Opel Frontera

since 1992 of release

Repair and car operation



Fronter's Opel
+ Opel Frontera brand Cars
+ Current leaving and service
- Engine
   Removal and OHC engine installation
   Removal and DOHC engine installation
   Engine dismantling
   Engine assembly
   Head of cylinders and valves
   Pistons and rods
   Block of cylinders
   Cranked shaft and bearings of a cranked shaft
   Camshaft drive
   Engine mounts
   Compression check
   Greasing system
   Works with system of greasing of the OHC/DOHC engine of 2.0 l
   Works with greasing system on the engine of 2.4 l
   Oil filter
   Oil radiator (if it is established)
   Pressure and oil temperature
+ cooling and heating Systems
+ Power supply system and release
+ engine Electric equipment
+ Coupling
+ Manual box of gear shifting
+ Driveshafts, main transfer
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Governing bodies and operation
+ electric equipment Schemes



Head of cylinders and valves

GENERAL INFORMATION

Removal and installation of a head of cylinders (the engine is not removed)

The head of cylinders can be removed on the established engine. This operation is shortly described below. It is necessary also will familiarize with the contents of the section describing removal of the engine as many works on removal of the engine are necessary for executing also at removal of a head of cylinders. If the engine is already removed, a preparatory work can not be carried out.
Removal of a head of cylinders without removal of the engine is required, for example, at replacement of laying of a head of cylinders or for polishing of valves. Heads of cylinders are authorized to be removed only after engine cooling (to room temperature).
Removal of a head of cylinders for various types of the engine is described separately. However here all differences which are taking place for various types of the engine are described not.

THE OHC ENGINE – THE C20 NE TYPE – TILL 1995. RELEASE


Removal

PERFORMANCE ORDER
1. Disconnect a weight cable from the storage battery.
2. Merge liquid from cooling system (The section Filling of a cooler of system of cooling of Head the Current leaving and service) and disconnect hoses from the thermostat case. Collect in capacity cooling liquid for further application if it was in system short time.
3. Disconnect a reception pipe of system of release from a final collector.
4. Disconnect a cable of a drive of a butterfly valve from a sharnirny head and from a support. Its fastening is shown on иллюстр.
5. The head of cylinders can be removed together with a collector or the collector can be disconnected from a head of cylinders before its removal. If, for example, it is necessary to replace only laying of a head of cylinders, it is possible to disconnect the inlet pipeline from a head of cylinders and to shift it aside. Thus it is possible to save work on a detachment of various pipelines, cables and hoses.
6. If the head of cylinders has to act in film with a final collector, it is necessary to disconnect all hoses, pipelines, cables, etc. from a final collector.
7. Remove a belt of a drive of the generator.
8. Disconnect a hose of absorption of air from the butterfly valve case. Disconnect a hose from a cover of the case of bearings of a camshaft. It is the hose of ventilation connected to the inlet pipeline.
9. Disconnect cables from spark plugs and the ignition coil. If necessary mark cables.
10. The following operation is important and should be executed before removal of a gear belt. Insert a face key into the center of a pulley of a cranked shaft and turn a cranked shaft in the rotation direction so that it and a camshaft occupied the situation shown on иллюстр. (a camshaft - above, a cranked shaft - below). The label on a wheel of a camshaft should coincide with a label on a level, the pin on the bottom party should be opposite to a label of a cranked shaft.
11. Uncover camshaft cases.
12. Remove a gear belt. This work is described in appropriate section.
  – Holding a camshaft cogwheel from a provorachivaniye, unscrew a bolt in the center. Remove a wheel. Unscrew the top bolts of a back protective cover of a belt.
13. Unscrew bolts of fastening of a head of cylinders for some receptions in the sequence shown on иллюстр. For the first reception unscrew bolts no more, than on a turn quarter, for the second reception on a half of turn. For an otvorachivaniye use a face key.
14a. Remove the case of bearings of a camshaft from a head of cylinders. Operation is shown on иллюстр. 6.14a. If necessary for office of the case it is possible to use a rubber hammer. It is necessary to mean that the case has directing pins.
14b. Yokes, press elements and hydropushers (jacks of gaps of valves) take out on an order and mark. Details of one knot to hold together. The arrangement of details before removal is shown on иллюстр. 6.14b. It is necessary to put pushers in the vertical capacity filled with oil to exclude air hit in internal cavities.
15. Remove a head of cylinders and remove laying. Strongly sitting head of cylinders it is possible обстучать a rubber hammer. It is not necessary to separate a head of cylinders from the block of cylinders by means of a screw-driver. Capture of a head of cylinders at removal is shown on иллюстр.
Carefully clear surfaces of a head and the block of cylinders and check planeness of their surfaces a steel ruler as it is described below.
Openings under bolts of fastening of a head of cylinders should not contain oil which can form hydraulic pillows.

