Hyundai Elantra

since 2000-2004 of release

Repair and car operation



Elantr's Hyundai
- Petrol engines 1,6, 1,8 and 2,0 of l
   Compression check
   Gear belt
   Adjustment of a tension of a gear belt
   Adjustment of a tension of a poliklinovy belt
   Adjustment of a tension of a belt of a drive of the generator
   Camshafts
   Check and adjustment of gaps of valves on engines 1,8 and 2,0 of l (MLA)
   Hydraulic jacks of gaps of valves of the engine of 1,6 l
   Installation of a cover of a head of cylinders
   Directing to a chain
   Chain
   Installation of camshafts
   The mechanism of change of the moment of opening and closing of valves (CVVT) on l engines 1,8 and 2,0
   Repair of a head of cylinders
   Engine support
   Removal and engine and transmission installation
   Block of cylinders
   Cranked shaft
   Flywheel
   Piston
   Air filter (ACL)
   Final collector
   Inlet collector
   System of production of the fulfilled gases
   Search and elimination of malfunctions
+ Diesel engine of 2,0 l
+ greasing System
+ cooling System
+ Fuel system
+ Monitoring systems and decrease in toxicity of the fulfilled gases
+ ignition System
+ System of preliminary heating of the diesel engine
+ Coupling
+ Mechanical transmission
+ Automatic transmission
+ Power shafts, forward and back axes
+ Suspension bracket
+ Steering
+ Brake system
+ Body
+ air Central air
+ Electric equipment
Electric circuits



Repair of a head of cylinders



Dismantling

 PERFORMANCE ORDER

  1. The special tool 09221-32001, 09221-11000 in sequence shown in drawing for 2–3 passes turn out bolts of fastening of a head of the block of cylinders.
  1. The special adaptation 09222-28000, 09222-28100 compress a spring of the valve and remove from a valve core crackers. Slowly release the adaptation compressing a spring, and remove a valve spring, a plate of a spring and the valve from a head of the block of cylinders.

For storage of valves prepare the numbered plastic bags or containers.

  1. Passatizhami 09222–29000 remove a maslootrazhatelny cap.

Do not use repeatedly maslootrazhatelny cap.

Check

Head of the block of cylinders

 PERFORMANCE ORDER

  1. Examine a head of the block of cylinders on absence of damages, cracks, leakages of oil and cooling liquid. If necessary, replace a head of cylinders.
  1. Remove scale, hermetic and a deposit. The compressed air blow channels for greasing.
  1. Metal ruler and shchupy in six directions A, B... check planeness of a head of the block of cylinders. If necessary, перешлифуйте head of the block of cylinders.

Standard deviation from planeness: less than 0,03 mm.
Maximum permissible deviation from planeness: 0,05 mm.

Valves

 PERFORMANCE ORDER

  1. Wire brush clear the valve.
  1. Examine each valve on existence of wear, damages and deformation in zones A and B and, if necessary, repair or replace it. If the end face of a core is corroded or worn-out, as required restore facets. This restoration should be limited to the minimum removal of metal.

Also check thickness of working edges.

Thickness of a working edge of the valve:

Inlet valves: 1,15 mm:

- l engines 1,8 and 2,0: 1,15 mm;
- engines of 1,6 l: 1,1 mm.

Final valves:

- l engines 1,8 and 2,0: 1,35 mm;
- engines of 1,6 l: 1,3 mm.

Maximum permissible thickness of a working edge of the valve:

Inlet valves: 0,8 mm;
Final valves: 1,0 mm.

Valve spring

 PERFORMANCE ORDER

  1. Examine each spring of the valve on lack of cracks and damages. Measure length of a spring in a free condition.
  2. Establish a spring on a flat horizontal surface and measure a deviation of the top part of a spring from the vertical plane.

L engines 1,8 and 2,0

Length of a spring without loading: 48,86 mm
Length of a spring under loading of 18,3 kg: 39 mm
Length of a spring under loading of 40,0 kg: 30,5 mm
Tolerance of a spring from the vertical plane: no more than 1,5 °
Maximum permissible deviation of a spring from the vertical plane: no more than 3 °

Engines of 1,6 l

Length of a spring without loading: 44 mm

Length of a spring under loading of 21,6 kg: 35 mm
Length of a spring under loading of 45,1 kg: 27,2 mm
Tolerance of a spring from the vertical plane: no more than 1,5 °
Maximum permissible deviation of a spring from the vertical plane: no more than 4 °

Directing plugs of the valve

Check a gap between a core and the directing plug of the valve. If the gap exceeds maximum permissible value, replace directing plug of the valve with the plug of the increased repair size.

L engines 1,8 and 2,0

Gap between a core and the directing plug of the valve:

Inlet valves: 0,02–0,05 mm
Final valves: 0,035–0,065 mm

Maximum permissible gap between a core and the directing plug of the valve:

Inlet valves: 0,1 mm
Final valves: 0,13 mm

Engines of 1,6 l

Gap between a core and the directing plug of the valve:

Inlet valve: 0,03–0,06 mm
Final valve: 0,05–0,08 mm

Maximum permissible gap between a core and the directing plug of the valve:

Inlet valve: 0,1 mm
Final valve: 0,15 mm

Plug-in saddle of the valve

Check a valve saddle on existence of an overheat and violation of the working surface contacting to a plate of the valve. If necessary repair or replace a valve saddle.

