2.1.4. Head of the block of cylinders, gas distribution mechanism
The block of cylinders in collecting (4-cylinder models)| 1. Stopper of a maslozalivny mouth 2. Block head cover 3. Intensifying laying 4. Consolidation of a cover of a head of the block 5. Cam-shaft drive gear wheel you watch correctness of installation of a gear wheel when replacing a belt 6. Top cover of a belt of the drive of a cam-shaft 7. Gear remenprivoda of a cam-shaft 8. 45 N. of m. 9. Roller of a natyazhitel |
10. Back cover of a belt of the drive of a cam-shaft 11. 25 N. of m. 12. Laying of a head of the block the tag of "OBEN" has to be turned towards a block head 13. Consolidation surely replace 14. Cam-shaft cover 15. Block head bolt |
The head of cylinders can be removed without dismantle of the engine from the car.
At installation of the repaired head grease contact surfaces of cams of a cam-shaft and pushers.
Head of the block of cylinders – deformation check
| deformation of a head is checked by caliber 1030 and the probe tolerance from the plane of 0,1 mm |
Prevention
Installation of a head of the block of cylinders
Order of an inhaling of bolts
|
|
| PERFORMANCE ORDER | |||||||
|
Cam-shafts / valves (4-cylinder models)
|
|
|
1. 20 N. of m. |
9. Head of the block of cylinders 10. The directing plug 11. Oil scraper cap 12. External and internal springs removal / installation is carried out by adaptation 2037 13. The plate of a spring of the valve differs on outer diameter 14. Crackers 15. Segment spline check landing 16. 80 N. of m. 17. Cam-shaft check of an axial side play is carried out in compliance identification of a cam-shaft is carried out in compliance the radial gap of basic bearings is checked by plastic caliber limit gap 0, 1 mm limit development of 0,01 mm |
Check of an axial side play
| measure at the removed pushers and the established covers of the 1st and 5th bearings install indicator VW 387 adaptation according to the drawing the axial side play is measured by cam-shaft shift in the direction of an arrow limit side play of 0,15 mm |
Identification of a cam-shaft
| |
basic diameter of a cam and = 34,0 mm |
|
Engine code
|
Arrow I
|
Arrow II
|
|
3A
|
G
|
026
|
Covers of bearings of a cam-shaft
Before installation of a cam-shaft pay attention to landing of covers of bearings. At the wrong landing the shift of covers is observed. Correctly establish covers.
Correct installation
| |
Cam-shaft
| |
Removal
| PERFORMANCE ORDER | |||||||
|
Installation
Prevention
| PERFORMANCE ORDER | |||
|
Hydraulic pushers – check
Prevention
Always replace a pusher in collecting (the pusher is not subject to repair or adjustment).
At the first launch of the engine the rumble of low frequency from the gas distribution mechanism is allowed.
Cam-shaft epiploon
Removal
| PERFORMANCE ORDER | ||||||||||||||||||||||
|
||||||||||||||||||||||
Installation
| PERFORMANCE ORDER | ||
|
Sizes of valves
The sizes of valves in mm
|
Inlet valve
|
Final valve
| |
|
Diameter and
|
40,0
|
33,0
|
|
Diameter of b
|
7,97
|
7,95
|
|
Length with
|
91,0
|
90,8
|
Prevention
If necessary, carry out grinding in manually.
