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Repair of a head of cylinders
Dismantling Check Cylinder Head | - Inspect the cylinder head for damage, cracks, leaks, oil and coolant. If necessary, replace the cylinder head.
 | - Remove scale, sealant, and carbon deposits. Compressed air blow channels for lubrication.
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- Metal ruler and probe into six areas A, B ... check the flatness of the cylinder head. If necessary, pereshlifuyte cylinder head.
Standard deviation from flatness: less than 0.03 mm.
Maximum permitted flatness: 0.05 mm. |
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Valves |  | - Wire brush, clean the valve.
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 | - Examine each valve for wear, damage and deformations in the zones A and B and, if necessary, repair or replace it. If the end of the rod is worn or eaten, as appropriate, restore the chamfer. This recovery should be limited to the minimum metal removal.
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Also check the thickness of the working edges. The thickness of the edge of the valve: The intake valves 1.15 mm: - Engines of 1.8 and 2.0 x 1.15 mm;
- Engines 1.6 x 1.1 mm.
The exhaust valves: - Engines of 1.8 and 2.0 x 1.35 mm;
- Engines 1.6 x 1.3 mm.
Maximum allowable thickness of the working edge of the valve: The intake valves: 0.8 mm;
The exhaust valves 1.0 mm.
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Valve spring | - Inspect each valve spring for cracks and damage. Measure the length of the spring in a free state.
- Install the spring on a flat horizontal surface and measure the deflection of the spring from the top of the vertical plane.
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Engines 1,8 and 2,0 l The length of the spring-load: 48.86 mm
Spring length under a load of 18.3 kg: 39 mm
Spring length under a load of 40.0 kg: 30.5 mm
Tolerance springs from the vertical plane not more than 1,5 ?�
Maximum permissible deviation from the vertical plane of the spring: a maximum of 3 ?� Engines 1.6 liter  | The length of the spring without load: 44 mm
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Spring length under a load of 21.6 kg: 35 mm
Spring length under a load of 45.1 kg: 27.2 mm
Tolerance springs from the vertical plane not more than 1,5 ?�
Maximum permissible deviation of a spring from a vertical plane not more than 4 ?� Valve Guides  | Check the clearance between the rod and the valve guide. If the clearance exceeds the limit, replace the valve guide to the bushing repair size larger.
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Engines 1,8 and 2,0 l The clearance between the stem and the valve guide: The intake valves: 0.02-0.05 mm
The exhaust valves: 0,035-0,065 mm
Maximum permissible backlash between the shaft and valve guide: The intake valves: 0.1 mm
The outlet valve: 0.13 mm
Engines 1.6 liter The clearance between the stem and the valve guide: Intake valve: 0.03-0.06 mm
Exhaust valve: 0.05-0.08 mm
Maximum permissible backlash between the shaft and valve guide: Intake valve: 0.1 mm
The outlet valve: 0.15 mm
Valve seat inserts  | Check valve seat for the presence of heat and disturbance of the working surface in contact with the valve plate. If necessary, repair or replace the valve seat.
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Before replacement or repair of the valve seat, check the valve guide wear. If the valve guide sleeve is worn, replace it. Replacing the valve seat |  | Any of the valve seat insert worn to the limit must be replaced at room temperature by cutting the wall, as shown. |
- After removing the old valve seat is necessary to chisel nest under the increased size of the valve seat. Dimensions for the treatment are summarized in the table.
The increased size of the valve seat insert engines of 1.8 and 2.0 liters 3 Description | Label size | Seat height, mm | Hole diameter in the cylinder head, mm | | Saddle inlet valve and increased by 0.3 mm | thirty | 7.5-7.7 | 33,300-33,325 | | Saddle inlet valve and increased by 0.6 mm | 60 | 7.8-8.0 | 33,600-33,625 | | The seat of the exhaust valve and increased by 0.3 mm | thirty | 7.9-8.1 | 28,800-28,821 | | The seat of the exhaust valve and increased by 0.6 mm | 60 | 8.2-8.4 | 29,100-29,121 |
The increased size of the slide-valve seat 1.6 liter engine Description | Label size | Seat height, mm | Hole diameter in the cylinder head, mm | | Saddle inlet valve and increased by 0.3 mm | thirty | 5.1-5.3 | 30,700-30,721 | | Saddle inlet valve and increased by 0.6 mm | 60 | 5.4-5.6 | 31,000-31,021 | | The seat of the exhaust valve and increased by 0.3 mm | thirty | 6.2-6.4 | 27,300-27,3211 | | The seat of the exhaust valve and increased by 0.6 mm | 60 | 6.5-6.7 | 27,600-27,621 |
- Heat the cylinder head to a temperature of 250 ?� C and a press-fit the new valve seat repair size. When pressing the valve seat must be brought to room temperature.
- After installing a new valve seat must perform valve lapping. Width of a working facet of the valve seat should be within specifications.
Width of a working facet of a saddle of the inlet valve: - Engines of 1.8 and 2.0 liters: 1.1-1.5 mm;
- Engines of 1.6 liters: 0.8-1.2 mm.
Width of a working facet of a saddle of the exhaust valve: 1.3-1.7 mm |
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Replacing the valve guide
| - Using the adaptation 09221 - 22000 A / B press out the valve guide from the cylinder head in the direction of the cylinder block.
- Place the cylinder head to the opening of a new valve guide increased repair size.
 | - For adjustment of the valve guide 09221-22000 A / B press in the sleeve in the cylinder head. The device provides the press-fit sleeve at certain depths. Measure the protrusion of the upper part of the valve guide from the cylinder head. Please note that the protrusion of the valve guide is different for intake and exhaust valves.
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- After pressing in valve guides, insert new valves and check clearance.
- Each time you replace the valve guides, check and, if necessary, replace the valve seat.
The increased size of the valve guide Increased size | Label size | The diameter of the holes in the cylinder head | 0.05 | 5 | 11,050-11,068 | 0.25 | 25 | 11,250-11,268 | 0.5 | 50 | 11,500-11,518 |
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Assembly |  | - Before installation, clean all parts.
- Apply a thin coat of engine oil to all sliding surfaces.
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- Install the spring seat. Using a special device 09222 - 22001, set the valve stem seal.
| - Do not reuse the old stem seals.
- Improperly installed valve stem seals may reduce its working edge due to the eccentricity and leads to leakage of engine oil through the valve guide.
When installing, be careful not to twist the valve stem seal. |
 | - Lubricate the valve stem with engine oil and install valve. When installing the valve, do not apply excessive force, so as not to damage the valve stem seal. Check for smooth movement of the valve.
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- Install the spring and spring retainer. Springs should be installed side coated with enamel to the spring retainer.
 | - Special adaptation 09222 - 28000, 09222-28100 compress a spring. Place crackers and remove special tool for spring.
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| When you compress a spring, make sure that the valve stem seal is not pinched spring compressor. |
- Clean all the gasket surfaces of the cylinder and the cylinder head.
- Check the markings on the cylinder head gasket.
- Install the new cylinder head gasket so that the surface with the marking was directed to the cylinder head.
 | - In the sequence shown in the illustration, tighten the cylinder head bolts.
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Tightening torque cylinder head bolts engines 1,8 and 2,0 l M10: 25 N ??? m tighten on a corner 60-65 ?� tighten on a corner 60-65 ?�
M12: 30 N ??? m tighten on a corner 60-65 ?� tighten on a corner 60-65 ?�
Tightening torque cylinder head bolts 1.6 liter engines: 30 N ??? m to tighten on 90 ?� loosen all the bolts to 30 N ??? m to tighten on 90 ?�
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