S40/V40
1. General information
2. Operation and maintenance of the car
3. Design and technical characteristics of engines
4. Repair of the engine
4.1. Removal of a head of the block of cylinders
4.2. Installation of a head of the block of cylinders
4.3. Removal and installation of support of the engine
4.4. Removal of the engine
4.5. Dismantling and assessment of a condition of details of the engine
4.5.1. Dismantling of the engine
4.5.2. Dismantling, troubleshooting and repair of a head of the block of cylinders
4.6. Assembly and installation of the engine
5. Transmission
6. Brake system
7. Forward suspension bracket and steering
8. Back suspension bracket
9. Control system of the Fenix 5.1 engine
10. Electric equipment. Conducting and components
11. Body
12. Schemes of electric equipment
 



13c91ae0




4-5-2-razborka-defektovka-i-remont-golovki-bloka-cilindrov.html

4.5.2. Dismantling, troubleshooting and repair of a head of the block of cylinders

Sequence of actions:
1) using the holder 999 5199, remove pulleys of camshafts, having marked them with a felt-tip pen or something similar (inlet and final);

       NOTE
When the belt of the drive of the camshaft is taken off, not to allow rotation of pulleys of camshafts in order to avoid damage of valves.

2) serially turn out all bolts of the top section of a head of the block, moving from the center to edges;
3) remove the top section, carefully tapping with the plastic hammer near removable ledges and at a forward part of camshafts;
4) remove camshafts, at the same time lifting and turning them;
5) turn out bolts of fastening of the lower section of a head of the block of cylinders (moving ahead from the center to edges);
6) remove a head and laying from the block;
7) clear the surfaces of the socket on the top and lower sections of a head of the block of cylinders by means of mastic and the plastic pallet; wash out surfaces water and dry up alcohol;
8) take pushers from a head of cylinders. For simplification of extraction of pushers it is possible to use a magnet or a sucker; The Sizes of details are specified in the section 3 "Design and Technical Characteristics of Engines";
9) check existence of wear tracks on pushers. If necessary execute measurements;
10) in avoidance of an effluence of oil you store pushers in vertical position. Arrange pushers one after another — they cannot be interchanged the position. At long storage of pushers they should be placed in the vessel filled with oil, considering type of oil which will fill the engine after the end of repair;

Fig. 4.44. Hydraulic pusher of the valve


Fig. 4.45. Removal of valves


11) remove valves (fig. 4.45), using a clip for valves 998 6052 and a bracket 951 2051 (four valves on the cylinder);
12) remove crackers of valves, the top plates of valvate springs, springs of valves, valves;

Fig. 4.46. Removal of oil scraper caps


13) remove oil scraper caps of cores of valves, using adaptation 999 5219 (fig. 4.46);

       NOTE
Mark valves that at assembly to establish everyone on the place.

14) clear a cylinder head;
15) clear the surfaces of interface;
16) clear combustion chambers;
17) clear inlet and final channels;
18) clear saddles of valves;
19) examine a head of cylinders on existence of wear tracks;
20) clean a carving of nests of spark plugs (a tap of M14x1,25);
21) clear valves, springs of valves and a plate of valvate springs;
22) in the presence of cracks in saddles of valves process saddles by means of a mill 115 8280 with a guide with a diameter of 7 mm and a tilt angle of the cutting edge 45.

       PREVENTION
Not to concern a mill of walls of the combustion chamber.

Cleaning of channels of air supply

Sequence of actions:
1) smooth out channels of air supply (4 mm) on the maximum depth. Blow channels compressed air from an admission on the top part of a head of cylinders. Make sure that air passes across canals;
2) check planeness of the lower section of a head of cylinders;

       ATTENTION
Machining of a head of cylinders for removal of zadir and traces of corrosion damage from the surfaces of interface of a head to the block of cylinders is carried out only if not planeness of a head of cylinders is in norm limits.


Fig. 4.47. Measurement of wear of the directing plugs of valves


3) measure wear of the directing plugs of valves by means of the indicator of the sentry like (fig. 4.47) fixed on a magnetic rack;

       NOTE
When checking of the directing plug raise the valve approximately by 2 — 3 mm over a saddle.

4) check springs of valves. Check the sizes of valves. The sizes of details are specified in section 3: "Design and technical characteristics of engines".

