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Cylinder head
1 - head cover;
2 - sealing plate;
3 - a cover of a camshaft;
4 - camshaft;
5 - the valve tappet thermal gap;
6 - the cylinder head bolts;
7 - cylinder head;
8 - cylinder head gasket; | 9 - crackers;
10 - upper spring seat;
11 - external valve spring;
12 - internal valve spring;
13 - lower spring seat;
14 - the valve;
15 - valve stem seal;
16 - angle sensor (T8 DOHC). |
Removal and dismantling
The description of the removal and installation of the cylinder head on the engine from which the subsidiary previously removed parts, timing belt pulleys and camshafts.
Check
Check the cylinder head.
| PERFORMANCE ORDER | | 1. Inspect the cylinder head for damage, cracks, leaks, oil and coolant. If necessary, replace the cylinder head. | 2. The metal ruler and probe in six directions check the flatness of the cylinder head. If necessary, pereshlifuyte cylinder head.
Permissible flatness: 0.15mm |  | | 3. Measure the height of the cylinder head from the bottom surface of the head to the mounting surface of the cylinder head cover gasket.
The permissible height of the head:
FE DOHC: 133,95-134,05 mm
T8 DOHC: 133,8-134,0 mm
Maximum allowable thickness of grinding layer: 0.20 mm |
A warning  Before buffing, check the following and, if necessary, replace the cylinder head:
- Deepening of the valve seat;
- Damage to the gasket face of collectors;
- Clearance of the camshaft bearings and axial play.
|  | 4. The metal ruler and stylus in two directions measure planeness of interfaced surfaces of collectors. Deviation from flatness:
FE DOHC: 0,15 mm
T8 DOHC: 0,20 mm | | 5. If the flatness exceeds the allowable limits, grind the surface or replace the cylinder head. |
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Check valves
| PERFORMANCE ORDER |  | 1. Examine each valve on revealing of following defects:
- Damage or deformation of the valve stem;
- Damage to the valve plate;
- Damage or uneven wear of the valve stem end. | | 2. If necessary, repair or replace the valve. | | 3. Measure the height of the edge of the valve disc. If necessary, replace the valve. The height of the edge of the valve disc:
Intake: 0.85 mm
Graduation: 0.9 mm |  | 4. Measure the length of each valve. The length of the valve:
The inlet valve:
FE DOHC: 103,18 mm
T8 DOHC: 102,92 mm
Exhaust valve:
FE DOHC: 103,94 mm
T8 DOHC: 101,42 mm |  | 5. micrometer at several places in height, measure the diameter of the valve stem.
The diameter of the valve stem:
Intake valve: 5,970-5,985 mm
Exhaust valve: 5,965-5,980 |  | 6. Nutromer in several places, measure the inside diameter of the valve guides. The inner diameter of the guide inlet and exhaust valves: 6,01-6,03 mm |  | 7. Calculate the gap between the guide sleeve and valve stem. For this subtract the outer diameter of the valve stem from the inner diameter of the corresponding valve guide.
Gap:
The inlet valve:
inlet: 0,025-0,060 mm
Graduation: 0,030-0,065 mm
Limit: 0,020 mm | | 8. If the backlash exceeds the limit, replace the valve and / or valve guide. |  | 9. Measure the height of each protrusion of the valve sleeve. If necessary, replace the valve guide.
The inlet valve A: 11,4-11,9 mm |  |
A warning Note that guides the intake and exhaust valves vary in shape.
|  | 10. Gradually heat the cylinder head in the water to a temperature of about 90 ?� C. |  | 11. When using tool OK201 120 001 Extract the valve guide from the side opposite the combustion chamber. | | 12. Gradually heat the cylinder head in the water to a temperature of about 90 ?� C. |  | 13. When using tool OK201 120 molded with the valve guide 001 on the side opposite the combustion chamber, as long as it will not protrude above the head of the block above the recommended amount. |
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Check the valve seat
| PERFORMANCE ORDER | 1. Check the work surface and chamfer the valve seat for the following defects:
- Roughness;
- Burning;
- Pitting;
- Cracks. |  | 2. Special cutting tool 45 ?� restore a working edge of the valve seat and / or valve face. | | 3. Apply a specially formulated blue on a working facet of the valve and the valve and let dry composition. |  | 4. Install the valve in the valve seat, push and rotate by 360 ?�. If the blue structure is not completely removed from a working facet of the valve, replace the valve. If the blue structure is not completely removed from a working facet of the valve seat, re-treat with the valve seat. |  | 5. Measure the width of a working facet of the valve.