Saddles of valves – regrinding
The minimum size for the inlet valve of 33,8 mm
The minimum size for the final valve of 34,1 mm
"And" to subtract the minimum size from the measured distance
The maximum permissible amount of regrinding (removal of a facet) of b saddle turns out
Calculations of the maximum permissible amount of regrinding of a saddle of b
| insert the valve and strongly press to a saddle measure distance and between an end face of a core of the valve and the plane of a head of the block calculate the maximum permissible amount of regrinding of a saddle of b, knowing the size and |
Minimum size
if the measured distance and is less than the minimum size, then a hydraulic pusher will not work and the head of the block of cylinders should be replaced
Saddle of the inlet valve – regrinding
| and = 39,2 mm b = maximum permissible amount of regrinding Z = plane of a head of the block of cylinders 30 ° = a corner of the aligning facet 45 ° = valve saddle facet corner |
Saddle of the final valve – regrinding
| and = 32,4 mm b = maximum permissible amount of regrinding with = 2,4 mm are approximately equal Z = the plane of a head of the block of cylinders (from the lower party) 30 ° = a corner of the aligning facet 45 ° = valve saddle facet corner |
Grinding in of valves
Prevention
Check of the directing plugs is carried out first of all. Oil scraper caps – replacement (without removal of a head of the block)
The head of the block of cylinders can be removed without dismantle of the engine from the car. At installation of the repaired head of the block grease cams of a cam-shaft and hydraulic pushers. Head of the block of cylinders – deformation check 1 – an inhaling with m 40 N.' moment. 2 – an inhaling with m 60 N.' moment. 3 – an inhaling – tighten on 1/2 turns (180 °) one movement (it is allowed доворот in two steps on 90 °) limit axial side play of 0,15 mm check correctness of provision of covers of bearings on symmetry of their installation Valve sizes Saddles of valves – regrinding The minimum size for the inlet valve of 33,8 mm The minimum size for the final valve of 34,1 mm "And" to subtract the minimum size from the measured distance The maximum permissible amount of regrinding (removal of a facet) of b saddle turns out Minimum size If the measured distance and is less than the minimum size, then a hydraulic pusher will not work and the head of the block of cylinders should be replaced. Saddle of the inlet valve – regrinding b = maximum permissible amount of regrinding with = about 2,0 mm Z = plane of a head of the block of cylinders 30 ° = a corner of the aligning facet 45 ° = valve saddle facet corner
Saddle of the final valve – regrinding b = maximum permissible amount of regrinding with = about 2,0 mm Z = plane of a head of the block of cylinders 30 ° = a corner of the aligning facet 45 ° = valve saddle facet corner Inserts of final valves have smaller diameter. When grinding saddles do not damage the top edge. Check of a pusher always replace a pusher assembled the pusher is not subject to repair or adjustment Cam-shaft epiploon Removal Installation Arrangement valves / cam-shaft in collecting (Coupet's model) at installation of covers of bearings you watch symmetry of their arrangement The directing plugs – replacement Oil scraper caps Removal (without removal of a head of the block)
Installation 1. Stopper of a maslozalivny mouth Head of the block of cylinders – deformation check
tolerance from the plane of 0,1 mm Head of the block of cylinders – grinding the minimum size is 118,1 mm
apply pritirochny paste on a saddle, insert the valve into a saddle and turn in the direction back and forth (it is specified by shooters), having clamped the valve in a mandrel
Prevention
The directing plugs – check
PERFORMANCE ORDER
1) remove the deposit remains solvent
2) measurement of a gap is carried out by means of indicator VW 387 adaptation
3) insert the new valve into the directing plug
4) the end face of a core of the valve has to coincide with edge of the plug
Prevention
5) shake the valve, having rested against it an indicator leg
6) wear of guides corresponds to the indication of the indicator
1. Indication of the indicator
2. Inlet valves
3. Final valves
1,0 mm
1,3 mm
The directing plugs – replacement
Prevention
PERFORMANCE ORDER
1) to a vypressuyta worn-out guides of the plug from a cam-shaft by means of adaptation 10-206
Prevention
2) apply lubricant on new plugs and press them in a cold head of the block from a cam-shaft; press before full landing of plugs
Prevention
3) grease plugs with the lubricant cooling emulsion and deploy plugs by means of development 10-215
4) to a proshlifuyta of a saddle of valves
PERFORMANCE ORDER
1) remove a cam-shaft and pushers
2) turn out spark plugs
3) install the piston of the corresponding cylinder in the lower dead point
4) establish an emphasis 2036 and adjust the provision of hairpins
5) screw in a carving opening of a spark plug a head of a tester 1106 or an equivalent adapter, give pressure not less than 6 atm
6) remove springs VW 541/1 stripper
Prevention
7) by means of adaptation 3047-A remove oil scraper caps
8) put on the plastic plug A a valve core
9) grease an oil scraper cap In, insert it into a mandrel 10-204 and carefully dress a cap on the directing plug
Prevention
Prevention
Head of the block of cylinders (5-cylinder models)
1. 10 N. of m.
2. Intensifying laying
3. Spring washer
4. Back cover of a belt of the drive of a cam-shaft
5. Gear wheel
when replacing a belt, you watch for
correctness of provision of a gear wheel
6. 80 N. of m.
7. Top cover of a belt of the drive of a cam-shaft
8. 10 N. of m.