Installation

The head of cylinders as follows is established:

PERFORMANCE ORDER
1. Put on a head of cylinders laying so that the inscription of OBEN/TOP was above and from a drive of the mechanism of distribution.
2. Establish a head on the block of cylinders and обстучите its rubber hammer. Directing plugs should enter into the corresponding openings.
3. Establish hydropushers, press elements and yokes. Grease details with a small amount of graphite greasing. Details should be surely established on the former places.
4. Grease with hermetic the interfaced plane of a head of cylinders.
5. Establish the case of bearings of a camshaft on a head of cylinders. Temporarily insert a camshaft wheel to be convinced that the label is in the necessary situation.
6. Screw new bolts of fastening of a head of cylinders (them always it is necessary to replace) and tighten them against the stop.
7. Tighten bolts in sequence, the return scheme provided on иллюстр.
8. The inhaling of bolts should be made with application already mentioned above a set of face heads as follows: Tighten all bolts in the specified sequence the moment of 25 Nanometers.
9. By means of a face head in the specified sequence tighten each bolt on a corner 90 ° (a turn quarter) without application of a dinamometrichesky key.
10. From this situation also in the specified sequence again tighten each bolt on 90 °.
11. Once again tighten all bolts in the specified sequence on 90 °. Thus, the dovorachivaniye on 90 ° is made three times.
The operation specified above is made as follows. The head is established on a bolt so that the handle was parallel to a head of cylinders. After turn on 90 ° the handle should occupy situation, perpendicular a longitudinal axis of a head of cylinders. In specialized workshops for observance of a corner of an inhaling use the graduated washer shown on иллюстр.
12. Fix bolts a back protective cover of a gear belt (6 Nanometers) and put on a camshaft a wheel. Holding a wheel from a provorachivaniye, tighten a bolt of its fastening the moment of 45 Nanometers.
13. Connect a final collector to a reception pipe of system of release.
14. Put on a gear belt and pull it. Details of performance of this operation are described in appropriate section.
15. All other works are carried out in sequence, return dismantling. In summary pull a belt of a drive of the generator and the power steering pump.

THE OHC ENGINE – TYPE X 20 SE – FROM THE MIDDLE OF 1995. RELEASE

Removal

Removal of a head of cylinders of this engine similarly to removal of a head of cylinders of the engine of earlier release. However there are some differences owing to change of a design of the engine. Before removal of a head of cylinders the engine should be cooled to room temperature. The head of cylinders acts in film as follows:

PERFORMANCE ORDER
1. Rasstykuyte shtekerny connection also disconnect from the inlet pipeline hoses.
2. Rasstykuyte both shtekerny connections shown on иллюстр. This connection of sensors of temperature of cooling liquid (1) and the provision of a cranked shaft (2).
3. Merge cooling liquid from system.
4. Disconnect two hoses of cooling liquid from the thermostat case.
5. Turn out bolts and remove a protective leaf of the pallet of a case.
6. Remove from a forward part of the engine a damper of krutilny fluctuations. For an exception of a provorachivaniye of a cranked shaft it is necessary to hold the central bolt at an otvorachivaniye of bolts of fastening of a damper of fluctuations, as is shown in иллюстр.
7. Remove a forward protective cover of a gear belt.
8. Rasstykuyte shtekerny connection of the sensor of temperature of cooling liquid (1) also disconnect the top hose of cooling liquid (2) from the final union. The locations of connections are shown on иллюстр.
9. The following operation should be executed before removal of a gear belt. Insert a face head into the center of a pulley of a cranked shaft and turn it in the rotation direction so that the shaft occupied the situation shown on иллюстр. The corner "And" should make 60 °.
10. Now remove a gear belt. For this purpose weaken a bolt of fastening of a tension roller and turn the adjusting clown in the arrow direction (clockwise) so that the index (1) on иллюстр. was opposite to the left emphasis. Now carefully separate a gear belt from a camshaft cogwheel.
11. Disconnect a cable eyeliner from a cover of a head of cylinders.
12. Disconnect three hoses of ventilation of a case from a cover of the case of the camshaft, two of them are located on one party (on the party of a cable eyeliner), and one is on the opposite side.
13. Unscrew bolts of fastening and disconnect a cover of the case of bearings of a camshaft.
14. Holding from a provorachivaniye a cogwheel, unscrew a bolt in the center. Remove a cogwheel.
15. Turn out two bolts from an end face of a case of a camshaft.
16. Unscrew bolts of fastening and remove a gruzozakhvatny bracket (engine transportation) from the case of bearings of a camshaft.
17. Unscrew bolts of fastening and disconnect a reception pipe with catalytic converter from a final collector. The considered knot is shown on иллюстр. 3.20
18. Unscrew for some receptions bolts of fastening of a head of cylinders in the sequence shown on иллюстр. For the first pry bolts turn away no more than on a turn quarter. "Torx 55" key is for this purpose used.
19. Remove the case of bearings of a camshaft from a head of cylinders. If necessary for office of the case it is possible to use a rubber hammer. One after another remove yokes, press elements and hydropushers and mark them. The details relating to one cylinder, store together. The arrangement of considered details before removal is shown on иллюстр.
20. Remove a head of cylinders and remove laying. Strongly sitting head of cylinders it is possible обстучать a rubber hammer. It is not necessary to separate a head from the block of cylinders by means of a screw-driver.
Carefully clear interfaced surfaces of a head and the block of cylinders and check their planeness a steel ruler as it is lower. Openings under bolts of fastening of a head of cylinders should not contain oil which can form hydraulic pillows.

