Chevrolet Lanos (since 2004 of release)
1. The car device
2. Recommendations about operation
3. Malfunctions in a way
4. Maintenance service
5. The engine
5.1. Features of a design
5.2. Compression check in cylinders
5.3. Removal and installation of mudguards of the engine
5.4. Replacement of support of a suspension bracket of the power unit
5.5. Installation of the piston of the first cylinder in position ВМТ of a step of compression
5.6. Removal, installation and дефектовка a flywheel
5.7. Replacement of details of consolidation of the engine
5.8. A head of the block of cylinders
5.8.1. Removal, дефектовка and camshaft installation
5.8.2. Replacement of hydrojacks of backlashes in the mechanism of a drive of valves
5.8.3. Possible malfunctions of hydrojacks of backlashes in the mechanism of a drive of valves, their reasons and ways of elimination
5.8.4. Dismantling, repair and assemblage of a head of the block of cylinders
5.8.5. Grinding in of valves
5.9. Removal and engine installation
5.10. Engine repair
5.11. Greasing system
5.12. Cooling system
5.13. System of release of the fulfilled gases
5.14. The engine power supply system
5.15. System of catching of steams of fuel
5.16. System рециркуляции the fulfilled gases
6. Transmission
7. A running gear
8. A steering
9. Brake system
10. An electric equipment
11. A body
12. Wheels and tyres
13. Purchase of spare parts
14. A trip on HUNDRED
15. Winter operation of the car
16. Preparation for checkup
17. Councils to the beginning mechanic
18. Appendices
19. Electric equipment schemes


5.8.4. Dismantling, repair and assemblage of a head of the block of cylinders

If repair of a head of the block of cylinders of the engine established on the car is necessary, remove it («Replacement of a lining of a head of the block of cylinders» see). In most cases repair of a head of the block of cylinders consists in grinding in or replacement of valves, polishing of saddles of valves. At such malfunctions as infringement of tightness of channels of a shirt of system of cooling and коробление привалочной surfaces to the block of cylinders, replace a block head.
It be required to you: keys «on 10», «on 12», «on 13», a candle key, a magnetised screw-driver (or tweezers), the adaptation for compression клапанных springs.
1. Remove a head of the block of cylinders from the car («Replacement of a lining of a head of the block of cylinders» see).

Fig. 5.5. Sequence отворачивания nuts and bolts of fastening of an inlet pipe

2. Remove press levers of valves and directing crackers of levers (Replacement of hydrojacks of backlashes in a drive of valves »see«).
3. Turn away ten bolts and nuts of fastening of an inlet pipe in the sequence shown on fig. 5.5, remove from hairpins an inlet pipe in gathering with a fuel stage, throttle knot and hoses of system of cooling …
4. … and its lining.
5. Turn out three bolts of fastening of the thermoscreen of a final collector (Removal and installation of thermoscreens »see«) and remove the thermoscreen.

Fig. 5.6. Sequence отворачивания nuts of fastening of a final collector

6. Turn away eight nuts of fastening of a final collector in the sequence shown on fig. 5.6.
7. Remove from hairpins a final collector and the lining established under it.
8. Turn out spark plugs (Replacement and service of spark plugs »see«).
9. Turn out two bolts of fastening of a cover of the thermostat and remove the thermostat (Removal and thermostat installation »see«).
10. If necessary turn out from a head of the block the gauge of temperature of a cooling liquid of a control system of the engine (Check and replacement of gauges of a control system with the engine »see«).
11. Establish the adaptation for compression of springs of valves, compress springs …

Fig. 5.7. Installation of the adaptation for compression of springs of valves: 1 – a head of the block of cylinders; 2 – the adaptation for compression of springs
For compression of springs of valves of a head of the block which has been removed from the engine, it is more convenient to use the adaptation shown on fig. 5.7. In this case it is not required to establish a support under «рассухариваемый» the valve and, except that, the adaptation fixes a spring in the compressed position that considerably facilitates removal of crackers.

12. … remove crackers …
13. … the top plates of springs and a spring …
14. … the bottom plates of springs …
15. … and mechanisms of rotation of final valves, and then take valves from directing plugs.

After long operation at the top end face of the valve the agnail грибообразной forms can be formed. Before выниманием the valve from the directing plug remove this agnail надфилем. Categorically it is forbidden to beat out the valve from the directing plug a hammer through the mandrel without agnail removal as the internal surface of the plug will be thus inevitably damaged.

16. Remove resinous adjournment from the top surface of a head and from inlet channels. These adjournment can be softened and washed off kerosene or diesel fuel.
17. Clean a deposit from chambers of combustion and final channels. A deposit remove the round metal brush established in a cartridge of an electrodrill.

Preliminary soak a deposit kerosene.
Be careful: avoid to inhale a dust formed at cleaning of chambers of combustion. For prevention of formation of a dust periodically moisten a deposit with kerosene.

18. Clear internal surfaces of directing plugs of valves a thin cylindrical brush from the copper wire clamped in a cartridge of an electrodrill.
19. Remove from a surface прилегания heads to the block of cylinders burnt rests of a sealing lining.