9. Gear belt of the drive of a cam-shaft 10. Remote plug
11. Laying of a head of the block
before removal remember the provision of a head
install on pins in the block of cylinders
12. Block of cylinders
13. Head of the block of cylinders
14. Block head bolt
observe an assembly order
15. Consolidation of a head of the block
is subject to replacement
16. Cover of a gopovka of the block of cylinders.
the maximum deviation from the plane of 0,1 mm
Installation of a head of the block of cylinders
Prevention
PERFORMANCE ORDER
1) screw the directing adaptation 3070 hairpins in openings of the 9 and 10 bolts of fastening of a head of the block
2) establish laying of a head of the block on the aligning hairpins (are specified by shooters)
3) attach a block head to the block of cylinders
4) wrap other 10 bolts of a head of the block, tighten them by hand
5) the screw-driver of adaptation 3070 turn out the directing hairpins from openings of the 9 and 10 bolts of fastening of a head of the block; wrap the 9th and 10th bolts of fastening of a head of the block, tighten them by hand
Bolts of fastening of a head of the block – an order of a vvorachivaniye and an inhaling
Order of an inhaling of bolts
tighten bolts according to numbering in the drawing, turn off upside-down
Tighten bolts in three steps on the cold engine:
Prevention
Cam-shaft / valve (5-cylinder engines)
1. Covers of bearings of a cam-shaft
2. 20 N. of m.
3. Cam-shaft
check of an axial side play is carried out
in compliance
identification of a cam-shaft
it is carried out in compliance
the radial gap of basic bearings is checked by plastic caliber
limit gap of 0,1 mm
4. Cam-shaft epiploon
grease working and external edges
5. Crackers
6. External and internal springs
removal / installation by adaptation 2037
7. Oil scraper cap
8. Lower plate
removal / installation by adaptation 3047
9. The directing plug
10. Block head
the size maintained when regrinding and = 132,75 mm
11. Valves
12. Head of the block of cylinders
13. The directing plug
14. Top plate of a valve spring
differs in the flat wide external surface turned towards a cam-shaft
15. Hydraulic pushers
before installation of new pushers check an axial side play of a cam-shaft
are not subject to repair and mutual substitution
before replacement check an axial side play of a cam-shaft
Cam-shaft, check of an axial side play
measure at the removed pushers and the 1 and 4 bearings installed a cover
Identification of a cam-shaft
the identification tag "034L" is put between cams of the 1st cylinder
Covers of bearings of a cam-shaft – installation
before installation of a cam-shaft grease the surfaces of bearings and a support
Prevention
Calculation of the maximum permissible amount of regrinding of a saddle
PERFORMANCE ORDER
1) insert the valve and strongly press to a saddle
2) measure distance and between an end face of a core of the valve and the top plane of a head of the block
3) calculate the maximum permissible amount of regrinding of a saddle of b, knowing the size and
and = 39,2 mm
and = 32,4 mm
put the removed pusher on the pure place contact (with a cam-shaft) a surface down
1) at the first launch of the engine the increased noise from pushers is allowed
2) warm up the engine before the first operation of the electric fan
3) bring engine speed to 2500 rpm, keep the engine in such mode within 2 min.
4) if noise of pushers did not disappear, then arrive as follows:
4a) uncover a block head
4b) turn the crankshaft for a pulley bolt clockwise so that cams of a cam-shaft of the corresponding cylinder were directed up
4v) a wooden stick slightly displace a pusher;
if the pusher departs more than on 0,1 mm, then replace it
Prevention
PERFORMANCE ORDER
1) remove the top cover of a belt of the drive of a cam-shaft
2) install the crankshaft in VMT of the 1st cylinder
3) weaken a belt tension, take off a belt
4) remove the conducted cam-shaft gear wheel
5) get a segment spline from a cam-shaft
6) wrap against the stop a cam-shaft bolt together with a washer
7) turn out an internal cartridge of a stripper of 2085 from external on two turns (about 3 mm) and record the screw
8) grease a carving part of a stripper of an epiploon
9) establish a stripper and with effort insert into an epiploon
10) release the screw with a nakatka and rotate an internal cartridge of a stripper concerning a cam-shaft to a full exit of an epiploon
11) clamp a stripper in a vice and get an epiploon flat-nose pliers
PERFORMANCE ORDER
1) slightly grease sponges and an external part of an epiploon
2) press an epiploon by means of adaptation 10-203 until the forward plane of an epiploon is not established aflush with the surface of the case;
at a press fitting use a special bolt 10-203/1 with a six-sided head
Prevention
Cam-shaft
1. Covers of bearings of a cam-shaft
2. 15 N. of m.
