Disassembly
1. In the sequence shown in the figure, remove the cylinder head bolts in 2–3 passes.
2. Using the special tool 09222 - 27300, compress the valve spring and remove the crackers from the valve stem. Slowly release the spring compressor and remove the valve spring, spring cap and valve from the cylinder head.
Attention! Have numbered plastic bags or containers ready to store the valves.
3. Use pliers to remove the oil deflector cap.
Attention! Do not reuse the oil seal.
Examination
Cylinder head
1. Inspect the cylinder head for damage, cracks, oil and coolant leaks. If necessary, replace the cylinder head.
2. Remove scale, sealant and carbon deposits. Blow out the lubrication channels with compressed air.
3. With a metal ruler and feeler gauge in six directions, check the flatness of the cylinder head. Regrind the cylinder head if necessary.
Standard deviation from flatness:
- in width 0.03 mm;
- along the length of 0.09 mm;
- diagonally 0.012 mm.
Valves
1. Clean the valve with a wire brush.
2. Inspect each valve for wear, damage, and deformation in areas A and B and repair or replace as necessary. If the end of the rod is corroded or worn, restore the chamfers as necessary. This recovery should be limited to minimal metal removal.
Also check the thickness of the working edges.
Valve lip thickness:
- Intake valves: 1.16mm
- Exhaust valves: 1.30mm
Valve spring
1. Inspect each valve spring for cracks or damage. Measure the free length of the spring.
2. Install the spring on a flat horizontal surface and measure the deviation of the top of the spring from the vertical plane.
- Spring length without load: 39.14 mm
- Spring length under load 21.4 kg: 32 mm
- Permissible deviation of the spring from the vertical plane: no more than 1.5°
- Maximum allowable reduction in length: -1 mm
- Maximum permissible deviation of the spring from the vertical plane: no more than 4°
Valve guides
Check clearance between valve stem and valve guide. If the clearance exceeds the limit, replace the valve guide with an oversized bushing.
Clearance between stem and valve guide:
- Inlet valves: 0.022-0.067 mm
- Exhaust valves: 0.005-0.095mm
Maximum allowable clearance between valve stem and valve guide:
- Inlet valves: 0.1mm
- Exhaust valves: 0.15mm
Insert valve seat
Check the valve seat for overheating and damage to the seat in contact with the valve disc. Repair or replace the valve seat if necessary.
Before replacing or repairing the valve seat, check the valve guide for wear. If the valve guide is worn, replace it.
Assembly
1. Please clean the parts before installation.
2. Apply a light coat of engine oil to all sliding surfaces.
1. Install the spring seat.
2. Using the special tool 09222-27200, install the oil seal.
1. Do not reuse old oil seals.
2. Incorrect installation of the valve stem seal adversely affects its sealing lip due to eccentricity and causes engine oil to leak through the valve guides. When installing, be careful not to twist the oil seal.
3. Lubricate the valve stem with engine oil and install the valve. When installing the valve, do not apply much force so as not to damage the oil seal. Check for smooth valve movement.
4. Install springs and spring retainers. The springs must be installed with the enameled side towards the spring holders.
5. Use the special tool 09222-27300 to compress the spring. Install crackers and remove the special device for spring compression.
Attention! When compressing the spring, make sure the slinger cap is not pinched by the spring compressor.
6. Clean all mating surfaces of the cylinder block and cylinder head.
7. Determine the thickness of the cylinder head gasket:
- measure the protrusion of the piston installed at TDC with respect to the mating surface of the cylinder block;
- according to the piston protrusion according to the table, select the thickness of the gasket. The average of eight measurements is required as the piston protrusion. Even if one measurement exceeds the allowable limits, the gasket thickness must be selected based on the protrusion measurement of that point.
8. Install a new cylinder head gasket with the marked surface toward the cylinder head.
9. In the sequence shown in the figure, tighten the cylinder head bolts. Tightening torque: 50 Nm turn 120°.
performance | 2.0 l | ||
The value of the average protrusion of the pistons | 0.194–0.337 mm | 0.337–0.440 mm | 0.440–0.542 mm |
Gasket thickness | 1.13±0.05mm | 1.23±0.05mm | 1.33±0.05mm |
Limit of each discharge | 0.43 mm | 0.53mm | – |
Identification marks | 001 | 002 | 003 |