Opel Frontera

Since 1992 of release

Repair and car operation



Opel of Frontera
+ Cars of mark Opel Frontera
+ Current leaving and service
- The engine
   Removal and engine OHC installation
   Removal and engine DOHC installation
   Engine dismantling
   Engine assemblage
   Head of cylinders and valves
   Pistons and rods
   The block of cylinders
   Cranked shaft and bearings of a cranked shaft
   Camshaft drive
   Engine mounts
   Compression check
   Greasing system
   Works with system of greasing of engine OHC/DOHC of 2.0 l
   Works with greasing system on the engine of 2.4 l
   The oil filter
   Oil radiator (if it is established)
   Pressure and oil temperature
+ Cooling and heating systems
+ The power supply system and release
+ Engine electric equipment
+ Coupling
+ Manual box of a gear change
+ Kardannye shaft, the main transfer
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Controls and operation
+ Electric equipment schemes



Head of cylinders and valves

THE GENERAL DATA

Removal and installation of a head of cylinders (the engine is not removed)

The head of cylinders can be removed on the established engine. This operation is shortly described more low. It is necessary also will familiarise with the maintenance of section describing removal of the engine as many works on engine removal are necessary for executing also at removal of a head of cylinders. If the engine is already removed, a spadework can not be spent.
Removal of a head of cylinders without engine removal is required, for example, at replacement of a lining of a head of cylinders or for polishing of valves. Heads of cylinders are authorised to be removed only after engine cooling (to a room temperature).
Removal of a head of cylinders for various types of the engine is described separately. However here all differences which are taking place for various types of the engine are described not.

ENGINE OHC – TYPE C20 NE – TILL 1995 OF RELEASE


Removal

PERFORMANCE ORDER
1. Disconnect a cable of weight from the storage battery.
2. Merge a liquid from cooling system (Section Refuelling of a cooler of system of cooling of the Head Current leaving and service) and disconnect hoses from the thermostat case. Collect in capacity cooling liquid for the further application if it was in system short time.
3. Disconnect a reception pipe of system of release from a final collector.
4. Disconnect a cable of a drive throttle заслонки from шарнирной heads and from a support. Its fastening is shown on иллюстр.
5. The head of cylinders can be removed together with a collector or the collector can be disconnected from a head of cylinders before its removal. If, for example, it is necessary to replace only a lining of a head of cylinders, it is possible to disconnect the inlet pipeline from a head of cylinders and to shift it aside. Thus it is possible to save work on a detachment of various pipelines, cables and hoses.
6. If the head of cylinders has to act in film with a final collector, it is necessary to disconnect all hoses, pipelines, cables, etc. from a final collector.
7. Remove a belt of a drive of the generator.
8. Disconnect a hose всасывания air from the case throttle заслонки. Disconnect a hose from a cover of the case of bearings of a camshaft. It is the hose of ventilation connected to the inlet pipeline.
9. Disconnect cables from spark plugs and the ignition coil. If necessary mark cables.
10. The following operation is important and should be executed before removal of a gear belt. Insert a face key into the centre of a pulley of a cranked shaft and turn a cranked shaft in a rotation direction so that it and a camshaft have occupied the position shown on иллюстр. (A camshaft - above, a cranked shaft - below). The label on a camshaft wheel should coincide with a label on a lath, the pin on the bottom party should be opposite to a label of a cranked shaft.
11. Uncover camshaft cases.
12. Remove a gear belt. This work is described in corresponding section.
  – Keeping a cogwheel of a camshaft from проворачивания, turn away a bolt in the centre. Remove a wheel. Turn away the top bolts of a back protective cover of a belt.
13. Turn away bolts of fastening of a head of cylinders for some receptions in the sequence shown on иллюстр. For the first reception turn away bolts no more, than on a turn quarter, for the second reception on a half-turn. For отворачивания use a face key.
14a. Remove the case of bearings of a camshaft from a head of cylinders. Operation is shown on иллюстр. 6.14a. If necessary for case branch it is possible to use a rubber hammer. It is necessary to mean that the case has directing pins.
14b. Коромысла, press elements and hydropushers (jacks of backlashes of valves) take out one after another and mark. Details of one knot to hold together. The arrangement of details before removal is shown on иллюстр. 6.14b. It is necessary to put pushers in the vertical capacity filled with oil to exclude air hit in internal cavities.
15. Remove a head of cylinders and remove a lining. Strongly sitting head of cylinders it is possible обстучать a rubber hammer. It is not necessary to separate a head of cylinders from the block of cylinders by means of a screw-driver. Capture of a head of cylinders at removal is shown on иллюстр.
Carefully clear surfaces of a head and the block of cylinders and check up planeness of their surfaces a steel ruler as it is described more low.
Apertures under bolts of fastening of a head of cylinders should not contain oil which can form hydraulic pillows.