3. Epiploon
4. Cam-shaft drive chain
5. External spring of the valve
removal / installation is carried out by adaptation 2037 and / or adaptation 2036 together with VW541/1 and an emphasis of VW 541/5
6. Internal spring of the valve
removal / installation is carried out by adaptation 2037 and / or adaptation 2036 together with VW 541/1 and at the VW 541/5 ferry 7. Lower plate of a spring
removal / installation is carried out by adaptation 3047A
8. Oil scraper cap
9. The directing plug
10. Head of the block of cylinders
11. Inlet and final valves
grind in only manually
12. Cam-shaft cams
13. Pushers
14. Crackers
15. Top plate of a spring
Prevention
Removal
PERFORMANCE ORDER
1) remove the top cover of a belt of the drive of a cam-shaft
2) remove the top part of the soaking-up branch pipe
3) uncover a head of the block of cylinders
4) install the crankshaft in VMT of the 1st cylinder
5) weaken a tension of a gear belt, take off a belt
6) remove the conducted cam-shaft gear wheel
7) get a segment spline from a cam-shaft
8) uncover the 1 and 3 bearings;
turn off nuts of fastening of covers of the 2 and 4 bearings in a cross order on diagonal
Installation
at installation of a cam-shaft cams of the 1st cylinder have to be turned up
PERFORMANCE ORDER
1) check correctness of an arrangement of covers preliminary statement them into place
2) tighten nuts of fastening of covers of the 2 and 4 bearings in a cross order on diagonal; moment of an inhaling of 20 N. of m.
3) establish covers of the 1 and 3 bearings; moment of an inhaling of 20 N. of m.
4) establish the conducted gear wheel of a cam-shaft and tighten with the moment 80 N. of m.
The directing plugs – wear check
when checking wear install inlet and final valves in the corresponding guides of the plug as diameters of cores of these valves differ a little
PERFORMANCE ORDER
1) remove the deposit remains
2) install indicator VW 387 adaptation
3) insert the new valve into the directing plug
4) the end face of a core of the valve has to coincide with edge of the plug
5) shake the valve, having rested against it an indicator leg
6) wear of the directing plugs corresponds to the indication of the indicator
1. Limit indication of the indicator
2. Inlet valves
3. Final valves
The head of the block of cylinders, saddles of valves which do not allow further grinding or the head of the block of cylinders which was exposed to grinding to the extreme size, is not subject to further repair.
PERFORMANCE ORDER
1) to a vypressuyta worn-out guides of the plug from a cam-shaft by means of adaptation 10-206
2) if on the directing plugs there is a fillet, then it is necessary to press off them from the combustion chamber
3) apply lubricant on new plugs and press adaptation 10-206 in a cold head of the block from a cam-shaft
4) press against the stop in a fillet
5) deploy plugs manually by means of development 10-215
6) carry out development with the lubricant cooling emulsion
7) to a proshlifuyta of a saddle of valves
Prevention
Prevention
Arrangement of tools
PERFORMANCE ORDER
1) turn out spark plugs
2) remove a cam-shaft and pushers
3) install the piston of the corresponding cylinder in N.M.T.
4) establish an emphasis 2036 and adjust on height of hairpins
5) insert a hose 1106 or VW653/3 into a spark plug opening, give constant pressure not less than 6 atm
6) remove springs VW 541/1 stripper
7) if crackers badly give in to removal, then it is possible to weaken their landing easy percussion by the hammer on adaptation lever
Arrangement of components
PERFORMANCE ORDER
1) put on the plastic plug A a valve core
2) grease an oil scraper cap In and carefully dress a cap on the directing plug together with a plastic protector
Prevention
Head of the block of cylinders (Coupet's model)
2. Gas distribution mechanism cover
moment of an inhaling of bolts of fastening of 10 N. of m.
3. Block head bolt
4. 65 N. of m.
5. The conducted cam-shaft gear wheel
at installation of a gear belt you monitor the provision of an orientation tag 6. Head of the block of cylinders
7. Laying of a head of cylinders
8. Laying of a cover of the gas-distributing mechanism
9. Laying
10. The soaking-up collector
moment of an inhaling of bolts of fastening
20 N of m.
Prevention
deformation of a head is checked by caliber 1030 and the probe
measure distance between the plane of bolts of fastening of a head and the lower plane
Head of the block of cylinders – installation
Prevention
PERFORMANCE ORDER
1) establish laying of a head of the block on pins so that the party with marking of "OBEN" (or with number of a detail) was turned towards a head
2) establish a block head, wrap block head bolts, tighten bolts by hand
3) tighten bolts in the established sequence in three steps, observing the following order (the engine cold):
tighten bolts with m 40 N.' moment.
tighten bolts with m 60 N.' moment.
one movement tighten on 180 ° (it is allowed to carry out доворот in two steps on 90 °)
bolts upside-down turn away
Prevention