Installation

The head of cylinders as follows is established:

PERFORMANCE ORDER
1. Put on a head of cylinders laying so that the inscription of OBEN/TOP was above and from a drive of the mechanism of distribution.
2. Establish a head on the block of cylinders and обстучите its rubber hammer. Directing plugs should enter into the corresponding openings.
3. Establish hydropushers, press elements and yokes. Grease details with a small amount of graphite greasing. Details should be surely established on the former places.
4. Grease with hermetic the interfaced plane of a head of cylinders.
5. Establish the case of bearings of a camshaft on a head of cylinders.
6. Screw new bolts of fastening of a head of cylinders (them always it is necessary to replace) and tighten them against the stop.
7. Tighten bolts in sequence, the return scheme provided on иллюстр. The inhaling of bolts should be made with application already mentioned above a set of face heads as follows:
8. Tighten all bolts in the specified sequence the moment of 25 Nanometers.
9. By means of a face head in the specified sequence tighten each bolt on a corner 90 ° (a turn quarter) without application of a dinamometrichesky key.
10. From this situation also in the specified sequence again tighten each bolt on a corner 90 °.
11. Once again tighten all bolts in the specified sequence on a corner 90 °. Thus, turn on a corner 90 ° is made three times.
The angle of rotation of bolts specified above is reached as follows. The head is established on a bolt so that its handle was parallel to a head of cylinders. After turn on 90 ° the handle should occupy situation, perpendicular a longitudinal axis of a head of cylinders. In repair trucks for observance of a corner of an inhaling use the graduated scale shown on иллюстр.
12. Fix bolts a back protective cover of a gear belt (6 Nanometers) and put on a camshaft a cogwheel. Holding a wheel from a provorachivaniye, tighten a bolt of its fastening the moment of 45 Nanometers.
13. Tighten bolts gruzozakhvatny eyes (15 Nanometers).
14. Connect a reception pipe of the exhaust silencer to a final collector.
15. Put on and pull a gear belt.
16. All other works are carried out in sequence, return dismantling. In summary pull a belt of a drive of the generator and the power steering pump. Bolts of fastening of a damper of krutilny fluctuations tighten the moment of 20 Nanometers, holding a cranked shaft from a provorachivaniye.

THE OHC ENGINE OF 2.4 L (C 24 NE) (WITH THE CHAIN DRIVE OF THE MECHANISM OF DISTRIBUTION)

Removal

The head of cylinders acts in film only in a cold condition of the engine, i.e. at oil temperature no more than 20 ° Page.

PERFORMANCE ORDER
1. Disconnect a weight cable from the storage battery.
2. Disconnect a reception pipe of the exhaust silencer from a final collector. For this purpose it is necessary to use a head with the extension piece.
3. Weaken fastening of both collars shown by shooters on иллюстр. also remove a hose of absorption of air.
4. Merge liquid from cooling system.
5. Disconnect all hoses from the case of the thermostat and the pump of cooling liquid.
6. Disconnect a cable of a drive of a butterfly valve.
7. Rasstykuyte shtekerny connection of gates of injection and butterfly valve potentiometer.
8. Disconnect a weight cable from the inlet pipeline, having unscrewed the screw.
9. Mark both fuel hoses according to иллюстр. also remove, having weakened fastening of collars. Be careful – fuel can be under pressure.
10. Disconnect a tube of ventilation of a case of a camshaft from the inlet pipeline.
11. Uncover heads of cylinders, as is shown in иллюстр., having unscrewed bolts. Under a cover there is a camshaft. With Rasstykuyte one after another shtekerny connections of spark plugs, previously having marked them.
12. Establish the cylinder No. 1 piston in VMT. For this type of the engine to make it it is necessary precisely. Deepening in a camshaft should be in the situation shown on иллюстр. Besides in a flywheel there is a ball which should be opposite to a pin in the block of cylinders.
13. Remove a forward protective cover from a head of cylinders.
14. Turn out from a camshaft the plastic restrictive screw of supply of fuel and remove a cogwheel, holding a camshaft from a provorachivaniye. For this purpose the key which is inserted is required mnogoshlitsevy how is shown on иллюстр.
15. Turn both inserted from above the screw on the left and to the right outside. Screws fix the control unit to a head of cylinders.
16. Unscrew bolts of fastening of a head of cylinders evenly on a spiral outside inside. At first on a turn quarter, and then on a half of turn. It is necessary to apply a strong face key-shestigrannik to an otvorachivaniye of bolts. It is necessary to apply to an otvorachivaniye of two back bolts a shestigrannik on 10 mm of different length. A bolt (And = the right side), shown on иллюстр., the bolt (In = the left side) – a key in length of 103 mm turns away a key, in the length of 73 mm.
Application of keys of other length can cause difficulties at an otvorachivaniye of bolts.
17. Remove a head of cylinders from the block, thus it is necessary to watch to damaging the switch of a butterfly valve and a zaslonka.
18. Carefully clear interfaced surfaces of the block of cylinders and a head. For this purpose it is possible to use a flat shaber. Carefully remove the laying remains.