Installation

The head of cylinders as follows is established:

PERFORMANCE ORDER
1. Put on a head of cylinders a lining so that inscription OBEN/TOP was above and from outside a drive of the mechanism of distribution.
2. Establish a head on the block of cylinders and обстучите its rubber hammer. Directing plugs should enter into corresponding apertures.
3. Establish hydropushers, press elements and коромысла. Grease details with a small amount of graphite greasing. Details should be necessarily established on the former places.
4. Grease with hermetic an interfaced plane of a head of cylinders.
5. Establish the case of bearings of a camshaft on a head of cylinders. Temporarily insert a camshaft wheel to be convinced that the label is in the necessary position.
6. Screw new bolts of fastening of a head of cylinders (them always it is necessary to replace) and tighten them against the stop.
7. Tighten bolts in sequence, the return scheme resulted on иллюстр.
8. The inhaling of bolts should be made with application already mentioned above the complete set of face heads as follows: Tighten all bolts in the specified sequence the moment of 25 Nanometers.
9. By means of a face head in the specified sequence tighten each bolt on a corner 90 (a turn quarter) without application динамометрического a key.
10. From this position also in the specified sequence again tighten each bolt on 90 .
11. Once again tighten all bolts in the specified sequence on 90 . Thus, доворачивание on 90 it is made three times.
The operation specified above is made as follows. The head is established on a bolt so that the handle was parallel to a head of cylinders. After turn on 90 the handle should occupy position, perpendicular a longitudinal axis of a head of cylinders. In specialised workshops for observance of a corner of an inhaling use the graduated washer shown on иллюстр.
12. Fix bolts a back protective cover of a gear belt (6 Nanometers) and put on a camshaft a wheel. Keeping a wheel from проворачивания, tighten a bolt of its fastening by the moment of 45 Nanometers.
13. Connect a final collector to a reception pipe of system of release.
14. Put on a gear belt and pull it. Details of performance of this operation are described in corresponding section.
15. All other works are carried out in sequence, return dismantling. In summary pull a belt of a drive of the generator and the pump of the hydraulic booster of a wheel.

ENGINE OHC – TYPE X 20 SE – FROM THE MIDDLE OF 1995 OF RELEASE

Removal

Removal of a head of cylinders of this engine to similarly removal of a head of cylinders of the engine of earlier release. However there are some differences owing to change of a design of the engine. Before removal of a head of cylinders the engine should be cooled to a room temperature. The head of cylinders acts in film as follows:

PERFORMANCE ORDER
1. Расстыкуйте штекерное connection also disconnect from the inlet pipeline hoses.
2. Расстыкуйте both штекерные the connections shown on иллюстр. This connection of gauges of temperature of a cooling liquid (1) and positions of a cranked shaft (2).
3. Merge cooling liquid from system.
4. Disconnect two hoses of a cooling liquid from the thermostat case.
5. Turn out bolts and remove protective sheet of the pallet картера.
6. Remove from a forward part of the engine демпфер крутильных fluctuations. For an exception проворачивания a cranked shaft it is necessary to keep the central bolt at отворачивании fastening bolts демпфера fluctuations, as is shown in иллюстр.
7. Remove a forward protective cover of a gear belt.
8. Расстыкуйте штекерное connection of the gauge of temperature of a cooling liquid (1) also disconnect the top hose of a cooling liquid (2) from the final union. The locations of connections are shown on иллюстр.
9. The following operation should be executed before removal of a gear belt. Insert a face head into the centre of a pulley of a cranked shaft and turn it in a rotation direction so that the shaft has occupied the position shown on иллюстр. The corner "And" should make 60 .
10. Now remove a gear belt. For this purpose ослабьте a bolt of fastening of a tension roller also turn the adjusting clown in an arrow direction (clockwise) so that the index (1) on иллюстр. Was opposite to the left emphasis. Now cautiously separate a gear belt from a camshaft cogwheel.
11. Disconnect cable подводку from a cover of a head of cylinders.
12. Disconnect three hoses of ventilation картера from a cover of the case of the camshaft, two of them are located on one party (on the party cable подводки), and one is on an opposite side.
13. Turn away bolts of fastening and disconnect a cover of the case of bearings of a camshaft.
14. Keeping from проворачивания a cogwheel, turn away a bolt in the centre. Remove a cogwheel.
15. Turn out two bolts from an end face картера a camshaft.
16. Turn away bolts of fastening and remove грузозахватную скобу (engine transportation) from the case of bearings of a camshaft.
17. Turn away bolts of fastening and disconnect a reception pipe with каталитическим neutralizer from a final collector. The considered knot is shown on иллюстр. 3.20
18. Turn on for some receptions bolts of fastening of a head of cylinders in the sequence shown on иллюстр. For the first прем bolts turn away no more than on a turn quarter. The key "Torx 55" is for this purpose used.
19. Remove the case of bearings of a camshaft from a head of cylinders. If necessary for case branch it is possible to use a rubber hammer. One after another remove коромысла, press elements and hydropushers and mark them. The details concerning one cylinder, store together. The arrangement of considered details before removal is shown on иллюстр.
20. Remove a head of cylinders and remove a lining. Strongly sitting head of cylinders it is possible обстучать a rubber hammer. It is not necessary to separate a head from the block of cylinders by means of a screw-driver.
Carefully clear interfaced surfaces of a head and the block of cylinders and check up their planeness a steel ruler, as it more low. Apertures under bolts of fastening of a head of cylinders should not contain oil which can form hydraulic pillows.

