bolts of its fastening.
Remove the ignition coil.

Fig. 2.30. 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 unscrewed bolts of its fastening.
Remove a gear pulley of a camshaft.
Remove covers of bearings of camshafts and a driving chain.
Remove camshafts.
Remove hydraulic pushers of valves.
Assembly
Establish hydraulic pushers of valves.

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


Establish a driving 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, previously 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. 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 of 12-14 N · m.

Fig. 2.34. Press fitting of an epiploon of a camshaft


Opravka for a press fitting of an epiploon of a camshaft (adaptation number according to the NMS 09221-21000 catalog) press an epiploon, previously having greased with engine oil it working edges. For this purpose put on an epiploon for the forward end of a shaft and press it against the stop in 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 with 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 openings under pushers of valves should not be задиров and damages. Cracks in any places of a head of the block of cylinders are not allowed. At suspicion on hit of cooling liquid in oil check tightness of a head of the block of cylinders.
For check of tightness close openings of a cooling shirt caps and force the pump in a shirt of cooling of a head of the block of cylinders water under the pressure of 0,5 MPas (5 kgfs/cm 2 ). During 2 mines it should not be observed leakages of water from a head.
It is possible to check tightness of a head of the block of cylinders the compressed air for what muffle openings of a shirt of cooling by caps, lower a block head in a bath with the water which has been warmed up to 60–80 °C, and let's to it get warm within 5 minutes. Then submit in a head the compressed air under the pressure of 0,15–0,2 MPas (1,5–2 kgfs/cm 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–plate of a spring; 3–valve spring; 4–maslootrazhatelny cap; 5–basic washer of a spring; 6–the directing plug of the final valve; 7–saddle of the inlet valve; 8–inlet valve; 9–final valve; 10-saddle of the final valve; 11-the directing plug of the inlet valve; 12-basic washer of a spring; 13-maslootrazhatelny cap; 14-valve spring; 15-plate of a spring; 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–yoke of the final valve; 2–crackers; 3–plate of a spring; 4–valve spring; 5–maslootrazhatelny cap; 6–basic washer of a spring; 7–the directing plug of the final valve; 8–saddle of the inlet valve; 9–inlet valve; 10-final valve; 11-saddle of the final valve; 12-the directing plug of the inlet valve; 13-basic washer of a spring; 14-maslootrazhatelny cap; 15-valve spring; 16-plate of a spring; 17-crackers; 18-yoke of 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–plate of a spring; 3–valve spring; 4–maslootrazhatelny cap; 5–basic washer of a spring; 6–the directing plug of the final valve; 7–saddle of the inlet valve; 8–inlet valve; 9–final valve; 10-saddle of the final valve; 11-the directing plug of the inlet valve; 12-basic washer of a spring; 13-maslootrazhatelny cap; 14-valve spring; 15-plate of a spring; 16-crackers


Fig. 2.38. The adaptation for removal and installation of klapanny 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 of klapanny springs on engines in working volume of 1,5 and 1,6 l


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

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

Fig. 2.40. Nippers for removal of maslootrazhatelny caps


Nippers remove maslootrazhatelny caps (fig. 2.40) .

       NOTE
The removed maslootrazhatelny 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 length of klapanny springs in a free condition and under loading. At a deviation of length of springs from norm replace them.

       NOTE
Check of deformation of springs under loading is carried out on the special adaptation at service station.

Check a square a deviation of springs from a vertical. At excess of a tolerance from a vertical replace springs.
Nominal length of a spring in 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, a hail, 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. Gap 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 a gap between cores of valves and directing plugs (fig. 2.41 and 2.42) . If the size of a gap leaves out of the specified limits, replace plugs, having established plugs of the next repair size.
Nominal rates of a gap 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 are pressed in a head of the block of cylinders. To replace directing plugs as it is described below, it is possible by means of the adaptation for a press fitting of directing plugs of valves 09221-21200 (engines in working volume of 1,3 l), 09222-02100 (engines in working volume of 1,1 l) or other suitable adaptation.

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


By means of an adaptation opravka for a press fitting of directing plugs and a press выпрессуйте directing plug in the direction to the block of cylinders (fig. 2.43) .
Develop an opening 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.
Press the plug of the repair size by means of the adaptation for a press fitting of directing plugs of valves. The adaptation presses directing plugs, providing a certain size of their vystupaniye concerning a head of the block of cylinders. A press fitting carry out in the 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 a gap between cores of valves and directing plugs.
At replacement of directing plugs it is necessary to check 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 saddles of valves on existence of traces of an overheat and a non-uniform prileganiye of working facets of valves. If necessary прошлифуйте (fig. 2.44) or replace saddles of valves.

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


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


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


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


Before polishing of a saddle check degree of wear of the directing plug of the valve. In case of wear of the directing plug replace it and прошлифуйте a valve saddle with the grinding machine or a mill, watching preservation of the demanded width of a working facet of a saddle and its centering of rather 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 wear of a saddle of the valve, exceeding maximum permissible, remove a saddle, having removed by means of a mill the main part of a wall of a saddle.

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

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

       NOTE
The saddle of the valve should have room temperature.

After installation of a new saddle process its working facet.

Fig. 2.49. Valve cleaning by a metal brush


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

Fig. 2.50. Valve


Check each valve on existence of wear, damage and a buckling of a head and a valve core in area B (fig. 2.50) . If necessary carry out repair or editing of a core of the valve. Remove development or wear at an end face of a core of the valve in area A, the minimum quantity of metal thus should act in film. Proshlifuyte also working facets of valves.
Replace the valve at reduction of 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

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

Establish basic washers of klapanny springs and easy blows of a hammer on an adaptation opravka for a napressovka of maslootrazhatelny caps напрессуйте caps on directing plugs.

Fig. 2.51. Scheme of installation of a maslootrazhatelny cap: 1–maslootrazhatelny cap; 2–basic plate of a spring


Use of the adaptation provides a napressovka of caps in the necessary situation (fig. 2.51) . The wrong napressovka leads to deformation and эксцентриситету a condensing edge of a cap and thereof to leakage of oil in the cylinder via directing plug. Therefore at a napressovka it is necessary to watch that there was no cap distortion. The removed maslootrazhatelny caps are not subject to a reuse.
Grease cores of valves with engine oil. Insert valves into directing plugs, without making effort for core passing through a maslootrazhatelny cap. Check smoothness of sliding of the valve in the plug.
Establish klapanny springs and plates of springs. Springs establish so that the spring party with an enamel covering was turned towards a plate.
Compress a klapanny spring the adaptation for removal and installation of klapanny springs, watching that the lower part of a plate of a spring did not deform a maslootrazhatelny cap.
Establish valve crackers. After installation of the valve check correctness of landing of crackers.
Clear privalochny surfaces of the block and a head of the block of cylinders.
Check marking of laying of a head of the block of cylinders.
Establish laying of a head of the block of cylinders by marking to a block head.
Establish a head of the block of cylinders.