Width: 1,2-1,6 mm |  | 6. Check the depth of the working surface of the valve seat by measuring it in the center of the valve face. If the valve is mounted in the valve seat is too high, process valve seat scan angle of 60 ?�, and then scanned with an angle of 45 ?�. If the valve is mounted in the valve seat is too low, the valve seat treat scan angle 35 ?� (for the inlet valve) and 15 ?� (to the outlet), and then scanned with an angle of 45 ?�. | | 7. Using a special abrasive powder, grind the valve and valve seats. Clean the valves and valve seats of the remnants of the abrasive powder. |  | 8. Check the penetration of the valve seat. Install the valve in the cylinder head and measure protrusion (Size L) of the valve stem.
Size L: 36,8 mm | | If L is in the following range, the valve can be used. Size L:
Intake: 36,37-37,27 mm
Graduation: 36,36-37,26 mm If L is in the following limits should be set to adjust the gasket between the plate spring and the cylinder head. Size L:
Intake: 37,27-37,97 mm
Graduation: 37,26-37,96 mm
If L is greater below the size, replace the cylinder head. Size L:
Intake: 37.97 mm
Exhaust: 37.96 mm |
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Check the valve spring
| PERFORMANCE ORDER | | 1. Inspect each valve spring for cracks and damage. |  | | 2. Measure the length of the spring in the free state. Install the spring on a flat horizontal surface and measure the deflection of the spring from the top of the vertical plane.
The length of the spring in a free state:
Outdoor: 39.1 mm
The minimum allowable: 38.7 mm
Inner: 38.0 mm
The minimum allowable: 37.7 mm
Maximum permissible deviation from the vertical plane of the spring:
Outdoor: 1.36 mm
Inner: 1.33 mm |
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Checking camshaft
| PERFORMANCE ORDER |  | 1. Place the first and last cervical camshaft on V-shaped supports. Install the measuring head dial indicator to the middle neck of the bearing of a camshaft and establish an indicator scale on 0. Turn the camshaft and measure its palpation. Maximum permissible camshaft runout: 0.03 mm | | 2. Check the camshaft to the absence of uneven wear, cracks or damage. |  | 3. In the two points, measure the height of each cam camshaft. Height of cams of a camshaft: 45.052 mm
Minimum permissible height of the cams of the camshaft: 44.852 mm |  | 4. In the two perpendicular directions, measure the diameter of each camshaft necks. Nominal Diameter: 29,940-29,956 mm
Maximum allowable roundness: 0.05 mm | | 5. Measure the clearance of the camshaft bearing. | | 6. Clean the grease from the neck of the camshaft bearing, bearing caps and bearings in the cylinder head. | | 7. Install the camshafts on the cylinder head. |  | 8. In order to measure the clearance using a plastic calibrated round bar Plastigage. Plastigage rod is compressed between the bearing and the neck of the camshaft. After removing the camshaft bearing cap deformed plastic core Plastigage measured by a special pattern, which is available in the kit. Cut pieces of plastic rod and place them on the neck of a camshaft. After installation of the plastic rod do not turn the camshaft. | | 9. In accordance with the label, set the camshaft bearing caps. |  | 10. Screw the bearing cap bolts and in a certain sequence tighten their demanded moment. Torque: 18-26 N ??? m |  | 11. In certain sequence, remove the bolts and remove the camshaft bearing caps. |  | 12. By measuring the pattern width of the deformed plastic core, identify gaps in the camshaft bearings. Nominal backlash: 0,035-0,085 mm
Maximum permissible backlash: 0,15 mm | | 13. If the backlash exceeds the limit, replace the cylinder head. |  | 14. Install the camshafts in the cylinder head. Establish a measuring tip of a dial indicator on the end of the camshaft. Move a camshaft along the axis of the way to one side. | | 15. Set the arrow on the dial indicator to 0. Move a camshaft along the axis of the way to the other side. Read the readings on the dial gauge, which shows the amount of axial play of the camshaft. Nominal axial clearance: 0.08-0.10 mm
Maximum permissible backlash: 0,20 mm |
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Check of hydraulic jacks of backlashes of valves
| PERFORMANCE ORDER | | 1. Check the front side of the hydraulic jacks of backlashes of valves for wear or damage and, if necessary, replace them. |  | 2. Squeeze the hydraulic jack with two fingers. If the hydraulic valve clearance compensator is compressed, replace it. |
A warning Never attempt to rebuild or repair the hydraulic jacks of backlashes of valves.
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Assembly and installation
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