Installation

The head of cylinders as follows is established:

PERFORMANCE ORDER
1. Put on a head of cylinders a lining so that inscription OBEN/TOP was above and from outside a drive of the mechanism of distribution.
2. Establish a head on the block of cylinders and обстучите its rubber hammer. Directing plugs should enter into corresponding apertures.
3. Establish hydropushers, press elements and коромысла. Grease details with a small amount of graphite greasing. Details should be necessarily established on the former places.
4. Grease with hermetic an interfaced plane of a head of cylinders.
5. Establish the case of bearings of a camshaft on a head of cylinders.
6. Screw new bolts of fastening of a head of cylinders (them always it is necessary to replace) and tighten them against the stop.
7. Tighten bolts in sequence, the return scheme resulted on иллюстр. The inhaling of bolts should be made with application already mentioned above the complete set of face heads as follows:
8. Tighten all bolts in the specified sequence the moment of 25 Nanometers.
9. By means of a face head in the specified sequence tighten each bolt on a corner 90 (a turn quarter) without application динамометрического a key.
10. From this position also in the specified sequence again tighten each bolt on a corner 90 .
11. Once again tighten all bolts in the specified sequence on a corner 90 . Thus, turn on a corner 90 is made three times.
The angle of rotation of bolts specified above is reached as follows. The head is established on a bolt so that its handle was parallel to a head of cylinders. After turn on 90 the handle should occupy position, perpendicular a longitudinal axis of a head of cylinders. In repair trucks for observance of a corner of an inhaling use the graduated scale shown on иллюстр.
12. Fix bolts a back protective cover of a gear belt (6 Nanometers) and put on a camshaft a cogwheel. Keeping a wheel from проворачивания, tighten a bolt of its fastening by the moment of 45 Nanometers.
13. Tighten bolts грузозахватные eyes (15 Nanometers).
14. Connect a reception pipe of the muffler to a final collector.
15. Put on and pull a gear belt.
16. All other works are carried out in sequence, return dismantling. In summary pull a belt of a drive of the generator and the pump of the hydraulic booster of a wheel. Fastening bolts демпфера крутильных fluctuations tighten the moment of 20 Nanometers, keeping a cranked shaft from проворачивания.

ENGINE OHC OF 2.4 L (C 24 NE) (WITH THE CHAIN DRIVE OF THE MECHANISM OF DISTRIBUTION)

Removal

The head of cylinders acts in film only in a cold condition of the engine, i.e. at temperature of oil no more than 20 With.

PERFORMANCE ORDER
1. Disconnect a cable of weight from the storage battery.
2. Disconnect a reception pipe of the muffler from a final collector. For this purpose it is necessary to use a head with the extension piece.
3. Ослабьте fastening of both collars shown by arrows on иллюстр. Also remove a hose всасывания air.
4. Merge a liquid from cooling system.
5. Disconnect all hoses from the case of the thermostat and the pump of a cooling liquid.
6. Disconnect a cable of a drive throttle заслонки.
7. Расстыкуйте штекерное connection of gates of injection and a potentiometer throttle заслонки.
8. Disconnect a cable of weight from the inlet pipeline, having turned away the screw.
9. Mark both fuel hoses according to иллюстр. Also remove, having weakened fastening of collars. Be careful – fuel can be under pressure.
10. Disconnect a ventilation tube картера a camshaft from the inlet pipeline.
11. Uncover heads of cylinders, as is shown in иллюстр., having turned away bolts. Under a cover there is a camshaft. Расстыкуйте one after another штекерные connections of spark plugs, preliminary having marked them.
12. Establish the piston of the cylinder №1 in ВМТ. For the given type of the engine to make it it is necessary precisely. Deepening in a camshaft should be in the position shown on иллюстр. Besides in a flywheel there is a ball which should be opposite to a pin in the block of cylinders.
13. Remove a forward protective cover from a head of cylinders.
14. Turn out from a camshaft the plastic restrictive screw of giving of fuel and remove a cogwheel, keeping a camshaft from проворачивания. For this purpose it is required многошлицевой a key which is inserted how it is shown on иллюстр.
15. Turn both inserted from above the screw on the left and to the right outside. Screws крепят the management block to a head of cylinders.
16. Turn away bolts of fastening of a head of cylinders in regular intervals on a spiral outside inside. At first on a turn quarter, and then on a half-turn. For отворачивания bolts it is necessary to apply a strong face key-shestigrannik. For отворачивания two back bolts it is necessary to apply шестигранник on 10 mm of different length. A bolt (And = the right party), shown on иллюстр., 73 mm, a bolt (In = a left-hand side) – a key in length of 103 mm turn away a key, in the length.
Application of keys of other length can cause difficulties at отворачивании bolts.
17. Remove a head of cylinders from the block, thus it is necessary to watch to damaging the switch throttle заслонки and itself заслонку.
18. Carefully clear interfaced surfaces of the block of cylinders and a head. For this purpose it is possible to use flat шабер. Carefully remove the lining rests.

