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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Hyundai Getz (2002 release)

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Hyundai Getz
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Hyundai
Getz
Operation and Maintenance
Engine
Technical specifications Engine
Technical specifications Engine
Specifications Engine displacement of 1.5 and 1.6 liters
Specifications Engine displacement of 1.5 and 1.6 liters
Technical specifications of cars with engine capacity of 1.1; 13; 1.5 and 1.6 liters
The engines working volume of 1,1 and 1,3 l
The technical condition of the engine
General comments on the repair of engines
Removal and installation of the power unit
The general sequence of disassembly of the engine
Running the engine after repair
Checking the engine on the car after repair
Cylinder block
The connecting rod-piston group
The crankshaft and flywheel
Cylinder Head
The camshaft and its drive
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Lubrication system
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Possible engine malfunction, their causes and remedies
Malfunctions of hydraulic valve lifters
Malfunction of the fuel system and their solutions
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The connecting rod-piston group



Withdrawal
Remove the cylinder head, flywheel, oil pan, oil pump and nozzle maslozaborny.
Remove the ledge at the top of the cylinder, formed as a result of wear and tear.
If the connecting rods and covers of rods are not marked, mark them.

Piston and connecting rod
Fig. 2.2. Piston and connecting rod: 1 - top compression ring; 2 - lower compression ring; 3 - oil ring; 4 - piston; 5 - the piston pin; 6 - a connecting rod; 7 - the bolt connecting rod cap; 8 - the upper connecting rod bearings; 9 - the lower connecting rod bearings; 10 - a cover of a rod; 11 - a nut of fastening of a cover of a rod


The pistons (Fig. 2.2) of the first and fourth cylinders in the lower dead point.
Remove the fixing nuts, remove the cover of the first connecting rod and bearing, label inserts.
Slip pieces of rubber tubing to the connecting rod bolts so as not to damage the crankshaft and the cylinder wall when removing the piston assembly with rods.
Remove bearing shells and remove the rod from the top of the cylinder block through the hole.
Remove the similarly remaining connecting rods and pistons.

Disassembly and assembly of pistons with rods

Tool for disassembly and assembly of pistons with rods
Fig. 2.3. Tool for disassembly and assembly of pistons with rods


Disassembly and assembly of pistons with rods recommended with special tool 09234-33001 engine displacement of 1.1 / 1.3 L and supplies 09234-3302 engine displacement of 1.5 / 1.6 liters. Tool for disassembly and assembly of pistons with rods shown in Fig. 2.3.

Technical condition
The pistons and piston pins
Check pistons for scoring, scratches and other defects. Replace defective pistons.
Check out all the piston rings for the presence of chipping, damage or excessive wear. Replace the defective ring. When replacing the piston and replace the piston pin.
Check for excessive clearance between the piston pin bosses and the piston. Replace defective piston assembly with a finger. The piston pin must be a smooth entrance of the boss in the piston when pressed by hand (at room temperature).
Piston rings
Check the clearance between the piston rings and the corresponding grooves of the piston. If the clearance exceeds the limit value in use, install the new ring in the groove again, check the clearance between the ring and the groove. If the gap again exceeds the limit, replace the piston and rings. If the gap is less than the limit, replace the piston rings only.
The nominal gap between the ring and the groove, mm
upper compression ring:
1.3 liter engine ..... 0,04-0,085
Engine 1.1 l ..... 0,03-0,07
lower compression ring:
1.3 liter engine ..... 0,04-0,085
Engine 1.1 l ..... 0.02-0.06
Maximum permissible clearance for the upper and lower compression rings of 0.1 mm.
To check the clearance in the lock ring, insert the ring into the cylinder. Set the ring at right angles to the axis of the cylinder by gently pressing on him piston. Check backlash in the ring lock (Table 2.1.) Probe. If the clearance exceeds the limit, the ring should be replaced.

Table 2.1
The gap in the lock ring
Name rings
Clearance mm
nominal
maximum allowable
The upper compression ring:
1.3 liter engine
1.1 liter engine

0.20-0.35
0.15-0.30

10
10
The lower compression ring:
1.3 liter engine
1.1 liter engine

0,37-0,52
0.30-0.50

10
10
Scraper ring
0,20-0,70
10

When replacing the cylinder bore rings without backlash in the ring lock must be checked by setting the ring on the bottom, less worn portion of the cylinder. The rings should be replaced rings of the same size group.
Dimensional groups of piston rings in the gap in the castle and marking:
Nominal Without labeling
0.25 mm ............ 25
0.50 mm ............ 50
0.75 mm ............ 75
1.0 mm ............. 100

NOTE
Marking applied to the upper surface of the piston ring.