Before replacement or repair of a saddle of the valve check wear of the directing plug of the valve. If the directing plug of the valve is worn-out, replace it.

Replacement of a saddle of the valve

 PERFORMANCE ORDER

Any plug-in saddle of the valve which has been worn out to a limit, it is necessary to replace at room temperature with wall cutting, as is shown in drawing.
  1. After removal of an old saddle of the valve it is necessary to chisel a nest under the increased size of a saddle of the valve. The sizes for processing are specified in the table.

The increased sizes of a plug-in saddle of the valve of engines 1,8 and 2,0 л3

Description
Label of the size
Height of a saddle, mm
Diameter of a nest in a head of cylinders, mm
The saddle of the inlet valve increased by 0,3 mm
30
7,5–7,7
33,300–33,325
The saddle of the inlet valve increased by 0,6 mm
60
7,8–8,0
33,600–33,625
The saddle of the final valve increased by 0,3 mm
30
7,9–8,1
28,800–28,821
The saddle of the final valve increased by 0,6 mm
60
8,2–8,4
29,100–29,121

The increased sizes of a plug-in saddle of the valve of engines of 1,6 l

Description
Label of the size
Height of a saddle, mm
Diameter of a nest in a head of cylinders, mm
The saddle of the inlet valve increased by 0,3 mm
30
5,1–5,3
30,700–30,721
The saddle of the inlet valve increased by 0,6 mm
60
5,4–5,6
31,000–31,021
The saddle of the final valve increased by 0,3 mm
30
6,2–6,4
27,300–27,3211
The saddle of the final valve increased by 0,6 mm
60
6,5–6,7
27,600–27,621
  1. Heat up a head of cylinders to temperature 250°C and press a new saddle of the valve of the repair size. At a press fitting the saddle of the valve should have room temperature.
  2. After installation of a new saddle of the valve it is necessary to execute valve grinding in. The width of a working facet of a saddle of the valve should be within technical requirements.

Width of a working facet of a saddle of the inlet valve:

- l engines 1,8 and 2,0: 1,1–1,5 mm;
- engines of 1,6 l: 0,8–1,2 mm.

Width of a working facet of a saddle of the final valve: 1,3–1,7 mm

Replacement of the directing plug of the valve


 PERFORMANCE ORDER

  1. Using the adaptation of 09221-22000 A/B выпрессуйте the valve plug from a head of cylinders in the direction to the block of cylinders.
  2. Put to an opening of a head of cylinders the new directing plug of the valve of the increased repair size.
  1. The adaptation for installation of the directing plug of the valve of 09221-22000 A/B press the plug in a head of cylinders. The adaptation provides a plug press fitting on strictly certain depth. Measure a vystupaniye of the top part of the directing plug of the valve from a head of cylinders. Pay attention that vystupany the directing plug of the valve variously for inlet and final valves.
  1. After a press fitting of directing plugs of valves insert new valves and check a gap.
  2. Each time at replacement of directing plugs of valves check and, if necessary, replace saddles of valves.

The increased sizes of the directing plug of the valve

The increased sizes
Label of the size
Diameter of an opening in a head of the block of cylinders
0,05
5
11,050–11,068
0,25
25
11,250–11,268
0,5
50
11,500–11,518

Assembly

 PERFORMANCE ORDER

  1. Before installation clear all details.
  2. Apply a thin film engine oil on all surfaces of sliding.
  1. Establish a spring saddle. Using the special adaptation 09222-22001, establish a maslootrazhatelny cap.
  1. Do not use repeatedly old maslootrazhatelny caps.
  2. The wrong installation of a maslootrazhatelny cap adversely influences its working edge for the account эксцентриситета and leads to leakage of engine oil via directing plugs of the valve.
At installation be careful not to overwind a maslootrazhatelny cap.
  1. Grease a valve core with engine oil and establish the valve. At installation of the valve do not apply big efforts not to damage a maslootrazhatelny cap. Check smoothness of moving of the valve.
  1. Establish springs and holders of springs. It is necessary to establish springs the party enamelled, to holders of springs.
  1. The special adaptation 09222-28000, 09222-28100 compress a spring. Establish crackers and remove the special adaptation for spring compression.

At compression of a spring be convinced that the maslootrazhatelny cap is not clamped by the adaptation for spring compression.

  1. Clear all privalochny surfaces of the block of cylinders and a head of the block of the cylinder.
  2. Check marking existence on laying of a head of cylinders.
  3. Establish new laying of a head of the block of cylinders so that the surface with marking was directed to a head of cylinders.
  1. In the sequence shown in drawing tighten bolts of fastening of a head of cylinders.

Moment of an inhaling of bolts of fastening of a head of cylinders of engines 1,8 and 2,0 of l

М10: 25 N • m + to tighten on a corner 60–65 ° + to tighten on a corner 60–65 °
М12: 30 N • m + to tighten on a corner 60–65 ° + to tighten on a corner 60–65 °

Moment of an inhaling of bolts of fastening of a head of cylinders of engines of 1,6 l:

30 N • m + to tighten on a corner 90 ° + to weaken all bolts + 30 N • m + to tighten on a corner 90 °