Magentis and Optima repair since 2000 of release
1. Engines
1.1. Engines of 2,0 l of DOHC
1.2. Engines of V6 2,5 l
1.2.1. Specifications
1.2.2. Compression check
1.2.3. Adjustment of gaps of valves
1.2.4. Gear belt
1.2.5. Check and adjustment of a tension of poliklinovy belts
1.2.6. Tightening of bolts of fastening of a head of the block of cylinders
1.2.7. Head of the block of cylinders, valve and spring of valves
1.2.8. Engine support
1.2.9. Removal and engine and transmission installation
1.2.10. Camshafts
1.2.11. Hydraulic jacks of gaps of valves
1.2.12. Pistons and rods
1.2.13. Cranked shaft
1.2.14. Block of cylinders
1.2.15. Air filter of the V6 engine
1.2.16. Broad air chamber
1.2.17. Inlet collector
1.2.18. Final collector
1.2.19. Exhaust silencers
1.2.20. Search and elimination of malfunctions
2. Greasing system
3. Cooling system
4. Control and decrease in toxicity
5. Fuel system
6. Ignition system
7. Coupling
8. Transmission
9. Power shafts, axes
10. Suspension bracket
11. Steering
12. Brake system
13. Body
14. Central air
15. Electric equipment
16. Electric circuits
 










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1.2.7. Head of the block of cylinders, valve and spring of valves

Removal

 PERFORMANCE ORDER

1. Merge cooling liquid and disconnect the top hose of a radiator.
2. Remove a wide hose and an air inlet located between the air filter and a cover of a head.
3. Remove a vacuum hose, a hose of supply of fuel and a hose of cooling liquid.
4. Remove an inlet collector.
5. Remove from spark plugs tips of high-voltage wires.
6. Remove the ignition coil.
7. Remove top and bottom casings of a gear belt.

8. Remove a gear belt and asterisks of camshafts.

9. Remove the heat-shielding screen and a final collector.
10. Remove a pulley of the water pump and a cover.
11. Remove the camshafts operating inlet and final valves.

12. The special tool with a nest on 12 mm in a certain sequence for 2–3 passes turn out bolts of fastening of a head of the block of cylinders.

13. Remove the remains of laying of a head of the block of cylinders from the block of cylinders and a head of the block of cylinders.

At removal of the remains of laying be careful, that they did not get to canals of the block of cylinders.

Check

Head of the block of cylinders

 PERFORMANCE ORDER

1. Clear a head of the block of cylinders of a deposit and hermetic. The compressed air blow channels for supply of greasing.
2. 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.

3. A metal ruler and shchupy check planeness of a head of the block of cylinders.
Deviation from planeness of a head of the block of cylinders: 0,03 mm
The maximum deviation from planeness of a head of the block of cylinders: 0,20 mm

Directing plugs of the valve

 PERFORMANCE ORDER

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.

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

  • Inlet valve: 0,02–0,05 mm
  • Final valve: 0,035–0,065 mm

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

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

Valve

 PERFORMANCE ORDER

1. Examine each valve on existence of wear, damages and deformation 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.

2. Check a surface of a working facet of the valve and restore it or replace the valve.
3. Replace the valve, if thickness of an edge of a head of the valve of less admissible.

Thickness of an edge of a head of the valve :

  • Inlet valve: 1,0 mm
  • Final valve: 1,3 mm

Maximum permissible thickness of an edge of a head of the valve:

  • Inlet valve: 0,5 mm
  • Final valve: 0,8 mm

Valve spring

 PERFORMANCE ORDER

1. 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.

  • Length of a spring without loading: 42,5 mm
  • Length of a spring under loading of 21,9 kg: 35 mm
  • Tolerance of a spring from the vertical plane: no more than 1,5 °
  • Maximum permissible length of a spring without loading: 41,5 mm
  • Maximum permissible length of a spring under loading of 21,9 kg: 34 mm
  • Maximum permissible deviation of a spring from the vertical plane: no more than 3 °

Plug-in saddle of the valve

 PERFORMANCE ORDER

1. 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, then restore a valve saddle.

2. Repair of a saddle of the valve is necessary for carrying out a nazhdachny circle or a mill.

3. After repair grind in a saddle and the valve with use of abrasive paste.

Replacement of the directing plug of the valve

 PERFORMANCE ORDER

1. Using the special tool 09222-32200, squeeze out the old directing plug of the valve to the basis of a head of 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.

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
0,50
50
11,500–11,518

3. The adaptation for installation of the directing plug of the valve (09221–29000 (A), 09221–22000 (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.

4. After a press fitting of directing plugs of valves insert new valves and check a gap.
5. Each time at replacement of directing plugs of valves check and, if necessary, replace saddles of valves.

Do not establish directing plug of the valve of the same size.

Replacement of a saddle of the valve

 PERFORMANCE ORDER

1. Cut off an internal surface of a saddle of the valve for reduction of thickness of a wall and its removal from a head of the block of cylinders.

2. 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

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
7,9–8,1
33,300–33,325
The saddle of the final valve increased by 0,6 mm
60
8,2–8,4
33,600–33,625
The saddle of the inlet valve increased by 0,3 mm
30
7,9–8,1
28,600–28,621
The saddle of the final valve increased by 0,6 mm
60
8,2–8,4
28,900–28,921

3. 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.
4. After installation of a new saddle of the valve it is necessary to execute valve grinding in.

Width of a working edge of a saddle of the valve:

  • Inlet valve: 0,9–1,3 mm
  • Final valve: 0,9–1,3 mm

Installation

 PERFORMANCE ORDER

1. Establish a spring saddle.

2. Using the special adaptation (09222-32100), establish a maslootrazhatelny cap.

Do not use repeatedly removed maslootrazhatelny caps.

The wrong installation of a maslootrazhatelny cap leads to leakage of engine oil via directing plugs of the valve.

3. 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.

4. To establish springs and plates of springs. It is necessary to establish springs the party enamelled, to plates of springs.

5. With the petsialny adaptation 09222-21001 compress a spring. Establish crackers and remove the special adaptation for spring compression.

When the spring is compressed, check that the maslootrazhatelny cap is not clamped by a spring saddle.

6. Clear privalochny surfaces of laying of a head of the block of cylinders and the block of cylinders.

7. Check a marking arrangement on laying of a head of the block of cylinders.

8. Establish laying by marking to a head of the block of cylinders.

At installation of laying do not use hermetic.

9. A six-sided key on 12 mm screw bolts of fastening of a head of the block of cylinders in the sequence shown in drawing.

10. A tightening of bolts carry out to three stages, since the central part.

Moment of an inhaling of bolts of fastening of a head of the block of cylinders: 25 N • m + to tighten on a corner (60 °–64 °) + to tighten on a corner (45 °–49 °)


«on a step back
1.2.6. Tightening of bolts of fastening of a head of the block of cylinders
on the following page»
1.2.8. Engine support