Cranks
The installation of covers of rods made according to the cylinder number on the inside of at dismantling.
When installing a new rod, take care to installation recess rod inserts placed on one side.
Always replace damaged rods with one of the surfaces exposed to the axial load. Replace the presence rods laminate wear, and with a strong surface roughness of the working surface openings in the upper rod head.
Installation of the piston rings
The first set oil ring. First, install the groove expander, then set the upper and lower oil scraper ring.
After installing all the elements oil ring, make sure that the top and bottom rings rotated freely, without jamming.
Install the lower compression ring mark up.
Then set the top compression ring.
Turn the compression rings castles spread them as far as possible from one another, making sure that they are not in the same plane as the drive locks oil scraper ring and piston pin.
Compress piston rings with special tool and insert the piston into the cylinder.
When installing the covers of rods follow correspond to the numbers printed on the connecting rods and their covers during disassembly. Make sure that the label on the pistons and the crank installation (identification marks) facing the front of the engine.
When you install the new connecting rods, take care to installation recess inserts placed on one side.

Useful information and advice
Wear of the cylinder group
The car engine is sometimes compared to a man's heart. Indeed, it runs continuously until the car is moving. However, such a comparison is not quite correct. The heart, like any living organism, continuously restores itself: there are constant processes of the extinction of old cells and replacing them with new, young. What can not be said of inanimate mechanism - the engine. He is, despite all our efforts, wears almost irreversible. However, the intensity of the wear life of the engine overhaul, as well as the durability of the entire vehicle as a whole is largely dependent on how well it is done and well maintained.
Particularly susceptible to wear the main engine parts - pistons with piston rings, connecting rods and cylinders. Working piston engine most impressive. After moving reciprocally between the upper and lower dead point, they cover a great distance. Thus, when
engine speed of 5,000 min-1 and the stroke of the piston, for example, 75 mm total path surmounted piston per minute, is 375 m. One hour of engine operation, this distance will be 250 m 2 km, and after a month of operation for 8 hours per day excluding weekends (which, of course, it is unlikely for the average car), the piston will overcome the distance of 460 km. With intensive use of the vehicle for 5 years (ie the duration of operation of such a vehicle to engine overhaul confirmed by statistics), the piston will cover 24,000 km away!
Thus, the wear of the piston and mating with him parts (engine cylinder) is inevitable. However, the values of wear piston (pistons, piston rings) to overhaul the engines for various firms are very different from each other. For example, limiting the wear of piston rings and piston engines Mercedes-Benz, Volkswagen, BMW, the majority of American and Japanese firms comes after a run of about 300 000 km.
At the same time, other motors, for example, less sophisticated models require replacement of pistons and piston rings 50 after the 000 km (about 10 times less).
What was the reason? And the durability of these components depends on the operating conditions? To answer these questions, let us consider two typical designs of piston gasoline engine and a diesel engine. Note first that the gas pressure inside the cylinders of the engine at the beginning of the stroke differ by about two times. The gasoline engine - carburetor or with direct fuel injection, it is 40-55 kg / cm 2, in a diesel engine -
70-80 kg / cm 2. Therefore, the pistons of petrol and diesel engines differ from one another, although the major design decisions have the same.
The typical gasoline engine piston cast from an aluminum alloy and covered outside with a layer of tin to improve the running to the mirror cylinder. The diameter of its upper part - head - 0.1 mm smaller than the inner diameter of the cylinder. This is to prevent jamming of the piston head in the cylinder on heating to the working temperature. The piston ring grooves are located two compression rings and one oil scraper. The lower part of the piston - Skirt - oval in cross-section, and the height of the conical shape: at the top of a smaller diameter than the bottom. Moreover, inside the piston bosses with holes for piston pin has two steel thermostatic insert. All this is done to prevent an increase in friction between the skirt and the cylinder bore when heated piston. With less than that of aluminum, the coefficient of thermal expansion of the insert tightening the skirt in a direction perpendicular to the piston pin axis.
Hole piston pin in modern engines is usually displaced from the axis of symmetry of the piston to the right side of the engine. For proper piston rod assembly and install them into the cylinder near the opening of the boss has a tag which is intended to face towards the front of the engine. Such a shift is made to reduce the lateral component of the force of gas pressure, pressing the plunger to one side of the cylinder during the power stroke.
The connecting rod must also be oriented correctly in the engine. On its front side with holes for supplying oil to jet loaded side mirror of the cylinder (in some engines, these holes are not available). Inserts and cover the bottom of the connecting rod are also provided with corresponding labels for proper assembly. The accuracy of manufacture of the piston and the faithful of his selection to the opening of the cylinder depends essentially on its subsequent performance and durability. Leading engine-building companies used today system, whereby the pistons on the outer diameter typically divided into five or six classes by 0.01 mm. Besides
They are divided into three or four categories increments of 0.004 mm in accordance with the diameter of the piston pin hole. The cylinders of the engine also has a similar division into five classes. This system allows you to more accurately pick up the piston to anyone, even worn-out cylinder and piston pin of the category - the hole in the bosses and the connecting rod. For the overhaul of engines, which consists usually bore (increase in diameter) cylinders, parts manufacturers produce so-called reconstruction pistons increased size.