Installation

The head of cylinders in sequence is established, to return to its removal. Thus it is necessary to pay attention to the following:

PERFORMANCE ORDER
1. The interfaced planes of the case of bearings of the mechanism of distribution and the block of cylinders become covered by hermetic. The Opel firm uses for this purpose the hermetic No. 1503294 sold in tubes. Hermetic is put with the roller in width of 3 mm in a place shown on иллюстр. In this place there is a deepening where the rubber sealing ring is inserted. An epiploon (And) replace.
2. Put new laying and establish a head of cylinders, watching that. that directing plugs entered into openings.
3. Screw one after another new bolts of fastening of a head of cylinders and tighten them by hand. Tighten bolts in the sequence shown on иллюстр. Pay attention to an inhaling of two back bolts (look the instruction below):
– all bolts shown on иллюстр., tighten the moment of 60 Nanometers;
– all bolts shown on иллюстр. are tightened without application of a dinamometrichesky key on a corner 90 ° (a turn quarter).
Back bolts of fastening of a head of cylinders: Owing to feature of a design the tightening of back bolts cannot be made at once on a corner 90 °. At first one bolt on a corner 30 °, then another is tightened. It is necessary to apply face keys of various length.
4. Establish on a head of cylinders a cover of a drive of the mechanism of distribution (the moment of an inhaling of 25 Nanometers).
5. Check, that markings on a cogwheel of a camshaft and a camshaft arm coincided, and the ball on a flywheel was opposite to a pin in the block of cylinders. Fix a camshaft cogwheel the moment of 25 Nanometers (look иллюстр.).
6. Establish the new plastic screw of restriction of supply of fuel.
7. Further it is necessary to measure a gap between persistent surfaces of a cover and the restrictive screw. For this purpose enter щуп in a place specified on иллюстр. If the gap falls outside the limits 0.1 – 0.2 mm, the cover is necessary for removing and adjusting again, having struck blow with a stupid opravka to a persistent surface.
8. Check, whether interfaced surfaces are well cleared and establish new laying under a cover of a head of cylinders. In Opel firm repair trucks to consolidation apply "Pattex". Long bolts establish under an arm.
9. Join shtekerny connections of spark plugs.
10. Attach a hose of ventilation of a case to the inlet pipeline.
11. According to marking connect топливопроводы.
12. Attach to the inlet pipeline a weight cable.
13. Join all shtekerny connections, attach a cable of a drive of a butterfly valve and vacuum hoses.
14. Other works are made in sequence, return dismantling. It is necessary to grease bolts of connection of a reception pipe of the exhaust silencer and a final collector with graphite greasing. The hose of absorption of air joins according to иллюстр.

DOHC ENGINE

Removal

Head of cylinders before removal to cool to room temperature.

PERFORMANCE ORDER
1. Disconnect a weight cable from the storage battery.
2. Merge liquid from cooling system as it is described in the section the Section Filling of a cooler of system of cooling of Head the Current leaving and service. Cooling liquid can be collected in capacity and to use repeatedly if it was not too long maintained.
3. Rasstykuyte all shtekerny connections also disconnect hoses from the inlet pipeline.
4. Rasstykuyte the shtekerny connections shown on иллюстр. The tip (1) belongs to EGR system (A retsirkulyatsiya of the fulfilled gases), the tip (2) belongs to the sensor of the index of temperature of cooling liquid, the tip (3) also belongs to the sensor (another) of temperature of cooling liquid. A cable plait (4) disconnect from a collar and take aside.
5. Rasstykuyte two other shtekerny connections. One tip belongs to the ignition module, another to the regulating gate of an adsorber. The last is called also as the evaporator gate.
6. Disconnect a hose of cooling liquid from an adapter on the ignition module.
7. Lift and establish a forward part of the car on supports. Unscrew bolts and remove a guard of the pallet of a case from the chassis.
8. Remove from the forward party of the engine a damper of krutilny fluctuations. For prevention of a provorachivaniye of a cranked shaft at an otvorachivaniye of bolts of fastening of a damper hold the central bolt.
9. Unscrew bolts and disconnect a reception pipe from a final collector.
Uncover cables of spark plugs a cover of a head of cylinders.
10. On the party of a drive of the mechanism of distribution, approximately in the center of a gear belt расстыкуйте shtekerny connection (the sensor of provision of a camshaft).
11. Unscrew screws and uncover cables a protective cover of a gear belt, take aside cables and, having unscrewed all bolts, remove a protective cover.
12. Now remove a gear belt. For this purpose weaken a bolt of fastening of a tension roller and turn the adjusting clown in the arrow direction (clockwise) so that the index (1) on иллюстр. was opposite to the left emphasis (identical to OHC and DOHC engines). Now carefully remove a gear belt from a camshaft wheel.
13. Disconnect two hoses of cooling liquid from branch pipes.
14. Disconnect the top hose of cooling liquid from the thermostat case. The hose (1) is shown on иллюстр.
15. Disconnect an air hose from the return valve of system of secondary air. At new engines this system is absent.
16. Disconnect and take out a ventilating hose (1) on иллюстр.
17. Rasstykuyte shtekerny connections of spark plugs. For this purpose there is a special tool.
Uncover heads of cylinders. Pay attention to existence of a sealing ring.
18. Holding both cogwheels of a camshaft from a provorachivaniye the wrench which has been put on on a shestigrannik of a camshaft, unscrew bolts of fastening of wheels. Remove both cogwheels. Turn out also the sensor of provision of the camshaft, located in the middle between both camshafts.
19. Unscrew 5 bolts (two from below, three from above) and remove an internal guard of the engine.
20. Before removal of covers of bearings of a camshaft it is necessary to pay attention to digital marking of covers that will help to establish later them on the former places. Weaken nuts of fastening of covers for some receptions cross-wise (each reception from a half of turn to one turn) so that they freely turned away. One after another remove covers and take out camshafts. Ahead there is a persistent bearing.
Remove from a camshaft an epiploon. The arrangement of marking of covers is shown on иллюстр.
21. Unscrew bolts of fastening of a head of cylinders for some receptions in the sequence shown on иллюстр. For the first reception bolts turn away on a corner which is not exceeding a quarter of a turn. Bolts turn away a face key of "Torx 55". On иллюстр. the engine with eight valves, however an arrangement of bolts at the considered engine the similar is shown.
22. Remove a head of cylinders and remove laying. Strongly sitting head of cylinders it is possible обстучать a rubber hammer. It is not necessary to separate a head of cylinders from the block of cylinders by means of a screw-driver.
Carefully clear surfaces of a head and the block of cylinders and check planeness of their surfaces a steel ruler as it is described below. Openings under bolts of fastening of a head of cylinders should not contain oil which can form hydraulic pillows.