Replacement of guides
plugs of valves

Sequence of actions:

Fig. 4.48. The head of the block of cylinders established on a clamp 999 5363


1) fix a head of cylinders on a clamp of 999 5363 (fig. 4.48);
2) adjust a tilt angle by means of the top openings of a clamp on each side;
3) fix a head of cylinders on a clamp, using an opening 2 (shooters), at a vypressovka the mandrel has to settle down vertically;
4) to a vypressuyta the replaced directing plugs (it is carried out in three stages):
— to a vypressuyta the directing plugs by means of a mandrel 999 5364. Use plugs as laying for bolts of a head of cylinders. Slowly press a mandrel until it reaches a head of cylinders. If the directing plug is damaged, remove parts of metal;
— continue a vypressovyvaniye by means of a mandrel 999 5365. Examine the top part of an opening under the directing plug. (Leave old plugs on the places as guides at a press fitting of the new plug). If on walls of an opening there are deep risks and teases, it is necessary to use the directing plug of the repair size. For installation of the directing plug of the repair size it is necessary to develop an opening;

       NOTE
Expansion is carried out to one of the repair sizes (OS1 and OS2). In most cases for OS1 development is not required.

— grease and install the new directing plug on a mandrel 999 5505 and to slowly press it in a head of cylinders until the mandrel reaches a surface of a head of cylinders. The directing plug has to be pressed on 13±0,2 mm. Height is established by means of the tool. Deformation in the top part of a guide is eliminated with development. The new directing plugs can be shorter than plugs of the previous design.

       NOTE
The effort of a press fitting has to be not less than 920 kgfs. If the effort is less, it is necessary to take out the plug and to install the directing plug of the repair size.

Machining
valves and their saddles

The sizes of details are specified in the section 3 "Design and Technical Characteristics of Engines".
Sequence of actions:
— to a proshlifuyta of a facet of inlet valves. The final valves covered stellity have to get used precisely manually by means of grinding paste;
— process facets of saddles of valves. Not to concern a mill of walls of the combustion chamber at all;

Fig. 4.49. Check of height of a vystupaniye of a core of the valve


— check valve core vystupaniye height, using caliber of 999 5222 (fig. 4.49);
— establish caliber in nests of bearings of the camshaft;
— measure valve core vystupaniye height, having passed a caliper shaft through an opening in caliber.

Installation of valves

Sequence of actions:
— grease cores and the directing plugs of valves;
— install valves;
— install the lower plate of a valvate spring, valves on the places;
— establish an oil scraper cap on a valve core;
— as it is possible more deeply for a napressuyta an oil scraper cap on the directing valve plug, putting effort of a hand. To use a mandrel 999 5379;

       PREVENTION
In order to avoid damages it is impossible to use the hammer for installation of oil scraper caps of valves.

— establish a spring of the valve and the top plate of a spring, using a clip for valves and a bracket, valve crackers. To be convinced that in the absence of load of a spring both half of crackers are in the correct situation.

Repair of a carving


Fig. 4.50. Carving inserts. The insert has a pad with a cut which is broken out after installation


Repair of a female thread in the block of cylinders, intermediate section and a head of cylinders is carried out by means of carving inserts. However the carving in some openings cannot be repaired this way as surrounding metal has insufficient thickness. Carving inserts (fig. 4.50) made of a holodnokatany wire (stainless acidproof steel) have the carving profiles conforming to the MOS standards. Inserts are intended for installation in openings with a carving, according to tables of standard carving inserts.
Order of installation of a carving insert following:

Fig. 4.51. Drilling of the repaired opening


1) drill the repaired opening (fig. 4.51). Determine diameter of a drill and depth of drilling by the tables of carving inserts attached to the last. It is not necessary to zenkovat opening edges. Only small processing for the purpose of removal of agnails is recommended;
2) pick up a tap depending on material and other specific conditions. For example, for an opening with a carving of M10 use a carving insert of M10;

Fig. 4.52. Cutting of a carving tap


3) cut a carving on the necessary depth (fig. 4.52);
4) blow an opening compressed air;
5) pick up a carving insert of necessary length;

Fig. 4.53. The adjusting tool with a carving insert


6) place a carving insert in the adjusting tool (fig. 4.53). The insert has to settle down a pad down;
7) establish a carving insert in an opening.

Fig. 4.54. Vvorachivany a carving insert in an opening


8) holding the adjusting tool vertically over an opening with the cut carving, screw an insert in an opening (fig. 4.54). The insert is established so that she approximately on one step of a carving acted over an opening edge. In a through opening the carving insert should not support the lower edge of an opening;

Fig. 4.55. Breaking of a pad


9) break out a pad (fig. 4.55) by means of the special tool for breaking of a pad. Do not use the adjusting tool for this purpose. Take a pad and blow an opening compressed air;
10) by means of the corresponding bolt check that the insert is established correctly and the bolt is rolled freely.

"previous page
4.5.1. Dismantling of the engine
following page"
4.6. Assembly and installation of the engine