65637bd9



3.2.1.11. Head of cylinders

Prevention

To facilitate assembly, apply tags on the removed arms, and also to designate routes of laying of wires and hoses.

Removal
PERFORMANCE ORDER
1. Merge cooling liquid.
2. Remove cam-shafts (see subsection 3.2.1.9).
3. Keep in mind that in the description given below removal of a head assembled with the final and soaking-up collectors is meant. At the same time amount of works on removal of a head decreases, but manipulations with a head because of the increased amount and weight of all assembly are at a loss. It is recommended to remove at first both collectors (see subsection 6.1.12 and subsection 6.1.13).
4. On engines with preliminary preparation toplivno – air mix (single-channel system of injection) execute the following events:

  – remove the air filter;
  – execute actions for a decompression of fuel system and disconnect a hose of supply of fuel and the return hose from the camera of a butterfly valve (muffle all openings to exclude losses of fuel and hit of dirt in fuel system);
  – disconnect a cable of the drive of a butterfly valve;
  – disconnect conducting sockets from the camera of a butterfly valve, the soaking-up collector and other details;
  – disconnect hoses of the vacuum amplifier of brakes, cooling systems and systems of ventilation of a case from the corresponding valves and branch pipes mounted on a head of cylinders;
  – remove a basic arm of the soaking-up collector;
  – disconnect a reception pipe of the muffler from a final collector.
5. On engines with direct injection of fuel (with multichannel system of injection) execute the following events:

  – remove the air filter and an air duct;
  – execute actions for a decompression of fuel system and disconnect a hose of supply of fuel and the return hose from the fuel distributor (muffle all openings to exclude losses of fuel and hit of dirt in fuel system);
  – disconnect a cable of the drive of a butterfly valve;
  – disconnect conducting sockets from the camera of a butterfly valve, the soaking-up collector and other details. Disconnect conducting from nozzles and take aside that did not prevent removal of a head of cylinders;
  – disconnect hoses of the vacuum amplifier of brakes, cooling systems and systems of ventilation of a case from the corresponding valves and branch pipes mounted on a head of cylinders;
  – remove a basic arm(s) of the soaking-up collector;
  – disconnect a reception pipe of the muffler from a final collector.
6. On the cars equipped with automatic transmission disconnect a cable of switching to a low gear from the camera of a butterfly valve.
7. Weaken collars and disconnect hoses from the pump of cooling liquid, from a radiator of a heater and from the oil cooler (if it is provided). Disconnect also cooling system radiator hoses in a forward part of a head of cylinders.
8. On engines with direct injection of fuel of modification of Phase I remove a starter (see subsection 7.6) then weaken and turn off a bolt of fastening of pipelines of cooling liquid to a back part of the block of cylinders.
9. Disconnect conducting sockets from the ignition distributor, from the coil of ignition and from the transistor power supply unit. Disconnect a conducting sleeve from collars, take aside from a head of cylinders. Turn off bolts and remove all wires on weight fixed on a head of cylinders and on the soaking-up collector.
10. Release bolts of fastening of an arm of the generator to a head of cylinders.
11. Weaken an inhaling and turn off M6 bolts fixing a head of cylinders to a cover of a chain of the gas-distributing mechanism (if these bolts are not turned off yet), turn off also a bolt in a forward part of a head of cylinders.
12. Working in the sequence, return represented on the scheme, weaken an inhaling of all ten main bolts of fastening of a head of cylinders. Weaken bolts in stages, on 1/2 turns for reception until bolts do not begin to turn away by hand.
13. Get bolts and washers, having paid attention to their situation in a head of cylinders.
14. Remove a head of cylinders. It is desirable to carry out this operation with the assistant as a head assembled with cam-shafts quite heavy (especially if collectors are not removed). Remove laying from the block of cylinders, having paid attention to two adjusting pins. If pins get from openings, then remove them, having remembered the provision of initial installation, and you store with a head of cylinders. Pay also attention to the correct installation of oil nozzles in the block of cylinders. If nozzles are weakened and they can be taken out, then remove them and you store together with a head of cylinders.
15. Check existence of damages on demountable surfaces of a head and the block of cylinders (deep scratches, chips, etc.). Insignificant damages are removed a file, serious damages are removed only grinding.
16. If the head understands for capital repairs, then be guided by the description in the corresponding subsection.