Installation


The head of cylinders as follows is established:

PERFORMANCE ORDER
1. Put on a head of cylinders laying so that the inscription of "OBEN/TOP" was above and from a drive of the mechanism of distribution.
2. Establish a head on the block of cylinders and обстучите its rubber hammer. Directing plugs should enter into the corresponding openings.
3. Screw new bolts of fastening of a head of cylinders (them always it is necessary to replace) and tighten against the stop.
4. Tighten bolts in sequence, the return scheme provided on иллюстр. The inhaling of bolts should be made with application already mentioned above a set of face heads as follows:
– tighten all bolts in the specified sequence the moment of 25 Nanometers;
– by means of a face head in the specified sequence tighten each bolt on a corner 90 ° (a turn quarter) without application of a dinamometrichesky key;
– from this situation also in the specified sequence again tighten each bolt on 90 °;
– once again tighten all bolts in the specified sequence on a corner 90 °. Thus, turn on 90 ° is made three times.
The angle of rotation of bolts specified above is reached as follows. The head is established on a bolt so that its handle was parallel to a head of cylinders. After turn on a corner 90 ° the handle should occupy situation, perpendicular a longitudinal axis of a head of cylinders.
5. Grease with graphite greasing working surfaces of hydropushers and necks of camshafts and lay camshafts in a head of cylinders.
6. Grease with hermetic a being interfaced surface of the forward directing bearing (1) on иллюстр. also establish the bearing. Establish other covers of the bearing. At once check, whether markings of covers coincide with the corresponding markings on a head of cylinders (иллюстр. above).
7. Tighten nuts of fastening of covers cross-wise the moment of 8 Nanometers.
8. Tighten bolts a back protective cover of a gear belt. Screw the sensor of provision of a camshaft (6 Nanometers).
9. Put on cogwheels camshafts labels outside. The provision of cogwheels is shown on иллюстр. In the center "EH" and "IN" marking is visible. Cogwheels put on so that the wheel of a camshaft of inlet valves entered into an opening having marking of "EH".
10. Insert bolts and, holding a camshaft a wrench for a shestigrannik, tighten them. At first the moment of 50 Nanometers, then from the reached situation on a corner 60 ° and at the end once again on 15 °.
11. Turn camshafts so that the label on a cogwheel (2) rose opposite to a nouse on a forward cover of the bearing (1). Turn in the rotation direction a cranked shaft (a head on the central bolt of a cogwheel) so that marking on a wheel of a cranked shaft was opposite to a label of the block of cylinders. After that put on a gear belt and pull it as, it is described in appropriate section for the DOHC engine.
12. Establish a cover of a head of cylinders with new sealing rings.
13. Other works are carried out in sequence, return dismantling. At assembly maintain the next moments of an inhaling: damper of krutilny fluctuations of 20 Nanometers, flange of system of ventilation of a case (new laying) 25 Nanometers, forward and back protective covers of a gear belt of 8 Nanometers, cover of spark plugs of 3 Nanometers.

Dismantling and assembly of a head of cylinders


Because the design of a head of cylinders depends on engine type, the description of the section of assembly and dismantling of a head of cylinders is provided separately for each type of the engine. The description of dismantling and assembly of a head of cylinders irrespective of below is provided, it was under repair or not.

THE OHC ENGINE – WITH THE GEAR BELT OF THE DRIVE OF THE MECHANISM OF DISTRIBUTION


Dismantling

PERFORMANCE ORDER
1. Take out hydropushers and put as installation.
2. In the established sequence disconnect from a head of cylinders a branch pipe of cooling liquid, the thermostat case, the holder of the module of ignition, a spark plug (a special key), the heat-shielding screen, a final collector and the inlet pipeline.
3. Klapannye plates have marking (marks chertilky), as is shown in иллюстр., that allows to establish at assembly them on former places.
4. For removal of valves it is necessary to apply the adaptation to compression of klapanny springs. The adaptation is established not a head of cylinders, as is shown in иллюстр. By pressing the lever of the adaptation klapanny springs are compressed. After that crackers, springs, plates and maslootrazhatelny caps can be removed. Further directing plugs are taken out.
5. Remove carefully maslootrazhatelny caps by means of a screw-driver or nippers from directing plugs. Under them there are basic washers of springs which can be removed now. Caps should be thrown out at once (are subject to replacement).
Carefully clear all details and if it is required, check according to subsection requirements "Repair of a head of cylinders".