Installation

The head of cylinders in sequence, to return its removal is established. Thus it is necessary to pay attention to the following:

PERFORMANCE ORDER
1. Interfaced planes of the case of bearings of the mechanism of distribution and the block of cylinders become covered by hermetic. Firm Opel uses for this purpose hermetic № 1503294, sold in tubes. Hermetic is put by the platen in width of 3 mm in a place shown on иллюстр. In this place there is a deepening where the rubber sealing ring is inserted. An epiploon () replace.
2. Put a new lining and establish a head of cylinders, watching that. That directing plugs have entered into apertures.
3. Screw one after another new bolts of fastening of a head of cylinders and tighten them by hand. Tighten bolts in the sequence shown on иллюстр. Pay attention to an inhaling of two back bolts (look instructions more low):
– All bolts shown on иллюстр., tighten the moment of 60 Nanometers;
– All bolts shown on иллюстр. Are tightened without application динамометрического a key on a corner 90 (a turn quarter).
Back bolts of fastening of a head of cylinders: Owing to feature of a design the tightening of back bolts cannot be made at once on a corner 90 . At first one bolt on a corner 30 , then another is tightened. It is necessary to apply face keys of various length.
4. Establish on a head of cylinders a cover of a drive of the mechanism of distribution (the moment of an inhaling of 25 Nanometers).
5. Check up, that marks on a cogwheel of a camshaft and a camshaft arm coincided, and the ball on a flywheel was opposite to a pin in the block of cylinders. Fix a cogwheel of a camshaft the moment of 25 Nanometers (look иллюстр.).
6. Establish the new plastic screw of restriction of giving of fuel.
7. Further it is necessary to measure a backlash between persistent surfaces of a cover and the restrictive screw. For this purpose enter щуп in a place specified on иллюстр. If the backlash falls outside the limits 0.1 – 0.2 mm, the cover is necessary for removing and adjusting again, having put blow stupid оправкой on a persistent surface.
8. Check up, whether interfaced surfaces are well cleared and establish a new lining under a cover of a head of cylinders. In repair trucks of firm Opel to consolidation apply "Pattex". Long bolts establish under an arm.
9. Join штекерные connections of spark plugs.
10. Attach a ventilation hose картера to the inlet pipeline.
11. According to marks connect топливопроводы.
12. Attach to the inlet pipeline a weight cable.
13. Join all штекерные connections, attach a cable of a drive throttle заслонки and vacuum hoses.
14. Other works are made in sequence, return dismantling. It is necessary to grease bolts of connection of a reception pipe of the muffler and a final collector with graphite greasing. The hose всасывания air joins according to иллюстр.

ENGINE DOHC

Removal

Head of cylinders before removal to cool to a room temperature.

PERFORMANCE ORDER
1. Disconnect a cable of weight from the storage battery.
2. Merge a liquid from cooling system as it is described in section Section Refuelling of a cooler of system of cooling of the Head Current leaving and service. Cooling liquid can be collected in capacity and to use repeatedly if it was not too long maintained.
3. Расстыкуйте all штекерные connections also disconnect hoses from the inlet pipeline.
4. Расстыкуйте штекерные the connections shown on иллюстр. The tip (1) belongs to system EGR (рециркуляции the fulfilled gases), the tip (2) belongs to the gauge of the index of temperature of a cooling liquid, the tip (3) also belongs to the gauge (another) of temperature of a cooling liquid. A cable plait (4) disconnect from a collar and take aside.
5. Расстыкуйте others two штекерных connections. One tip belongs to the ignition module, another to the regulating gate of an adsorber. Last is called also as the evaporator gate.
6. Disconnect a hose of a cooling liquid from an adapter on the ignition module.
7. Lift and establish a forward part of the car on supports. Turn away bolts and remove a pallet guard картера from the chassis.
8. Remove from the forward party of the engine демпфер крутильных fluctuations. For prevention проворачивания a cranked shaft at отворачивании fastening bolts демпфера keep the central bolt.
9. Turn away bolts and disconnect a reception pipe from a final collector.
Uncover cables of spark plugs a cover of a head of cylinders.
10. On the party of a drive of the mechanism of distribution, approximately in the centre of a gear belt расстыкуйте штекерное connection (the gauge of position of a camshaft).
11. Turn away screws and uncover cables a protective cover of a gear belt, take aside cables and, having turned away all bolts, remove a protective cover.
12. Now remove a gear belt. For this purpose ослабьте a bolt of fastening of a tension roller also turn the adjusting clown in an arrow direction (clockwise) so that the index (1) on иллюстр. Was opposite to the left emphasis (equally for engines OHC and DOHC). Now cautiously remove a gear belt from a camshaft wheel.
13. Disconnect two hoses of a cooling liquid from branch pipes.
14. Disconnect the top hose of a cooling liquid from the thermostat case. The hose (1) is shown on иллюстр.
15. Disconnect an air hose from the return valve of system of secondary air. At new engines this system is absent.
16. Disconnect and take out a ventilating hose (1) on иллюстр.
17. Расстыкуйте штекерные connections of spark plugs. For this purpose there is a special tool.
Uncover heads of cylinders. Pay attention to presence of a sealing ring.
18. Keeping both cogwheels of a camshaft from проворачивания the wrench which has been put on on шестигранник of a camshaft, turn away bolts of fastening of wheels. Remove both cogwheels. Turn out also the gauge of position of the camshaft, located in the middle between both camshafts.
19. Turn away 5 bolts (two from below, three from above) and remove an internal guard of the engine.
20. Before removal of covers of bearings of a camshaft it is necessary to pay attention to digital marks of covers that will help to establish later them on the former places. Ослабьте nuts of fastening of covers for some receptions cross-wise (each reception from a half-turn to one turn) so that they freely turned away. One after another remove covers and take out camshafts. Ahead there is a persistent bearing.
Remove from a camshaft an epiploon. The arrangement of marks of covers is shown on иллюстр.
21. Turn away bolts of fastening of a head of cylinders for some receptions in the sequence shown on иллюстр. For the first reception bolts turn away on a corner which is not exceeding a quarter of a turn. Bolts turn away a face key "Torx 55". On иллюстр. The engine with восемью valves, however an arrangement of bolts at the considered engine the similar is shown.
22. Remove a head of cylinders and remove a lining. Strongly sitting head of cylinders it is possible обстучать a rubber hammer. It is not necessary to separate a head of cylinders from the block of cylinders by means of a screw-driver.
Carefully clear surfaces of a head and the block of cylinders and check up planeness of their surfaces a steel ruler as it is described more low. Apertures under bolts of fastening of a head of cylinders should not contain oil which can form hydraulic pillows.