Preparation for assembly

PERFORMANCE ORDER
1. The manufacturer recommends to measure bolts of fastening of a head of cylinders for the purpose of definition of their further suitability. Measure length of each bolt (previously having removed washers) from an internal surface of a head of a bolt to an end face of a carving part. If length of all bolts less than 158,2 mm, then bolts can be used. If length at least of one of bolts exceeds 158,2 mm, then all bolts in a set should be replaced. Taking into account those efforts which test bolts of a head of cylinders it is strongly recommended to replace them irrespective of a state.
2. Before installation of a head of cylinders on the engine carefully clear demountable surfaces of a head and the block. Remove the remains of a deposit and material of laying with the firm plastic or wooden pallet, clear also of a deposit of the bottom of pistons. When cleaning observe extra care as surfaces can be damaged easily. Also take the measures excluding hit of the deleted deposit to oil canals or channels of the cooling system in the block of cylinders, otherwise blocking of channels and violation of lubricant of details of the engine is possible. An adhesive tape and paper close openings of oil channels, channels of the cooling system and an opening under bolts in the block of cylinders. To exclude hit of dirt in a gap between the piston and the cylinder cover a gap with jellied lubricant on edge of the bottom of the piston. After cleaning of pistons remove with a brush lubricant from a gap and wipe the lubricant remains pure rags.
3. Check existence of damages on demountable surfaces of a head and the block of cylinders (deep scratches, chips, etc.). Insignificant damages are removed a file, serious damages are removed only grinding.
4. If there are suspicions on deformation of demountable surfaces, then check a deviation of these surfaces from the plane by means of caliber.

Installation

PERFORMANCE ORDER
1. Wipe dry demountable surfaces of a head and the block of cylinders. Put into place two adjusting pins (if acted) and insert oil nozzles into the block of cylinders.
2. Put new laying on the block of cylinders, having combined openings in laying with pins.
3. With the assistant carefully install a head on the block of cylinders, having combined a head with adjusting pins.
4. Grease carvings and the lower parts of heads of bolts with pure oil. Dress on bolts of a washer and carefully insert bolts into the corresponding openings in a head of cylinders (to drop bolts in openings it is not allowed). Wrap bolts and tighten by hand.
5. Tighten the main 10 bolts of fastening of a head of cylinders in the specified sequence, with the moment corresponding to the 1st stage of an inhaling. To tighten a dynamometer key with a face head.
6. After performance of the 1st stage of an inhaling tighten bolts with the moment of the 2nd stage.
7. Wait minute and release bolts in the sequence return specified on the scheme of tightening of bolts in item 5. Weaken an inhaling gradually, on 1/2 turns for reception until bolts do not begin to turn away by hand.
8. Again tighten 10 bolts by hand, then tighten, observing the sequence, with the moment of the 3rd stage of an inhaling.
9. After performance of the 3rd stage, tighten bolts on the corner specified for the 4th stage of an inhaling. The inhaling at this stage is recommended to be carried out a key with an angular scale to provide exact implementation of requirements to an inhaling. In the absence of a key with an angular scale apply with tag paint on a head of a bolt and on a surface of a head of cylinders. Tags have to settle down under the set corner. On these tags it is necessary to be guided when performing the 4th stage of an inhaling.
10. After performance of the 4th stage of an inhaling of the main bolts of a head of cylinders tighten bolts with the moment of the 5th stage, observing the specified sequence.
11. After a final inhaling of the main bolts of a head of cylinders wrap M6 bolts in a forward part of a head of cylinders and tighten them with the set moment.
12. Lay conducting still to a route, connect conducting sockets to the ignition distributor, to the coil of ignition and to the transistor power supply unit. Fix conducting in the place by bindings and collars.
13. Attach to a head of cylinders and to a wire collector, going on weight, reliably tighten bolts.
14. On engines with direct injection of fuel of modification of Phase I screw a bolt of fastening of a branch pipe of the cooling system in the block of cylinders and reliably tighten. Establish a starter (see subsection 7.6).
15. Attach cooling system hoses, observing an initial order of their installation, fix hoses by collars.
16. Being guided by the corresponding Part in Chapter 4, execute the following operations:

  – attach all conducting, hoses and cables of management to details of fuel system and to the soaking-up collector;
  – establish a basic arm of the soaking-up collector;
  – attach a reception pipe of the muffler to a final collector;
  – install the air filter and the channel of an air duct (if it is provided).
17. On the cars equipped with automatic transmission attach and adjust a cable of switching to a low gear.
18. Establish cam-shafts (see subsection 3.2.1.9).