Assembly

Assembly is made as follows:

PERFORMANCE ORDER
1. Grease valves with impellent oil and insert in directing (according to marking).
2. Put on valves and directing maslootrazhatelny caps. For an exception of damage of caps put on for the ends of cores of valves protective plastic tips (иллюстр.).
3. After installation of a spring, remote rings (final valves - 1), basic washers (inlet valves - 2), maslosjemny caps (3) and plates (5) compress springs (4) and insert crackers (6). Internal surfaces of crackers grease with a thin layer of greasing that they were pasted. Slowly release a spring, watching that crackers were correctly established.
The head of cylinders in sequence, its return dismantling gathers. Thus it is necessary to maintain the next moments of an inhaling: (look Specifications).
4a. Laying of hoses of the OHC engine from the middle of 1995 of release.
4b. At the OHC engine from the middle of 1995 of release on the case of bearings of a camshaft the cover with cardboard laying is established.
5. In summary oil hydropushers and insert them into the corresponding openings of a head of cylinders. Do not interchange the position of pushers.

INSTRUCTIONS ON THE OHC ENGINE WITH THE DISTRIBUTION DRIVE FROM THE GEAR BELT

At older models of engines "From 20 NE" at final valves devices of turn of valves, and at final valves steel rings are established. Differences in a design of valves are visible on иллюстр. above. With the advent of the engine devices of turn of valves were cleaned by "the X-th 20 SE", and on their place remote washers are established.
At the new engine the hose of ventilation of a case is deduced not to a case, and to a cover of bearings of a camshaft. Laying of hoses is shown on иллюстр. point 4а. Established on old model of the engine the distributor of ignition is replaced at the new engine with the ignition module. The case of bearings of a camshaft is closed by cardboard laying. It excludes application of an epiploon of a camshaft (иллюстр. point 4b).

PERFORMANCE ORDER
1. At new model of the engine heat-shielding pipes for protection of shtekerny connection of spark plugs are established. Here candles with a turnkey shestigrannik "on 16" were applied. Pipes act in film the special KM-834 tool.
2. The module of ignition mentioned above is behind, to the right of the engine in a place shown on иллюстр.

THE OHC ENGINE – WITH THE CHAIN MECHANISM OF DISTRIBUTION


Dismantling

PERFORMANCE ORDER
1. Unscrew bolts of fastening and remove the inlet pipeline, a final collector and the thermostat case.
2. Remove yokes and pushers. Unscrew bolts and remove both covers, back and lateral.
3. Carefully take out a camshaft from bearings, without striking cams and necks on working surfaces of bearings.
Instruction

The camshaft of the considered engine has "U" marking on a face surface. Besides, the camshaft has two-colored сине / brown marking. The camshaft with violet marking is repair at which diameter of necks is reduced by 0.10 mm.


4. Take out valves as it was described earlier, and spread out them as installation.
5. Take out nippers maslootrazhatelny caps.
6. Turn out spark plugs.

Assembly

The head of cylinders as follows gathers:

PERFORMANCE ORDER
1. Put on new maslootrazhatelny caps on directing valves (see иллюстр.) and напрессуйте their piece of a pipe.
2. Plentifully grease the maslootrazhatelny caps directing and cores of valves by oil and establish into place. Valves establish on the places according to marking or if they were ground, in the corresponding directing. Inlet valves have carving elements, final have no.
3. Plentifully oil necks of a camshaft and insert a shaft in front into a head of cylinders and prop up it through assembly openings.
4. Establish yokes and pushers.
5. Establish on places other removed details.

DOHC ENGINE


Dismantling

PERFORMANCE ORDER
1. Remove a flange of a supply of cooling liquid and the thermostat case.
2. Unscrew bolts and remove from a head of cylinders the holder of the module of ignition.
3. Remove the inlet pipeline and a final collector, unscrew bolts of fastening and remove eyes from a head of cylinders. Remove also load-lifting eye.
4. Remove valves as it was described for the OHC engine. The same treats removal of maslootrazhatelny caps. Valves as their installation on heads of cylinders insert into a cardboard box, having pierced its bottom. From a box where valves of a forward part of the engine are located put the corresponding marking.
5. Remove nippers basic washers of springs. All details carefully clear and check, how it is described in subsection "Repair of a head of cylinders". In need of a detail replace.
The head of cylinders in sequence, return dismantling and according to the description for the OHC engine gathers. Thus it is necessary to maintain the next moments of an inhaling: (see. Specifications).
In summary insert hydropushers into the corresponding openings (plentifully grease). The pushers which were in the use insert into the openings.

THE INSTRUCTION FOR THE DOHC ENGINE FROM THE MIDDLE OF 1995. RELEASE


PERFORMANCE ORDER
1. The engine of this type from the middle of 1995 of release has the valve of a retsirkulyatsiya of the fulfilled gases and the valve of ventilation of the fuel tank, the heads of cylinders located on a reverse side as it is shown on иллюстр.
2. At this engine the system of supply of secondary air is established also. Under certain conditions the electropump submits to operation additional air to a final collector for decrease in the content in the fulfilled gases of harmful substances. Thanks to it the temperature of the fulfilled gases raises also that in turn increases efficiency of effect of catalytic converter.
Before removal of a head of cylinders it is necessary to remove from a final collector of a detail of system of supply of secondary air. On a branch pipe of supply of air before its installation on a final collector the sealing ring should be replaced. The arrangement mentioned above details is shown on иллюстр. The module of ignition is behind, on the right on a head of cylinders just as it is shown on иллюстр. above.