The piston of the modern diesel engine designed to take higher pressures, so the thickness of the bottom of his bosses and more. Furthermore, the design of the piston of a diesel engine is somewhat different from that discussed above. The main difference - is the placement of the combustion chamber directly into the piston head. Since combustion of the fuel mixture occurs when finding the piston near the top dead center, the hot gases are heated more strongly piston head and the walls of the upper cylinder heated slightly smaller than gasoline engines. For a reliable sealing of the piston in the cylinder on its outer surface made five grooves for mounting piston rings. The three upper grooves installed compression rings. In the lower grooves there are two oil ring. Many companies produce compression ring rectangular, almost no different from the rings of gasoline engines. However, a more progressive, although more costly, is the design with a conical upper working surface of the ring. The angle of the cone of such rings are usually made at 10 ?�. The use of cone rings provides some increase in their longevity, as during the travel component of the force of gas pressure on the tapered surface of the ring further presses it to the mirror cylinder. Feature of maintenance and repair pistons with tapered compression ring is a need for precise control of clearances. The gaps between the groove and the oil control rings as well as gasoline engines.
The friction forces between the surfaces of the piston skirt and the cylinder bore in diesel engines than in petrol engines. To increase the durability of the surface of the piston skirt with a layer of special colloidal graphite coating. It greatly improves the running-piston to the cylinder and extend his work to overhaul. A similar treatment of the friction surfaces of pistons used today and gasoline engines.
In addition to surface wear skirts, worn grooves and compression rings of pistons. In addition, wear and groove maslosemnogo ring, although this is usually much less wear. When worn piston ring grooves are becoming more intensively to move up and down the height of the groove and all the more tangible becomes a so-called pumping action of the rings. This effect is all the more increases the cost of the engine motor oil. In the combustion chamber, oil is burnt there to form a blue smoke, which emerges from the exhaust pipe of a vehicle. With a significant deterioration of the replacement ring grooves in the new situation a little better. It occurs objective need to replace the entire piston, wherein the cylinder bore is very desirable to oversize. All these kinds of wear - it is a natural and, unfortunately, irreversible process.
Nevertheless, the wear and tear can stretch over time, so prodlivaya engine life. America does not need to open here. Just be sure to comply with the manufacturer's manual, using high-quality motor oil and oil filters, fuel equipment properly adjusted. Good results are obtained by the use of high-quality oil modifiers and fuel, drugs that alter the microstructure of the surface layers of the friction surfaces of engines.
In addition, the deterioration of the engine, as well as the entire vehicle as a whole is largely dependent on the driver, from his skill and technical expertise. It is not for nothing that the cars of the same brand in some drivers are long and trouble-free, while others - repaired almost every week. An experienced driver is almost never run the engine with the overload, and even more so with a detonation. He always listens to how the engine of his car, and immediately respond to any overloading, usually accompanied by a low-pitched sound of booming at low engine speeds. Acceleration mode also
accompanied by increased engine wear. Here the analogy with horse and rider: careful owner will not be unnecessarily whipping his four-legged friend, forcing him to run off the bat, especially if the horse has not yet warmed up. Of course, in an emergency, the driver can not afford dashing, very sharply accelerate the vehicle. But if such a cool style of driving is a habit, engine repair will be provided twice before the stipulated specifications.
Often, there is another not covered by any type of wear instructions. This emergency breakdown elements shatunno? Piston rings and above all bridges and piston ring grooves. In gasoline engines, it is primarily due to the detonation. Recall that knocking - is the explosive combustion of the fuel mixture in the cylinder, followed by an abrupt pressure rise in the combustion chamber. This is equivalent to a sharp blow with a sledgehammer on the stationary piston and rings. Details, of course, are not designed for this load and can break, then its fragments damaged the cylinder bore. Knock a few reasons. However, the main of them - the work of the engine on gasoline lower than that provided by the technical specifications, octane, as well as overheating and working on pereobogaschenie combustible mixture. An experienced driver is obliged to hear the detonation knocking when the engine and immediately reduce the supply of fuel during acceleration, and then remove the causes detonation. The sound of the detonation - a high-pitched metallic clicks that match the frequency with the frequency of rotation of the crankshaft. They may be barely audible in the background of other sound of the engine, especially at a slightly earlier the ignition, and disappear in the very slight decrease in supply of fuel (gas). This barely noticeable detonation indicates correctly adjusted ignition timing angle, but it also happens that the detonation knocking appear immediately when you press the accelerator pedal, which, of course, unacceptable. Continue to move in this mode is equivalent to breaking hammer engine internals.
Diesel engines are not as sensitive to changes in composition of the fuel, although they get into trouble, leading to increased wear of parts of the crank mechanism. This is primarily the engine to overheat and the associated reduction in viscosity of the oil, especially if the quality of the oil is low. Increased wear may also be due to incorrect adjustment of high pressure fuel pump and the deterioration of fuel atomization in the combustion chambers due to the disruption of the nozzles. And, of course, much depends on the driver.
So from all this we can draw the following conclusions. The durability of the engine of your car, as well as the whole vehicle as a whole, depends on two factors: the quality of workmanship, which is responsible for the manufacturer, and the level of technical operation for which is ultimately responsible driver. This should be remembered as when buying a car, and in the preparation and training of drivers.




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