Installation


The head of cylinders as follows is established:

PERFORMANCE ORDER
1. Put on a head of cylinders a lining so that the inscription "OBEN/TOP" was above and from outside a drive of the mechanism of distribution.
2. Establish a head on the block of cylinders and обстучите its rubber hammer. Directing plugs should enter into corresponding apertures.
3. Screw new bolts of fastening of a head of cylinders (them always it is necessary to replace) and tighten against the stop.
4. Tighten bolts in sequence, the return scheme resulted on иллюстр. The inhaling of bolts should be made with application already mentioned above the complete set of face heads as follows:
– Tighten all bolts in the specified sequence the moment of 25 Nanometers;
– By means of a face head in the specified sequence tighten each bolt on a corner 90 (a turn quarter) without application динамометрического a key;
– From this position also in the specified sequence again tighten each bolt on 90 ;
– Once again tighten all bolts in the specified sequence on a corner 90 . Thus, turn on 90 is made three times.
The angle of rotation of bolts specified above is reached as follows. The head is established on a bolt so that its handle was parallel to a head of cylinders. After turn on a corner 90 the handle should occupy position, perpendicular a longitudinal axis of a head of cylinders.
5. Grease with graphite greasing working surfaces of hydropushers and necks of camshafts and lay camshafts in a head of cylinders.
6. Grease with hermetic an interfaced surface of the forward directing bearing (1) on иллюстр. Also establish the bearing. Establish other covers of the bearing. At once check up, whether marks of covers coincide with corresponding marks on a head of cylinders (иллюстр. Above).
7. Tighten nuts of fastening of covers cross-wise the moment of 8 Nanometers.
8. Tighten bolts a back protective cover of a gear belt. Screw the gauge of position of a camshaft (6 Nanometers).
9. Put on cogwheels camshafts labels outside. Position of cogwheels is shown on иллюстр. In the centre marks "ЕХ" and "IN" are visible. Cogwheels put on so that the wheel of a camshaft of inlet valves has entered into an aperture having marks "ЕХ".
10. Insert bolts and, keeping a camshaft a wrench for шестигранник, tighten them. At first the moment of 50 Nanometers, then from the reached position on a corner 60 and in the end once again on 15 .
11. Turn camshafts so that the label on a cogwheel (2) has risen opposite to a nouse on a forward cover of the bearing (1). Turn in a rotation direction a cranked shaft (a head on the central bolt of a cogwheel) so that marks on a wheel of a cranked shaft were opposite to a label of the block of cylinders. After that put on a gear belt and pull it as, it is described in corresponding section for engine DOHC.
12. Establish a cover of a head of cylinders with new sealing rings.
13. Other works are carried out in sequence, return dismantling. At assemblage maintain following moments of an inhaling: демпфер крутильных fluctuations of 20 Nanometers, a flange of system of ventilation картера (a new lining) 25 Nanometers, forward and back protective covers of a gear belt of 8 Nanometers, a cover of spark plugs of 3 Nanometers.

Dismantling and assemblage of a head of cylinders


Because the design of a head of cylinders depends on engine type, the description of section of assemblage and dismantling of a head of cylinders is resulted separately for each type of the engine. The description of dismantling and assemblage of a head of cylinders irrespective of is more low resulted, it was under repair or not.

ENGINE OHC – WITH THE GEAR BELT OF THE DRIVE OF THE MECHANISM OF DISTRIBUTION


Dismantling

PERFORMANCE ORDER
1. Take out hydropushers and put as installation.
2. In the established sequence disconnect from a head of cylinders a branch pipe of a cooling liquid, the thermostat case, the holder of the module of ignition, a spark plug (a special key), the heat-shielding screen, a final collector and the inlet pipeline.
3. Klapannye plates have marks (marks чертилкой), as is shown in иллюстр. That allows to establish at assemblage them on former places.
4. For removal of valves it is necessary to apply the adaptation to compression клапанных springs. The adaptation is established not a head of cylinders, as is shown in иллюстр. By pressing the adaptation lever are compressed клапанные springs. After that crackers, springs, plates and маслоотражательные caps can be removed. Further directing plugs are taken out.
5. Remove cautiously маслоотражательные caps by means of a screw-driver or nippers from directing plugs. Under them there are basic washers of springs which can be removed now. Caps should be thrown out at once (are subject to replacement).
Carefully clear all details and if it is required, check up according to subsection requirements "Repair of a head of cylinders".