RECOMMENDATION ABOUT REPAIR OF ENGINES OF ALL TYPES

The piece of a pipe established on the top plate of a spring can be applied to removal of valves. The bottom basic washer should have a good support thus. Strike with a hammer sharp blow to a pipe piece so that crackers jumped out. They should remain in a pipe. That crackers did not fly away aside, the pipe should have good contact to a plate.

Repair of a head of cylinders

Given below the instruction treat the OHC engine. Concerning the differences concerning other engines, instructions are provided in the section end.

KLAPANNYE OF THE SPRING

PERFORMANCE ORDER
The length of a spring changes in a free condition, as is shown in иллюстр. All springs should have identical length.
The special adaptation should be applied to control of effort of a spring. At its absence arrive as follows:
1. Compare the spring which was in the use to the new. For this purpose springs put one to another and clamp in a vice. If springs are deformed on the same size, it indicates approximately their equal rigidity.
2. If the spring which was in the use is compressed more than new, it indicates fatigue of a spring and it should be replaced in a set.
3. Establish springs one after another on an equal surface (for example, on glass) the closed round down. Near a spring put a steel square. The gap between a spring and a square should not exceed 2.0 mm. The big size of a gap indicates a spring deformation. In this case the spring is replaced.

DIRECTING PLUGS OF VALVES

PERFORMANCE ORDER
1. Clear directing plugs by means of a fabric moistened in gasoline. Clear also cores of valves. After that insert valves into the directing.
2. Establish on heads of cylinders on the holder the indicator (иллюстр.). Put forward the valve from directing so that its end was aflush with an edge of a head of cylinders directing on another party, moving a plate of the valve forward and back in the arrow direction.
3a. Move a hand a plate of the valve and take readings of the indicator. If the indicator shows a deviation more than 1.0 mm at inlet and more than 1.3 mm at the final valve, in most cases it indicates need of replacement directing. Measurement of internal diameter directing and external diameter of a core of the valve by means of a micrometer, as shown, respectively on иллюстр gives more exact results. 3a and 3b in several sections and the directions.
At the left measurement places are shown.
3b. The difference between the greatest value of diameter of the plug and to the smallest values of diameter of a core gives a gap in interface. At replacement of directing plugs it is necessary to mean the following:
4. In the course of assembly at plant on the engine valves with the increased repair size can be established.
5. Directing plugs and valves have marking. Details with the minimum amount of marking have no, the details going as spare parts have marking "To". Other markings mean the following (in brackets designation spare directing):
6. Directing plugs can be developed the next repair size. In this case on the directing the corresponding marking is put. Are developed directing from above (иллюстр.).
7. Check the general condition of a head of cylinders before replacing the directing.
8. Directing выпрессовывается from a head of cylinders from the combustion chamber by means of an opravka. Opravka should have on the end a pro-point, diameter equal to internal diameter of the directing.
9. If are replaced directing, to replacement are subject as well valves. After that it is necessary to grind in saddles of valves.
Plentifully grease new directing and press them from a camshaft in a cold head of cylinders.
10. Develop directing after a press fitting special development. If such development is not present, it is possible to use adjustable development. To develop directing it is necessary taking into account a gap given in Specifications. If replacement directing is made, saddles of valves should be milled. Therefore at first it is necessary to read the instructions provided in subsection "Saddle of valves".

SADDLES OF VALVES

Control of saddles of valves is made by means of special Cali. Owing to complexity of considered work it is recommended to hand over a head of cylinders in repair in a repair truck.

PERFORMANCE ORDER
1. Check all saddles on existence of wear tracks and any damages. It is possible to eliminate small wear tracks with a mill with a corner 45 °. If saddles have considerable wear, they are necessary for milling. It is necessary to mean that saddles should not run into a head of cylinders too deeply. For this purpose the valve is inserted into an opening and on the other hand the length of an acting part of a core of the valve in special calibre is measured.
2. Saddles should be milled, if new directing plugs were established. It is made as follows:
– mill a saddle at an angle 45 °;
– slightly mill the top edge of a saddle at an angle 15 °, and bottom at an angle 60 ° so that the width of a working facet of a saddle of the inlet valve made 1.0 – 1.5 mm, and final 1. 7–2.2 mm.
If as a result of milling of saddles the core of the valve acts too far from a head of cylinders, it is necessary to carry out measurement with new valves. If in this case the result turns out unsatisfactory, it is necessary to change a head of cylinders.
At the OHC engine of a saddle of valves are not subject to replacement.
3. After milling of saddles they should be ground in. For this purpose pritirochny paste is put on a surface of a saddle, and the valve is inserted into the nest. On a head of the valve the sucker and the valve is established turns alternately in both parties (иллюстр.). Periodically the valve should be lifted a sucker and to turn on a turn quarter.
4. After grinding in all details carefully clear of pollution and paste and check interface of the valve to a saddle. Interface is satisfactory if as a result of a valve povorachivaniye on details there is the continuous and well visible ring which width is equal to width of the interfaced surface.
5. Put with a pencil strokes on all circle of a working facet of the valve at distance about 1 mm from each other. After that carefully lower valves in an opening of the directing plug and turn the valve on 90 °, having slightly pressed it.
6. Again take out the valve and check, whether pencil strokes from a working facet of a plate of the valve disappeared. If the width of a working facet corresponds set, the head of cylinders can be established into place. Otherwise saddles demand processing. In case of impossibility of achievement of preset values machining of a head of cylinders is subject to replacement. Concerning repair of a head of cylinders you can receive consultations in a repair truck.