It is forbidden to clear привалочную a head surface metal brushes or наждачной a skin. Use a shovel from a firm tree or plastic, preliminary having softened the rests of a lining solvent.

20. After clearing examine a block head not to admit its operation with damages of carving apertures, cracks (especially between saddles of valves and in final channels), corrosion, inclusions of alien materials, bowls and fistulas.

It is forbidden to make cracks, bowls and fistulas. A defective head replace.

21. Check up by means of the metal ruler established on an edge, and щупа planeness of a surface прилегания heads to the block in longitudinal and cross-section directions, and also on diagonals. If the backlash between an edge of a ruler and a head surface exceeds 0,1 mm, replace a head.
22. Clear of the rests of linings and a deposit of a surface of flanges of a head for installation of an inlet pipe and a final collector.
23. Check up presence of deformations of flanges for an inlet pipe and the final collector, the deformed head replace.
24. The damaged carving apertures repair prorace of a carving by taps or installation of the repair plug (ввертыша).
25. Check up installation density заглушек cooling shirts. At easing of their landing restore its stamping.
26. Define deterioration of directing plugs of valves, having measured internal diameter of an aperture of the plug, diameter of a core of the valve and on a difference of these sizes having defined a backlash. The backlash for inlet valves should be 0,030–0,065 mm, for final – 0,050–0,085 mm.
27. If a backlash more admissible, repair plugs expansion to nearest of three repair sizes with increase in diameter of an aperture at 0,075 mm, 0,150 and 0,250 mm concerning nominal diameter. Thus in them it is necessary to establish valves of the corresponding repair size with maintenance of a nominal backlash in interface. Develop apertures of plugs, using a set of development with a directing shaft. In avoidance выкрашивания surfaces of the plug a layer of removed metal at each pass and tool giving should be minimum.

Directing plugs are made of a steel by a method of powder metallurgy, запрессованы in a head of the block and replacement are not subject.

Directing plugs and valves of the repair sizes can be established for technological reasons on manufacturer at assemblage of the new engine.
For simplification of selection of complete sets of repair details factory marks are put on plugs and valves (tab. 5.2) applied in technological process of manufacturer, and service, used on servicing deports.

Table 5.2 the Repair sizes of valves and directing plugs
*Маркируется a sign «–» (dash)

Fig. 5.8. The profile grew grey valves: and – the inlet valve; – the final valve

28. Check up a condition of saddles of valves. On working facets of saddles there should not be wear tracks, bowls, corrosion, etc. can replace Saddles of valves in a specialised workshop. Insignificant damages (and so forth) can be deduced small risks, scratches grinding in of valves («Grinding in of valves» see).
29. More major defects of saddles of valves eliminate polishing, maintaining the sizes shown on fig. 5.8. Saddles are recommended to be ground in a specialised workshop as special tools and the equipment for this purpose are required.
30. Remove a deposit from valves and examine them. Deformation of a core of the valve and a crack on its plate are not supposed. In the presence of damages replace the valve. Check up, whether it is not too worn out and whether the working facet is damaged. Grinding of a working facet of valves (in the repair shops having the corresponding equipment) is supposed. After grinding the corner of a facet concerning a plate plane should be 45°30’±5 ’, and the thickness of a cylindrical part of a plate should be not less than 0,5 mm. Insignificant risks and scratches on a facet can be deduced valve grinding in to a saddle («Grinding in of valves» see).

That on cores of valves risks were not formed, do not clear their wire brushes and metal scrapers.

31. Check up концентричность arrangements of a plate of the valve and a saddle: put on a facet of a head of the valve a thin paint coat (for example, the Berlin azure), insert it in directing plug and, slightly having pressed to a saddle, turn. In the wake of a paint on a saddle facet it is possible to judge about концентричности valve and saddle arrangements.

Fig. 5.9. Zones of deterioration of the valve: 1 – a zone of the least deterioration of a core; 2 – a core end face; 3 – проточка under crackers; 4 – zones of the greatest deterioration of a core; 5 – a working facet; 6 – a plate edge

32. Check up deterioration of a core of the valve in the places shown on fig. 5.9. Nominal diameter of cores of all valves of 7,935-7,950 mm.
33. Check up a condition the protocheck 3 (fig. 5.9 see) valve core under crackers. At detection of traces выкрашивания edges the protocheck and deterioration of a cylindrical part replace the valve.
34. Replace маслосъемные caps irrespective of their condition.
35. Examine springs of valves. Cracks and decrease in elasticity of springs are not supposed. At possibility define elasticity of springs on developed effort. According to technical requirements it should make 625–650 Н at length of a spring of 21,5 mm and 275–290 Н at length of 31,5 mm. The bent springs (deformation in a free condition more than 1,6 mm) and springs with cracks replace.
36. Check up a condition of basic plates of springs. Replace plates with considerable deterioration of basic flutes under springs.
37. Linings of an inlet pipe, a final collector and a head of the block of cylinders always replace new as removed, even the outwardly not damaged linings can appear strongly pressed out and will not provide tightness of consolidations.

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5.8.3. Possible malfunctions of hydrojacks of backlashes in the mechanism of a drive of valves, their reasons and ways of elimination
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5.8.5. Grinding in of valves