Assemblage

Assemblage is made as follows:

PERFORMANCE ORDER
1. Grease valves with impellent oil and insert in directing (according to marks).
2. Put on valves and directing маслоотражательные caps. For an exception of damage of caps put on the ends of cores of valves protective plastic tips (иллюстр.).
3. After installation of a spring, remote rings (final valves - 1), basic washers (inlet valves - 2), маслосъемных caps (3) and plates (5) compress springs (4) and insert crackers (6). Internal surfaces of crackers grease with a thin layer of greasing that they were pasted. Slowly release a spring, watching that crackers were correctly established.
The head of cylinders in sequence, its return dismantling gathers. Thus it is necessary to maintain following moments of an inhaling: (look Specifications).
4a. A lining of hoses of engine OHC from the middle of 1995 of release.
4b. At engine OHC from the middle of 1995 of release on the case of bearings of a camshaft the cover with a cardboard lining is established.
5. In summary oil hydropushers and insert them into corresponding apertures of a head of cylinders. Do not interchange the position of pushers.

INSTRUCTIONS ON ENGINE OHC WITH THE DRIVE OF DISTRIBUTION FROM THE GEAR BELT

At older models of engines "With 20 NE" at final valves devices of turn of valves, and at final valves steel rings are established. Differences in a design of valves are visible on иллюстр. Above. With the advent of the engine "X 20 SE" devices of turn of valves have been cleaned, and on their place remote washers are established.
At the new engine the ventilation hose картера is deduced not to картеру, and to a cover of bearings of a camshaft. The lining of hoses is shown on иллюстр. Point 4а. Established on old model of the engine the ignition distributor is replaced at the new engine by the ignition module. The case of bearings of a camshaft is closed by a cardboard lining. It excludes application of an epiploon of a camshaft (иллюстр. Point 4b).

PERFORMANCE ORDER
1. At new model of the engine heat-shielding pipes for protection штекерного connections of spark plugs are established. Here candles with шестигранником on a turn-key basis "on 16" have been applied. Pipes act in film special tool KM-834.
2. The module of ignition mentioned above is behind, to the right of the engine in a place shown on иллюстр.

ENGINE OHC – WITH THE CHAIN MECHANISM OF DISTRIBUTION


Dismantling

PERFORMANCE ORDER
1. Turn away bolts of fastening and remove the inlet pipeline, a final collector and the thermostat case.
2. Remove коромысла and pushers. Turn away bolts and remove both covers, back and lateral.
3. Cautiously take out a camshaft from bearings, without striking cams and necks on working surfaces of bearings.
Instructions

The camshaft of the considered engine has on a face surface marks "U". Besides, the camshaft has two-coloured sine / brown marks. The camshaft with violet marks is repair at which diameter of necks is reduced by 0.10 mm.


4. Take out valves as it was described earlier, and spread out them as installation.
5. Take out nippers маслоотражательные caps.
6. Turn out spark plugs.

Assemblage

The head of cylinders as follows gathers:

PERFORMANCE ORDER
1. Put on new маслоотражательные caps on directing valves (see иллюстр.) and напрессуйте their piece of a pipe.
2. Plentifully grease маслоотражательные the caps directing and cores of valves with oil and establish into place. Valves establish on the places according to marks or if they were ground, in the corresponding directing. Inlet valves have carving elements, final have no.
3. Plentifully oil necks of a camshaft and insert a shaft in front into a head of cylinders and prop up it through assembly apertures.
4. Establish коромысла and pushers.
5. Establish on places other removed details.

ENGINE DOHC


Dismantling

PERFORMANCE ORDER
1. Remove a flange of a supply of a cooling liquid and the thermostat case.
2. Turn away bolts and remove from a head of cylinders the holder of the module of ignition.
3. Remove the inlet pipeline and a final collector, turn away bolts of fastening and remove eyes from a head of cylinders. Remove also a load-lifting eye.
4. Remove valves as it was described for engine OHC. The Same concerns removal маслоотражательных caps. Valves as their installation on heads of cylinders insert into a cardboard box, having pierced its bottom. From outside boxes where valves of a forward part of the engine are located put corresponding marks.
5. Remove nippers basic washers of springs. All details carefully clear and check up, how it is described in subsection "Repair of a head of cylinders". In need of a detail replace.
The head of cylinders in sequence, return dismantling and according to the description for engine OHC gathers. Thus it is necessary to maintain following moments of an inhaling: (Specifications) see.
In summary insert hydropushers into corresponding apertures (plentifully grease). The pushers which were in the use insert into the apertures.

INSTRUCTIONS FOR ENGINE DOHC FROM THE MIDDLE OF 1995 OF RELEASE


PERFORMANCE ORDER
1. The engine of this type from the middle of 1995 of release has the valve рециркуляции the fulfilled gases and the valve of ventilation of the fuel tank, the heads of cylinders located on an underside as it is shown on иллюстр.
2. At this engine the system of giving of secondary air is established also. Under certain conditions operation the electropump submits additional air to a final collector for maintenance decrease in the fulfilled gases of harmful substances. Thanks to it the temperature of the fulfilled gases raises also that in turn raises efficiency of action каталитического neutralizer.
Before removal of a head of cylinders it is necessary to remove from a final collector of a detail of system of giving of secondary air. On a branch pipe of giving of air before its installation on a final collector the sealing ring should be replaced. The arrangement mentioned above details is shown on иллюстр. The ignition module is behind, on the right on a head of cylinders just as it is shown on иллюстр. Above.