VALVES

Insignificant damages on a working surface of a head of the valve can be corrected by grinding in as it is described above.

PERFORMANCE ORDER
1. Measure the parameters of valves specified on иллюстр (a = diameter of a plate of the valve, b = diameter of a core of the valve). In case of discrepancy to preset values valves replace with the new. Keep in mind differences between inlet and final valves. Necessary data are provided in Specifications.
2. If the ends of cores of valves have wear, valves are replaced, as cores are not ground.
3. Plates of valves can be ground on the special grinder. However this operation cannot more than 1-2 times are made. As it was already mentioned, the valve vystupaniye from a reverse side of a head of cylinders should have a certain size which as a result of grinding of a plate of the valve can change.

The damaged valves can be restored by means of grinding in. If it does not manage to be reached, the valve is replaced. It is necessary to measure diameters of cores of valves and openings of directing plugs and on the basis of the received result to draw a conclusion on expediency of carrying out further works with a head of cylinders.

HEAD OF CYLINDERS


PERFORMANCE ORDER
1. Carefully clear interfaced surfaces of a head and the block of cylinders. Check a surface of a head of cylinders on not planeness. For this purpose impose on a surface a steel ruler, as is shown in иллюстр., also check shchupy a gap between a ruler and a surface of a head of cylinders. If in a gap passes щуп more than 0.10 mm, the head of cylinders is necessary for grinding.
2. If the gap is even more, it is necessary to replace a head of cylinders.

The head of cylinders can be ground until its height did not become minimum admissible (see. Specifications). Otherwise it is necessary to replace a head of cylinders. It is necessary to take also into consideration need of observance of a certain size of a vystupaniye of the valve over a head of cylinders.

CAMSHAFT


The works connected with a camshaft are described in subsection "The gazoraspredeleniye mechanism".

Assembly of a head of cylinders

The head of cylinders gathers according to already given above in the section "Dismantling and assembly of a head of cylinders" instructions according to engine type.

ONLY FOR THE ENGINE OF 2.4 L


PERFORMANCE ORDER
1. For working capacity restoration valves can be ground 1-2 time (repair truck work). Watch that the width of working facets of heads of valves did not leave for the established values.
2. As it was described above, the vystupaniye of a core of the valve over a head of cylinders should have a certain size. For measurement the special tool is used.
3. The corner of a working facet of a plate of the valve makes 44 °, a corner of a working facet of a saddle of the valve 45 °. It is not necessary to confuse them.
4. There are directing plugs of two repair sizes (diameters are increased by 0.075 and 0.150 mm). The corresponding marking is put on the right and left parties of an opening under spark plugs.
5. The width of a working facet of a saddle makes 1.15 – 1.65 mm for inlet and 1.5 – 2.0 mm for final valves. The top adjustment corner makes 30 ° and bottom 75 °.
6. The width of a working facet makes 2.6 – 3.0 mm at inlet and 3.7 – 4.1 mm at final valves.
7. The gap in interface of a core of the valve to the directing plug makes 0.035 – 0.073 mm at inlet and 0.045 – 0.085 mm at final valves. There are valves of the repair sizes. It is necessary to mean that at plant can be established directing the repair sizes.
8. Check in the way described above not planeness of an interfaced surface of a head of cylinders. On length of 150 mm the gap should not exceed 0.015 mm. On all greatest length not planeness should not exceed 0.04 mm. As a result of polishing of a head of cylinders its minimum height should not be less than 102.45 mm.

REALLY ONLY FOR THE DOHC ENGINE

PERFORMANCE ORDER
1. Compare the data received as a result of measurement of size of a vystupaniye of the valve, with the data provided in Specifications. If data leave for the established values, the head of cylinders is replaced (previously it is necessary to insert new valves and to measure vystupaniye size with them).
2. For the engine of this type are available directing the normal size and two repair directing with a diameter increased by 0.075 and 0.150 mm. Marking corresponds to OHC engine marking.
3. The width of a working facet of the inlet valve makes 1.0 – 1.4 mm, final 1.4 – 1.8 mm.
4. The height of a head of cylinders between two interfaced planes at the DOHC engine is various (134.0 mm).
5. If the plate of the valve is ground on the machine, it is necessary to maintain a corner of a facet 44 ° 40'’.
6. The ends of cores of valves are not ground. However they should not have any забоин.
7. Measure valves according to the scheme on иллюстр. 6.186 also compare the obtained data with data of Specifications. Too narrow working facets of valves reduce tightness of the chamber of combustion.
8. The corner of a working facet of a saddle of the valve makes 45 ° (2). The top adjustment corner is equal 30 ° (1), bottom 60 ° (3). The scheme of an arrangement of corners is shown on иллюстр.