Disassembly, Troubleshooting and repair of cylinder head

Sequencing:

1) Using Holder 5199 999, remove the camshaft pulleys, marking them felt-tip pen or something similar (inlet and outlet);

2) alternately turn out all bolts the upper section of the cylinder head, moving from the center to the edges;

3) Remove the upper section by gently tapping with a plastic hammer next to the removable tabs and the front of the camshaft;

4) Remove the camshafts while lifting and turning them;

5) Remove the bolts securing the lower section of the cylinder head (moving from the center to the edges);

6) remove the block and head gasket;

7) clear the parting surfaces of the top and bottom sections of the cylinder head with mastic and plastic spatula; rinse with water and dry the surface with alcohol;

8) remove the tappets from the cylinder head. To facilitate the extraction of the pushers can use a magnet or suction cup; Dimensions of parts listed in Section 3 "Design and specifications of engines";

9) Check for signs of wear on the pusher. If necessary measure;

10) in order to avoid oil leakage pushers keep upright. Place the pushers in order - they can not be interchanged. For prolonged storage pushers should be placed in a vessel filled with oil, taking into account the type of oil, which will be filled after the engine repair;

11) Remove the valve (Fig. 4.45) using the clamp valve and bracket 6052 998 951 2051 (four valves per cylinder);

12) remove crackers of valves, the upper plate of the valve springs, valve springs, valves;

13) Remove the valve stem seals the valve stem using the tool 999 5219 (Fig. 4.46);

14) Clean the cylinder head;

15) Clean the mating surface;

16) Clean the combustion chamber;

17) Clean the inlet and outlet channels;

18) Clean the valve seats;

19) Inspect the cylinder head for wear;

20) Clean the threads of the spark plug (tap M14h1,25);

21) Clean the valves, valve springs and valve plate springs;

22) for the presence of cracks in the valve seats treat the saddle by milling guide 115 8280 with a diameter of 7 mm and an inclination angle of the cutting edge 45.

Cleaning the air channels

Sequencing:

1) Clean the air supply channels (F 4 mm) to the maximum depth. Purge channels the compressed air inlet side on the top of the cylinder head. Make sure that the air passes through the channels;

2) Check the flatness of the lower section of the cylinder head;

3) measure the wear of valve guides using a dial indicator (Fig. 4.47), mounted on a magnetic rack;

4) Check the valve springs. Check valve sizes. Dimensions of parts listed in section 3: "Design and specifications of engines."

Replacement guides

plugs of valves

Sequencing:

1) secure the cylinder head on the retainer 999 5363 (Fig. 4.48);

2) Adjust the angle with the upper holes on the sides of the retainer;

3) fix the cylinder head on the retainer, using the hole 2 (arrow) when pressing out the mandrel must be placed vertically;

4) Extract the interchangeable guides (performed in three stages):

- Extract the guides using tool 999 5364. Use the sleeve as gaskets for the cylinder head bolts. Slowly pressed mandrel until it reaches the cylinder head. If the guide sleeve is damaged, remove the metal particles;

- Continue pressing off with drift 999 5365. Zoom into the upper part of the hole under the guide sleeve. (Leave the old sleeve in place as a guide for pressing the new bushings). If the walls of the holes are deep risks and burrs, use a repair guide sleeve size. To install the guide sleeve oversize hole should be deployed;

- Lubricate and install a new guide sleeve on the mandrel 999 5505 and slowly embed it into the cylinder head until the mandrel reaches the surface of the cylinder head. Guide bush must be pressed at 13 ?� 0.2 mm. The height is set by the tool. Deformation of the upper portion of the guide is eliminated scan. New guides may be shorter sleeves previous design.

Mechanical restoration

valves and their seats

Dimensions of parts listed in Section 3 "Design and specifications of engines."

Sequencing:

- Grind chamfer intake valves. The exhaust valves, covered with stellite should definitely get ground manually using a grinding paste;

- Treat the bevel valve seats. In no case do not touch the cutter combustion chamber walls;

- Check the height of the protrusion of the valve stem, using a caliber 999 5222 (Fig. 4.49);

- Set the fire in the socket bearings of a camshaft;

- Measure the height of the protrusion of the valve stem, stem caliper skipping through the hole in the gauge.

Installing valves

Sequencing:

- Lubricate hinges and valve guides;

- Set the valves;

- Insert the bottom plate of the valve, the valve in its place;

- Install the valve stem cap on the valve stem;

- Press them as far as possible the valve stem seal on the valve guide with a torque arm. Use mandrel 999 5379;

- Install the valve spring and the upper spring using clamp valve and bracket, crackers valve. Make sure that when there is no load on the spring two halves of biscuits are in the correct position.

Thread Repair

Repair of the internal thread in the cylinder block, the intermediate section and the cylinder head is performed by means of threaded inserts. However, some of the openings in the thread can not be repaired by this method, as the surrounding metal has an insufficient thickness. Threaded inserts (Fig. 4.50), made of cold-rolled wire (stainless acid-resistant steel) have a thread profile corresponding to ISO standards. The inserts are designed to be installed in threaded holes, according to the tables of standard threaded inserts.

To install the threaded insert the following:

1) drill repairable hole (Fig. 4.51). The diameter of the drill and determine the drilling depth on the threaded inserts tables annexed to the latter. Do not countersink hole edge. It recommended only slight processing for deburring;

2) Pick a tap according to material and other specific conditions. For example, threaded holes M10 using M10 threaded insert;

3) cut the thread to the desired depth (Fig. 4.52);

4) the blow hole with compressed air;

5) pick up the threaded insert the desired length;

6) Place the threaded insert in the installation tool (Fig. 4.53). Insert foot should be placed down;

7) Install the threaded insert into the hole.

8) Keep installation tool vertically over the hole with a threaded, screw insertion hole (Fig. 4.54). Box set so that it is about one pitch of the thread protruding above the edge of the hole. The through hole threaded insert must not protrude beyond the lower edge of the hole;

9) Break off the foot (Fig. 4.55) using a special tool of cracks in the foot. Do not use for this purpose installation tool. Remove the foot and blow a hole with compressed air;

10) using the screws, check that the insert is installed correctly and the bolt is screwed smoothly.