THE RECOMMENDATION ABOUT REPAIR OF ENGINES OF ALL TYPES

The piece of a pipe established on the top plate of a spring can be applied to removal of valves. The bottom basic washer should have a good support thus. Strike a hammer sharp blow to a pipe piece so that crackers have jumped out. They should remain in a pipe. That crackers have not flown away aside, the pipe should have good contact to a plate.

Repair of a head of cylinders

Resulted below instructions concern engine OHC. Concerning the differences, concerning other engines, instructions are resulted in the end of section.

КЛАПАННЫЕ SPRINGS

PERFORMANCE ORDER
The length of a spring changes in a free condition, as is shown in иллюстр. All springs should have identical length.
The special adaptation should be applied to the control of effort of a spring. At its absence arrive as follows:
1. Compare the spring which was in the use to the new. For this purpose springs put one to another and clamp in a vice. If springs are deformed on the same size it specifies in approximately their equal rigidity.
2. If the spring which was in the use is compressed more than new it specifies in weariness of a spring and it should be replaced in the complete set.
3. Establish springs one after another on an equal surface (for example, on glass) the closed coil downwards. Near to a spring put a steel square. The backlash between a spring and a square should not exceed 2.0 mm. The big size of a backlash specifies a spring in deformation. In this case the spring is replaced.

DIRECTING PLUGS OF VALVES

PERFORMANCE ORDER
1. Clear directing plugs by means of a fabric moistened in gasoline. Clear also cores of valves. After that insert valves into the directing.
2. Establish on heads of cylinders on the holder the indicator (иллюстр.). Put forward the valve from directing so that its end was заподлицо with an edge of a head of cylinders directing on another party, moving a valve plate forward and back in an arrow direction.
3a. Move a hand a plate of the valve and take readings of the indicator. If the indicator shows a deviation more than 1.0 mm at inlet and more than 1.3 mm at the final valve in most cases it specifies in necessity of replacement directing. More exact results are given by measurement of internal diameter directing and external diameter of a core of the valve by means of a micrometer, as shown, accordingly on иллюстр. 3a and 3b in several sections and directions.
At the left measurement places are shown.
3b. The difference between the greatest value of diameter of the plug and to the least values of diameter of a core gives a backlash in interface. At replacement of directing plugs it is necessary to mean the following:
4. In the course of assemblage at factory on the engine valves with the increased repair size can be established.
5. Directing plugs and valves have marks. Details with the minimum sizes of marks have no, the details going as spare parts have marks "To". Other marks mean the following (in brackets a designation spare directing):
6. Directing plugs can be developed the next repair size. In this case on the directing corresponding marks are put. Are developed directing from above (иллюстр.).
7. Check up the general condition of a head of cylinders before to replace the directing.
8. Directing выпрессовывается from a head of cylinders from outside chambers of combustion with the help оправки. Оправка should have on the end проточку, diameter equal to internal diameter of the directing.
9. If are replaced directing to replacement are subject as well valves. After that it is necessary to grind in saddles of valves.
Plentifully grease new directing and запрессуйте them from outside a camshaft in a cold head of cylinders.
10. Develop directing after запрессовки special development. If such development is not present, it is possible to use adjustable development. To develop directing it is necessary taking into account a backlash resulted in Specifications. If replacement directing is made, saddles of valves should be milled. Therefore at first it is necessary to read the instructions resulted in subsection "Saddle of valves".

SADDLES OF VALVES

The control grew grey valves is made by means of special кали. Owing to complexity of considered work it is recommended to hand over a head of cylinders in repair in a repair truck.

PERFORMANCE ORDER
1. Check up all saddles on presence of wear tracks and any damages. Small wear tracks can be eliminated a mill with a corner 45 . If saddles have considerable deterioration, they are necessary for milling. It is necessary to mean that saddles should not run into a head of cylinders too deeply. For this purpose the valve is inserted into an aperture and on the other hand the length of an acting part of a core of the valve in special calibre is measured.
2. Saddles should be milled, if new directing plugs were established. It is made as follows:
– Mill a saddle at an angle 45 ;
– Slightly mill the top edge of a saddle at an angle 15 , and bottom at an angle 60 so that the width of a working facet of a saddle of the inlet valve made 1.0 – 1.5 mm, and final 1. 7 – 2.2 mm.
If as a result of milling the valve core grew grey acts too far from a head of cylinders, it is necessary to spend measurement with new valves. If and in this case the result turns out unsatisfactory it is necessary to change a head of cylinders.
At engine OHC of a saddle of valves are not subject to replacement.
3. After milling of saddles they should be ground in. For this purpose paste is put on a saddle surface притирочная, and the valve is inserted into the nest. On a valve head the sucker and the valve is established turns alternately in both parties (иллюстр.). Periodically the valve should be lifted a sucker and to turn on a turn quarter.
4. After grinding in all details carefully clear of pollution and paste and check up interface of the valve to a saddle. Interface is satisfactory if as a result поворачивания the valve on details there is the continuous and well visible ring which width is equal to width of the interfaced surface.
5. Put a pencil strokes on all circle of a working facet of the valve on distance about 1 mm from each other. After that cautiously lower valves in an aperture of the directing plug and turn the valve on 90 , slightly having pressed it.
6. Again take out the valve and check up, whether pencil strokes from a working facet of a plate of the valve have disappeared. If the width of a working facet corresponds set, the head of cylinders can be established into place. Otherwise saddles demand processing. In case of impossibility of achievement of preset values machining of a head of cylinders is subject to replacement. Concerning repair of a head of cylinders you can receive consultations in a repair truck.

VALVES

Insignificant damages on a working surface of a head of the valve can be corrected grinding in as it is described above.

PERFORMANCE ORDER
1. Measure the parametres of valves specified on иллюстр (a = diameter of a plate of the valve, b = diameter of a core of the valve). In case of discrepancy to preset values valves replace with the new. Keep in mind differences between inlet and final valves. The necessary data is resulted in Specifications.
2. If the ends of cores of valves have deterioration, valves are replaced, as cores are not ground.
3. Plates of valves can be ground on the special grinding machine tool. However this operation cannot is made more than 1 – 2 times. As it was already mentioned, выступание the valve from an underside of a head of cylinders should have certain size which as a result of grinding of a plate of the valve can change.

The damaged valves can be restored by means of grinding in. If it does not manage to be reached, the valve is replaced. It is necessary to measure diameters of cores of valves and apertures of directing plugs and on the basis of the received result to draw a conclusion on expediency of carrying out of the further works with a head of cylinders.

HEAD OF CYLINDERS


PERFORMANCE ORDER
1. Carefully clear interfaced surfaces of a head and the block of cylinders. Check up a surface of a head of cylinders on неплоскостность. For this purpose impose on a surface a steel ruler, as is shown in иллюстр., also check up щупом a backlash between a ruler and a surface of a head of cylinders. If in a backlash passes щуп more than 0.10 mm, the head of cylinders is necessary for grinding.
2. If the backlash is even more, it is necessary to replace a head of cylinders.

The head of cylinders can be ground until its height did not become is minimum admissible (Specifications see). Otherwise it is necessary to replace a head of cylinders. It is necessary to take also into consideration necessity of observance of certain size выступания the valve over a head of cylinders.

CAMSHAFT


The works connected with a camshaft are described in subsection "the Mechanism газораспределения".

Assemblage of a head of cylinders

The head of cylinders gathers according to already resulted above in section "Dismantling and assemblage of a head of cylinders" instructions according to engine type.

ONLY FOR THE ENGINE OF 2.4 L


PERFORMANCE ORDER
1. For restoration of working capacity valves can 1 – to be ground 2 times (repair truck work). Watch that the width of working facets of heads of valves did not leave for the established values.
2. As it has been described above, выступание a valve core over a head of cylinders should have certain size. For measurement the special tool is used.
3. The corner of a working facet of a plate of the valve makes 44 , a corner of a working facet of a saddle of the valve 45 . It is not necessary to confuse them.
4. There are directing plugs of two repair sizes (diameters are increased by 0.075 and 0.150 mm). Corresponding marks are put on the right and left parties of an aperture under spark plugs.
5. The width of a working facet of a saddle makes 1.15 – 1.65 mm for inlet and 1.5 – 2.0 mm for final valves. The top adjustment corner makes 30 and bottom 75 .
6. The width of a working facet makes 2.6 – 3.0 mm at inlet and 3.7 – 4.1 mm at final valves.
7. The backlash in interface of a core of the valve to the directing plug makes 0.035 – 0.073 mm at inlet and 0.045 – 0.085 mm at final valves. There are valves of the repair sizes. It is necessary to mean that at factory can be established directing the repair sizes.
8. Check up in the way described above неплоскостность an interfaced surface of a head of cylinders. At length of 150 mm the backlash should not exceed 0.015 mm. On all greatest length неплоскостность should not exceed 0.04 mm. As a result of polishing of a head of cylinders its minimum height should not be less than 102.45 mm.

REALLY ONLY FOR ENGINE DOHC

PERFORMANCE ORDER
1. Compare the data received as a result of measurement of size выступания of the valve, to the data resulted in Specifications. If the data leaves for the established values, the head of cylinders is replaced (it is preliminary necessary to insert new valves and to measure size выступания with them).
2. For the engine of this type are available directing the normal size and two repair directing with a diameter increased by 0.075 and 0.150 mm. Marks correspond to engine OHC marks.
3. The width of a working facet of the inlet valve makes 1.0 – 1.4 mm, final 1.4 – 1.8 mm.
4. The height of a head of cylinders between two interfaced planes at engine DOHC is various (134.0 mm).
5. If the valve plate is ground on the machine tool it is necessary to maintain a corner of a facet 44 40 ".
6. The ends of cores of valves are not ground. However they should not have any забоин.
7. Measure valves according to the scheme on иллюстр. 6.186 also compare the obtained data to the data of Specifications. Too narrow working facets of valves reduce tightness of the chamber of combustion.
8. The corner of a working facet of a saddle of the valve makes 45 (2). The top adjustment corner is equal 30 (1), bottom 60 (3). The scheme of an arrangement of corners is shown on иллюстр.